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V-TEK TM-401 User Manual

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TM-401 User's Guide
Original Instructions
EC Declaration of Conformity
ISO 9001:2008 Certified
V-TEK, Incorporated
European Representative
751 Summit Avenue
QNET BV
Mankato, MN 56001
Hommerterweg 286
USA
6436 AM Amstenrade
(P) 507-387-2039
The Netherlands
(F) 507-387-2257
www.vtekusa.com
User's Guide # D292104B

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  • Page 1 TM-401 User’s Guide Original Instructions EC Declaration of Conformity ISO 9001:2008 Certified V-TEK, Incorporated European Representative 751 Summit Avenue QNET BV Mankato, MN 56001 Hommerterweg 286 6436 AM Amstenrade (P) 507-387-2039 The Netherlands (F) 507-387-2257 www.vtekusa.com User’s Guide # D292104B...
  • Page 2 Vendor Provided Material Significant portions of this documentation were provided by: KEYENCE CORPORATION OF AMERICA 1100 North Arlington Heights Road, Suite210, Itasca, IL 60143 1-888-KEYENCE (1-888-539-3623) www.keyence.com...
  • Page 3 EC Declaration of Conformity Manufacturers Name: V-TEK Incorporated. Manufacturers’ Address: 751 Summit Avenue, Mankato, Minnesota 56002, USA Declare that the machinery described below complies with applicable health and safety requirements of Part 1 of Annex 1 of the Machinery Directive 2006/42/EC and EMC Directive 2004/108/EC. Confidential technical documentation has been compiled in accordance with Part A of Annex VII of Machinery Directive 2006/42/EC and is available to European national authorities on written request only.
  • Page 5 Introduction Contents Introduction ..........ii Theory of Operation .
  • Page 6 Introduction Thank you for purchasing the TM-401 Component Handling Machine. The TM-401 is a table- top pick and place tape and reel machine with vision, designed for use in production environ- ments for electronic devices. This machine accepts devices loaded in tubes, and a dual tube input option is available.
  • Page 7 As the tape advances, it passes sensors which detect jams in tape. Once the carrier tape reaches the TM-401 sealer assembly, cover tape is applied. The part is then sealed in the pocket with either a Heat Seal or Pressure Sensitive Adhesive (PSA) cover tape. When the sealing pro- cess is complete, the finished tape is routed onto a take-up reel.
  • Page 8 Note: The TM-401 is designed and tested to meet the CE Directives: 2006/42/EC, 2004/ 108/EC. These tests were conducted with the power requirements of 230V 50Hz. However, the TM-401 can also handle other voltage levels seen in other parts of the world including voltages from 208V-240V @ 50/60 Hz.
  • Page 9 Intended Use The intended use of the TM-401 Taping Machine is to produce taped reels of individually sealed and consistently orientated components. Use of this equipment in any other way is not recom- mended. The TM-401 is designed to accommodate a full range of electronic devices. The Tube Feeder accommodates all common tube based parts size 0805 or larger.
  • Page 10 The enclosure doors may be left open during basic set-up procedures such as positioning the pick head at place or pick locations. If the enclosure doors are left open during setup the TM-401 automatically reduces the speed of the pick head to a fraction of its normal operating speed to prevent operator injury due to collision, etc.
  • Page 11 Ear protection is not necessary during nor- mal operation. When running the TM-401, the operator should stand or sit in front of the touch screen to assure easy access to all controls and the Power/Emergency Stop Button. This position allows the oper- ator to view all parts of the TM-401 while it is in operation.
  • Page 12 HMI. Reset Button The TM-401’s blue Reset button is located on the left side of the machine above the Emergency Stop Switch. When the machine is powered up, it is automatically placed into an emergency stop state to prevent the motors from moving until the operator is ready to begin operating the machine.
  • Page 13 The enclosure doors may be left open during basic set-up procedures such as positioning the pick head at place or pick locations. If the enclosure doors are left open during setup the TM-401 automatically reduces the speed of the pick head to a fraction of its normal operating speed to prevent operator injury due to collision, etc.
  • Page 14 A blinking red light and a solid amber light indicates the machine is at the end of a job, the leader creation sequence is complete and the TM-401 is ready for the next process. Safety Features...
  • Page 15 Consult User’s Guide for proper procedure. Disconnect power and air supplies and refer to Chapter 8: Maintenance of this manual before performing maintenance on the TM-401. Note: Do not remove or obstruct any of the warning or instruction labels on the TM-401.
  • Page 16 Contact Information V-TEK, Inc. 751 Summit Ave Mankato, MN 56001 TEL: (507) 389-2039 FAX: (507) 387-2257 email:service@vtekusa.com website: http://www.vtekusa.com For customer service, please refer to the Customer Service Contact Sheet at the back of this manual. European Representative: QNET BV...
  • Page 17 Unpacking the TM-401........

  • Page 18: Table Of Contents

    Table of Contents (continued) Chapter 3: The Human Machine Interface ........3-1 Introduction .
  • Page 19 Table of Contents (continued) Chapter 6: Operation ........... . .6-1 Quick Start: Running a Job .
  • Page 20 Table of Contents (continued) Chapter 8: Maintenance ..........8-1 Safe Maintenance Steps .
  • Page 21 Assembling the TM-401 ........

  • Page 22: Preparing The Work Area

    Space Requirements The TM-401 is a table-top machine which needs to be placed on a flat, stable surface in a well lit work area that is a minimum of 7’ high x 11’ wide x 9‘deep (2.2 m x 3.5 m x 2.7 m) to provide suf- ficient space for the assembled machine when it is fully loaded with a variety of tape reel sizes.

  • Page 23: Table Requirements

    1- 3 Table Requirements The TM-401 should be placed on a user-supplied table or bench that is capable of supporting a minimum of 230 lb. (104.5 Kg). An optional 80/20 frame (pictured above) is also available for mounting the TM-401.

  • Page 24: Power Requirements

    Power Requirements The TM-401 will also require access to a 85-110 PSI air pressure system and a 120/240 VAC, 50/60 Hz power supply. Locate the machine so electrical power cables can be routed away from areas where personnel are expected to move.

  • Page 25: Unpacking The Tm-401

    1- 5 Unpacking the TM-401 Prior to shipment, the TM-401 is partially disassembled, then shrink wrapped, placed in a crate, and strapped to the crate floor. The disassembled TM-401 parts, which include the Carrier Tape Arm, the Take-up Assembly, the Tower Light and the Spare Parts Kit, are individually bubble- wrapped and packed around the base machine.

  • Page 26: Assembling The Tm-401

    Note: Read the TM-401 User’s Guide before assembling the TM-401. Unpack the TM-401 Crate Move the Crate to the Work Area. Use a fork lift to move the TM-401 crate to the pre- pared work area. Ensure the fork is centered under the crate before lifting.
  • Page 27 Lift the machine from the crate and place it onto the prepared work table/bench. Position the TM-401 in the work area so there is at least 3 feet of clearance on all sides. (See the Preparing the Work Area section earlier in this chapter for details.) The TM-401 is shipped with zip ties securing the pick head, the 2D Camera and any mobile portions of the machine.
  • Page 28 TM-401 User’s Guide Re-assemble the TM-401 Position the Tower Light Lift Tower Light, snapping it in place in an upright position perpendicular to the TM-403.. Connecting the Carrier Tape Arm a. Remove the black knob from the right side of the Track Support Bracket.
  • Page 29 45 degree angle from the baseplate assembly. Engage the dowel pin into the desired position and secure it into place with the black knob.. b. Plug the electrical connector into the take-up motor receptacle. D292104.4.fm Assembling the TM-401...
  • Page 30 V-TEK. The TM-401 is fully tested before shipping. No further grounding or testing is required during re-assembly and installation. The TM-401 is ready to power up. Follow the instructions in Chapter 3: Machine Setup to setup the machine for operation.

  • Page 31: Chapter 2: Machine Overview

    Chapter 2: Machine Overview Contents Front View ........... . 2-2 Right Side View .

  • Page 32: Front View

    TM-401 User’s Guide Front View A. Take-up Arm H. Vision System B. Air Regulator I. Taper Track C. Idler Wheel J. Pick & Place Head Assembly & Bridge D. Drive Sprocket K. Touch Screen HMI E. Cover Tape Arm L. Tower Light F.

  • Page 33: Right Side View

    Chapter 2: TM-401 Overview Right Side View A. Tower Light E. Taper Input B. Pick & Place Head Enclosure F. Tube Feeder(s) C. Carrier Tape Arm G. Main Power Switch D. Carrier Tape Arm Adjustment Knob D292104.5a.fm Right Side View...

  • Page 34: Left Side View

    TM-401 User’s Guide Left Side View A. Pick & Place Head Assembly G. Take-up Arm B. Enclosure Doors (3) H. Cover Tape Arm C. Tube Feeders I. Tower Light D. Air Regulator J. Heat/PSA Sealer E. Take-up Motor Connection K. Reset Button F.

  • Page 35: Back View

    Chapter 2: TM-401 Overview Back View A. Carrier Tape Arm J. Ethernet Connection B. Carrier Arm Adjustment Knob K. Cover Tape Arm C. Main Power Switch L. Heat/PSA Sealer D. Fuse Holders (Bowl application only) M. Tube Feeder Power Connection E.

  • Page 36: Controls, Connections & Labeling

    TM-401 User’s Guide Controls, Connections & Labeling Reset Button The TM-401’s blue Reset Button is located on the left side of the machine below the Take-up Arm. (pictured below) Emergency Stop Switch The Emergency Stop Switch is located on the left side of the machine below the blue Reset Button.
  • Page 37 Chapter 2: TM-401 Overview Main Power Switch The Main Power Switch is located on the right side of the machine behind the Carrier Tape Arm on the lower sheet metal enclosure. Serial Plate This is an example of the Serial Plate which is permanently affixed to the back of the TM- 401.

  • Page 38: The Taper

    TM-401 User’s Guide The Taper A. Take-up Arm H. Sensor Amplifiers B. Take-up Guide I. Cover Tape Guide C. Drive Sprocket J. Heat/PSA Sealer D. Idler Wheel K. Tape Jam Sensor E. Sealer Controls & Pressure Gauge L. Adjustable Width Track F.
  • Page 39 Chapter 2: TM-401 Overview Taper: Sealer A. Idler Wheel G. Heat Sealer B. Drive Sprocket H. PSA Pressure Wheels C. Outer Seal Lock I. PSA Pressure Adjustment Screws D. Outer Seal Adjuster J. Cover Tape Guide E. Inner Seal Lock K.

  • Page 40: Pick & Place Assembly

    2-10 TM-401 User’s Guide Pick & Place Assembly Pick & Place Head A. Nozzle D. Pick Actuator Adjustment Screw B. Nozzle Vacuum Sensor E. Place Actuator Adjustment Screw C. Nozzle Vacuum Filter Pick & Place Controls A. Blow-off Air Pressure Gauge & Control B.

  • Page 41: Tube Feeder

    D. Y Axis Clamping Bolts E. Slotted Plate Note: Tooling for the Tube Feeder will vary to fit part parameters. The TM-401 can be equipped with one or two Tube Feeders, as desired. Adjust Feeder position on Slotted Plate D292104.5a.fm...

  • Page 42: 2D Vision System

    E. M12 Ethernet Cable (not shown) Note: For advanced Vision configuration, a computer is required. This can be provided by the user or purchased as an option from V-TEK, Inc. System requirements for the vision computer follow: • Operating system: Microsoft® Windows 7 (32 or 64 bit) •...
  • Page 43 Chapter 3: Human Machine Interface Contents Introduction ..........3-2 Touch Screen .

  • Page 44: Introduction

    Chapter 5: Operation for instructions on how to run a job Touch Screen The user interacts with the TM-401 through a touch screen HMI which is located on the front of the machine below the Taper. Touching the HMI screen has the same effect as a left click with the mouse.
  • Page 45 Chapter 3: Human Machine Interface The active tab button is shaded grey. In the example on the right, the Job Tab is selected. Each tab contains a variety of toggle buttons and open fields. Press any field to open a numeric or alpha-numeric keypad and enter the appro- priate information.

  • Page 46: Job Tab

    TM-401 User’s Guide Job Tab When the TM-401 is initially powered up, the HMI will open to the Job Tab with a red Home Required button at the top of the Tab Menu and the other tab buttons grayed out.
  • Page 47 Chapter 3: Human Machine Interface As the homing sequence is completed, the bar gradually turns from black to green. A Homing Succeeded! message appears at the end of the sequence. If a problem arises during homing, the status bar will turn and a Homing Failed message will...
  • Page 48 TM-401 User’s Guide Job Tab Overview The Job Tab allows the user to select a pre-programmed job, change job information and move to the other tab screens. It also features an easy-to-use Job Wizard which leads the user through the job set-up process. The Job Tab is pictured below.

  • Page 49: Job Wizard

    Chapter 3: Human Machine Interface Job Wizard Pressing the Job Wizard button in the Job Tab opens the Job Wizard. The Job Wizard has 15 screens that lead the user through the job set-up process. Instructions at the top of each Job Wizard screen explain each step. The Arrow buttons on the bottom of the window move the user forward and backwards through the process.
  • Page 50 TM-401 User’s Guide Job Wizard Step 2 Arrow Buttons In the second Job Wizard screen the user enters the Quantity of parts that will be run and a brief Description of the job. When the job parameters are set, press the right Arrow key to move to the next Job Wizard screen.
  • Page 51 Arrow Key to move to the next Job Wizard screen. Note: The TM-401 accommodates a wide range of carrier tapes and cover tapes. Set- tings may vary from one tape product to another. The recommended starting point is 90°...
  • Page 52 3-10 TM-401 User’s Guide The fifth Job Wizard screen is used to enter the number of tubes that will be loaded in the MTID. Job Wizard Step 5 Enter the number of tubes that will be processed. If two Tube Feeders are installed, this will include the total number of tubes to be processed from both feeders.
  • Page 53 Chapter 3: Human Machine Interface 3-11 Center the Pick Head over the first track pocket using the HMI Jog but- tons or the Jog buttons on top of the Sealer enclosure. To see an illus- tration of the correct head placement, push the Help icon. An illustration of the Tube Feeder with the first track pocket identified will appear.
  • Page 54 3-12 TM-401 User’s Guide The next six Job Wizard screens are used to set the Nozzle positions at the Pick and Place locations. The first is shown below. Job Wizard Step 8 Press Pick Extend/Pick Retract to lower the Nozzle to the tube pocket. Follow the directions in Chapter 4: Setup for manually adjusting the Pick Actuator to set the correct Nozzle Height.
  • Page 55 Chapter 3: Human Machine Interface 3-13 If no rotation is required for part placement, skip this step. If part rotation is required for placement, press Rotate Part to rotate the Nozzle 90°. Follow the directions in Chapter 4: Setup for manually adjusting the Solenoid to set Pick Head Rotation.
  • Page 56 3-14 TM-401 User’s Guide Press the right Arrow Key to move to the next Job Wizard screen.. Job Wizard Step 11 Press Place Extend to lower the Nozzle to the Carrier Tape Pocket. Note: The Place Extend button toggles between Place Extend and Place Retract.
  • Page 57 Test the job settings, using the Pick Part and Place Part buttons to pick and place parts. If adjustment are required, use the left Arrow key to return to the desired step and adjust settings until the TM-401 picks and places parts as desired, D292104.6.fm Job Tab...
  • Page 58 3-16 TM-401 User’s Guide Press the right Arrow Key to move to the next Job Wizard screen. Job Wizard Step 14 Select the Camera State to ON ( I ) or OFF (O) as desired. If the camera is ON, enter the number of pockets between the Place point and the Inspection point in the Parts Until Inspection field.
  • Page 59 Chapter 3: Human Machine Interface 3-17 Note: The Save function will overwrite the information stored for the currently selected job. Therefore, it is important to select the desired job prior to pressing the Save button. Press the Save button to save job settings to the selected job name. Press Finish to close the Job Wizard and return to the Job Tab.

  • Page 60: Taper Tab

    3-18 TM-401 User’s Guide Taper Tab The Taper Tab allows the user to adjust taper settings by leading them through four Taper Setup screens. The first screen of the Taper Tab is shown below. Taper Screen 1 A. Tab Menu B.
  • Page 61 PASS message or a red FAIL message. Note: For more detailed inspection configuration and procedures, see the Cognex Checker User’s Guide which was included with the TM-401. Pressing the right Arrow button opens the next Taper Setup screen.
  • Page 62 The Measured field shows the current Heat Sealer temperature in degrees Cel- sius. Note: The TM-401 accommodates a wide range of carrier tapes and cover tapes. Set- tings may vary from one tape product to another. The recommended starting point is 90°...
  • Page 63 Sensor is ON. Note: The Low Cover error message is only displayed once during a job. When Leader State is ON ( I ), the TM-401 will create a leader of the specified length at the end of the job.

  • Page 64: Head Tab

    3-22 TM-401 User’s Guide Head Tab The three Head Setup Tab screens allow the user to set pick and place head positions, head speed, and blow off time. There are also buttons that allow the user to manually pick, place and rotate parts.
  • Page 65 Chapter 3: Human Machine Interface 3-23 Press the right Arrow button to open the second Head Setup screen (shown below). Head Screen 2 The user can either jog the head to the correct position or click inside the location field to the left of the Set buttons and manually enter the correct position. Once the correct position is entered, press the Set Pick/Place Position button to save •The Set Pick Position 1 button saves the current position as the pick position for the first tube in the feeder.
  • Page 66 3-24 TM-401 User’s Guide the pick head is homed, the current position will be 0.00. This distance is measured in mil- limeters. Press the right Arrow button to open the second Head Setup screen (shown below). Head Screen 3 The Pick Extend/Pick Retract button actuates the pick solenoid to enable the operator to set the pick height.
  • Page 67 Tab Menu to move to a new tab. Note: The TM-401 will use these settings for the current job. To save Head Settings for future jobs, go to the Job Tab, select a job name and Save.

  • Page 68: Mtid Tab

    3-26 TM-401 User’s Guide MTID Tab The Manual Tube Input Device (MTID) Setup Tab allows the user to set the number of tubes and utilize the Pitch Wizard to calculate pick position.. A. Tab Menu B. Number of Tubes Fields C.
  • Page 69 Chapter 3: Human Machine Interface 3-27 Press the Pitch Wizard button to open the Pitch Wizard.. A. Help Icon B. Head Jog Controls C. Pick Wizard Control buttons To see an illustration of the correct head placement, push the Help icon. An illustration of the Tube Feeder with the first track identified will appear.
  • Page 70 Press the Finish button to calculate tube pitch and return to the MTID Tab. Note: The TM-401 will use these settings for the current job. To save MTID Settings for future jobs, go to the Job Tab, select a job name and Save.

  • Page 71: Run Tab

    Chapter 3: Human Machine Interface 3-29 Run Tab When Run is selected from the Tab Menu, the Run Tab opens. It includes job information, current job statistics, Status messages and Run control buttons. The Run Screen with all status mes- sages displayed appears below.
  • Page 72 3-30 TM-401 User’s Guide When Reset Job is pressed, the following message appears. • The System Homing button allows the user to home the motor. Homing motors should be done once following every system power up. When System Homing is selected, the Homing Status window will appear.
  • Page 73 Chapter 3: Human Machine Interface 3-31 If a problem arises during homing for the motor, the status bar will turn and a Homing Error message will appear. Pressing the Left Arrow button returns the user to the Run Tab. The Statistics section keeps a running tally of the current job’s Parts Placed, Run Time, and Parts Per Hour.
  • Page 74 3-32 TM-401 User’s Guide Run Tab D292104.6.fm...

  • Page 75: Chapter 4: Machine Setup

    Chapter 4: Machine Setup Contents Quick Start: Setup ......... . .4-2 Power Up the System .

  • Page 76: Quick Start: Setup

    TM-401 User’s Guide Quick Start: Setup The following is an outline of the basic steps required to setup the TM-401 for operation. More detailed instructions follow in the next section of this chapter. Caution: Users should always wear protective eye wear when operat- ing or maintaining the TM-401.

  • Page 77: Power Up The System

    Press the blue Reset Button on the left side of the machine. There will be a brief popping sound as the Air Dump Valve releases air to the machine. As the TM-401 powers up the PLC, Servo Drivers and HMI Monitor will boot up. On top of the machine, the Tower Light will flash red indicating the machine is on but not running.

  • Page 78: Home Motors

    TM-401 User’s Guide Home Motors Step 2: Note: The TM-401 needs to be homed once after each power up or Emergency Home Stop activation. The HMI will prompt the operator to home the motors whenever it Motors is required. Once the motors have been homed, they remain homed until the machine is powered down or the E-Stop is activated.

  • Page 79: Load The Manual Tube Input Device (Mtid)

    Chapter 4: Setup 4- 5 Load the Manual Tube Input Device (MTID) Step 3: Load the MTID The MTID must be loaded with tubes and config- ured for operation. Begin by preparing the MTID, then move to the HMI to adjust settings as needed (Step 6).
  • Page 80 The minimum number of tubes is one. Note: The TM-401 is designed to work with one or two MTIDs. If two MTIDs were included with this TM-401, install them both at this time.

  • Page 81: Nozzle Installation

    • (1) SPT Vacuum Cup • (1) Convum Vacuum Cup • (2) O-Rings Note: Nozzle Tips are available in a wide range of sizes and style. Contact V-TEK Service for information on ordering additional Nozzle Tips. Selecting the Correct Nozzle & Nozzle Tip To achieve the best picking results, select the largest cup size the part can accommo- date.

  • Page 82: Installing Nozzle & Nozzle Tip

    TM-401 User’s Guide Installing Nozzle & Nozzle Tip Step 4: Nozzle Move the Pick & Place Head to the Place position Installation so it is easily accessible from the front. . SELECT NOZZLE Remove the air line from the Nozzle Shank, sup- porting the Nozzle with one hand while gently pull- ing the tube off the Nozzle Barb.

  • Page 83: Taper Setup

    Chapter 4: Setup 4- 9 Taper Setup Step 5: Load Taper Loading Tape The Taper must be loaded with carrier and cover tapes and configured for operation. Begin by preparing the Taper, then move to the HMI to adjust settings. (Step 7) Load Carrier Tape Step 5: Setup...
  • Page 84 4-10 TM-401 User’s Guide Step 5: Mount the bulk carrier tape reel on the spindle, ensuring that there is sufficient tape Setup for the batch to be run. Taper CARRIER The carrier tape should roll off to the left, unwinding from the top so it will feed right side up into the carrier tape channel underneath the Pick Head Enclosure.

  • Page 85: Load Cover Tape

    Chapter 4: Setup 4- 11 Load Cover Tape Step 5: Remove the Reel Lock mechanism and place a reel of cover tape of the correct Setup width to match the carrier tape on the cover tape spindle. The tape should unwind Taper to the right from the bottom of the reel.

  • Page 86: Load Take-Up Reel

    Mechanical Hazard! Avoid placing fingers between the carrier tape and the Take-up Reel when the TM-401 is in operation. Pinching or entrapment may occur if safety precautions are not observed. Taper Setup...

  • Page 87: Configure Hmi Settings

    4- 13 Configure HMI Settings Step 6: Setup The TM-401’s Job Wizard leads the user through the HMI setup process. OPEN JOB WIZARD a. Open the HMI Job Screen. b. Press the Job Wizard button to open the Job Wizard.
  • Page 88 4-14 TM-401 User’s Guide ENTER JOB PARAMETERS. a. Enter Job Quantity b. Enter Job Description. Press the right Arrow key to open the next Job Wizard screen. Step 6: TAPER SETUP Setup HMI Enter Pitch, Seal Type and Dwell Time.
  • Page 89 Settings. Allow the heat sealer to reach operating temperature before continuing. Note: The TM-401 accommodates a wide range of carrier tapes and cover tapes. Set- tings may vary from one tape product to another. The recommended starting point is 90° C. The maximum recommended operat- ing temperature is 160°...
  • Page 90 (leader) and the end (trailer) of the finished reel of placed parts. Therefore, when the reel is being taped on the TM-401, the trailer is the first length of empty carrier tape run before the first part is taped and the leader is the length of empty carrier tape run after the last part is taped.
  • Page 91 Chapter 4: Setup 4- 17 Step 6: ENABLE LEADER. Setup HMI TAPER a. Select Leader State and enter Leader Length if enabled. b. Press the right Arrow key to move to the next screen. D292104.7a.fm Configure HMI Settings...
  • Page 92 4-18 TM-401 User’s Guide Step 6: MANUAL TUBE INPUT DEVICE (MTID) SETUP The next three Job Wizard Setup HMI screens are used to detect Tube Pitch and enter the number of tubes that will be TUBE loaded in the MTID.
  • Page 93 Chapter 4: Setup 4- 19 Step 6: c. Use the Jog controls to position the nozzle Setup HMI over the center of the first tube pocket. TUBE FEEDER d. Press Learn, then press the right Arrow key to move to the next screen. 1st Pocket Last Pocket e.
  • Page 94 NOZZLE a. Place a part in the MTID pick location. b. Open the TM-401 enclosure doors to access the pick head. c. Press Move to Pick to move the Pick Head over the MTID tube pocket in the pick position.
  • Page 95 Chapter 4: Setup 4- 21 and the part. Because the Convum Nozzle Tips are flexible, it is all right if the tip is programmed to touch the part when picking. Press the right Arrow Key to move to the next Job Wizard screen. Step 6: Nozzle Setup: Manual Rotation Setup HMI...
  • Page 96 4-22 TM-401 User’s Guide Set Place Position a. Use the Arrow keys to position the Pick Head and Carrier Tape so the Nozzle is centered over the carrier tape placement position. Step 6: The Up/Down Arrow keys move the Pick Head forward and backward. The Setup HMI Left/Right Arrow keys move the tape left and right in the Taper Track.
  • Page 97 Chapter 4: Setup 4- 23 set at the Place position.. a. To manually set the Place Actuator to the correct nozzle height, press Place Extend b. Use a 2.5mm hex wrench to hold the Actuator Adjustment Screw in place from the bottom, while loosening the Jam Nut on top of the Actuator Adjustment Screw with an 8mm open ended wrench.
  • Page 98 4-24 TM-401 User’s Guide Step 6: Set Rotation Angle Setup HMI NOZZLE a. Enter the placement angle which was manually set in Step 7. The options are 0, -90 and +90. • If rotation is set at 0, the part will be placed...
  • Page 99 Chapter 4: Setup 4- 25 Verify Job Settings Test the job settings, using the Pick Part and Place Part buttons to pick and place parts. If adjustments are required, use the left Arrow key to return to the desired step and adjust settings. Press the right Arrow Key to move to the next Job Wizard screen.
  • Page 100 4-26 TM-401 User’s Guide Step 6: Save Job Settings Setup HMI SAVE SETTINGS a. Browse through the Job Library using the Up/Down Arrow keys to move up or down through the list. To select a Job Name from the list, press the Enter key.

  • Page 101: Test Seal

    Chapter 4: Setup 4- 27 Test Seal Step 7: Seal Test Perform a Seal Test to ensure a good seal. Adjust Sealer settings in the HMI Taper tab as necessary. Run the tape through the taping module by pressing the Continuous Advance button in the HMI Taper Tab.
  • Page 102 Seal Adjust and the Outer Seal Adjust to the desired position, then tighten the Position Locks to secure them. Perform a Seal Test. The V-TEK PT-55 Peel Force Tester is pictured on the right. (Sold separately.) Proceed to Chapter 5: Vision Setup to configure the Vision System for operation.

  • Page 103: Chapter 5: Vision Setup

    Chapter 5: Vision Setup Contents Quick Start: Vision Setup ........5-2 Connect Vision .

  • Page 104: Quick Start: Vision Setup

    Disk prior to operation and conduct periodic back-ups as needed. Visit the computer manufacturer’s website for instruc- tions on creating a recovery disk. V-TEK, Inc. does not create or maintain recovery information for this laptop. Creating a recovery disk is solely the users’ responsibility.

  • Page 105: Connect Vision

    Step 1: Vision Setup Note: The TM-401 vision system can be run with a computer or a Keyence IV-G CONNECT Monitor. These options are not included with the TM-401. They can be purchased separately from V-TEK, Inc. or the user may provide their own computer.
  • Page 106 Keyence IV-G Monitor. If using one of these options, skip this step and proceed to Configure Inspection. On the TM-401 HMI, select the Taper Tab, then press the Right Arrow key to advance to the second Taper screen.

  • Page 107: Connect Computer

    Chapter 5: Setup 5- 5 Connect Computer Step 1: Vision Follow the steps below to connect the Keyence IV-G Camera to the vision computer. Setup (Proceed to the next section if using the Keyence Monitor instead of a computer.) CONNECT LAPTOP Open the Control Panel, then select Network and Sharing Center.
  • Page 108 TM-403 User’s Guide Step 1: Double click Internet Protocol version4 (TCP/IPv4) Vision Setup CONNECT LAPTOP Ensure Obtain an IP address automatically is selected. Click OK. Connect Vision D292104.16.fm...
  • Page 109 Chapter 5: Setup 5- 7 Step 1: To select a stored inspection or configure a new inspection, open Vision the Keyence Inspection System software by double-clicking on Setup the IV Navigator icon on the desktop. CONNECT LAPTOP Select Direct Connection. The following pop-up will appear.
  • Page 110 TM-403 User’s Guide Step 1: A Connecting to Sensor status window will open. Vision Setup CONNECT LAPTOP Once the connection is complete, the Run/Program window will open. Connect Vision D292104.16.fm...

  • Page 111: Connect Keyence Monitor

    Connect the Monitor's power cable to the power connection on the back of the TM- 401 (B). Turn the TM-401 ON. The Keyence Monitor will automatically start and open the Keyence software program. Select Direct Connection, then press Connect to establish a connection between the Keyence Monitor and the Keyence Camera.

  • Page 112: Configure Inspection

    America. In order to use the Keyence IV Vision System, the camera must be configured and set to Run Mode in the Keyence HMI as well as being enabled on the TM-401 HMI. Please complete the following instructions to cor- rectly configure the vision system.
  • Page 113 Chapter 5: Setup 5- 11 Step 2: Click Trigger ON, then center a part under the camera. Vision Setup CONFIGURE COMPUTER Select or create a program from the Program drop-down menu. A yellow Selection Box will appear over the part image. Click NAVI Sensor Setup.
  • Page 114 5-12 TM-403 User’s Guide Step 2: The Image Optimization window will open. Vision Setup CONFIGURE COMPUTER Select the Trigger Options button on the right. Configure Inspection D292104.16.fm...
  • Page 115 Chapter 5: Setup 5- 13 Step 2: Adjust Trigger Options to External Trigger with a 0ms Trigger Delay. Vision Setup CONFIGURE COMPUTER Select the Brightness Adjustment button on the right Set the Imaging Mode to High Gain, then click the Automatic Brightness Adjustment button.
  • Page 116 5-14 TM-403 User’s Guide Step 2: Vision Setup CONFIGURE COMPUTER Select the Focus Adjustment button on the right. Click the Automatic Focus Adjustment button. One or more yellow dots may appear above the Undo button, representing the best focus point(s). Click on the yellow dot(s) to jump to the associated focus point and select the best one.
  • Page 117 Chapter 5: Setup 5- 15 Step 2: Vision Setup CONFIGURE COMPUTER Select the Extended Functions button on the right. Click on the Imaging Area tab (not shown) and adjust the selection box so it captures the minimum area needed to achieve the desired inspection. D292104.16.fm Configure Inspection...
  • Page 118 5-16 TM-403 User’s Guide Step 2: Vision Setup CONFIGURE COMPUTER Click on the Lighting tab and select ON and Flash. Then click the Next to STEP2 button which is located in the bottom right corner of the window. The Save Master window will open. Configure Inspection D292104.16.fm...
  • Page 119 Chapter 5: Setup 5- 17 Step 2: Select Register Live image as master. Vision Setup CONFIGURE COMPUTER Select Register the image. Once the image has been registered, click OK. Then click Next to STEP3. D292104.16.fm Configure Inspection...
  • Page 120 5-18 TM-403 User’s Guide Step 2: The Tool Settings window will open. Vision Setup CONFIGURE COMPUTER Select Add Tool. Configure Inspection D292104.16.fm...
  • Page 121 Chapter 5: Setup 5- 19 Step 2: Select the Outline tool, then click OK. Vision Setup CONFIGURE COMPUTER A green outline will now appear around the selected mark. Click OK. D292104.16.fm Configure Inspection...
  • Page 122 5-20 TM-403 User’s Guide Step 2: The Tool Settings Options will now appear as below. Vision Setup CONFIGURE COMPUTER Configure Inspection D292104.16.fm...
  • Page 123 Chapter 5: Setup 5- 21 Step 2: Adjust the yellow Selection Box so it surrounds the selected mark. Vision Setup CONFIGURE COMPUTER In the Fine Tune Outline section, click the Remove Outline button. D292104.16.fm Configure Inspection...
  • Page 124 5-22 TM-403 User’s Guide Step 2: The Eraser Settings window will open. Vision Setup CONFIGURE COMPUTER The Eraser appears as a white square on the image. Adjust eraser size as needed, then click and drag it over any unwanted data that is outlined in green on the image.
  • Page 125 Chapter 5: Setup 5- 23 Step 2: Vision Setup CONFIGURE COMPUTER Click Live Adjustment and the sensor will continuously take measurements. Adjust the threshold to yield the highest difference between good and bad parts, then click OK. D292104.16.fm Configure Inspection...
  • Page 126 5-24 TM-403 User’s Guide Step 2: The Output Assignment window will open. Set up the Outputs as shown below. Vision Setup CONFIGURE COMPUTER • Set OUT1 to Total Status. • Set OUT2 to Tot.StatusNG. •Set all remaining output to OFF. •Set Trigger Error Output to Disable.
  • Page 127 Chapter 5: Setup 5- 25 Step 2: Click Complete to return to the Run/Program window. Select Run. Vision Setup CONFIGURE COMPUTER Click the Manual Trigger button which is located under the Program button to test the inspection criteria. The test results will appear on the right side of the window. D292104.16.fm Configure Inspection...
  • Page 128 Vision Setup CONFIGURE COMPUTER On the TM-401 HMI, open the Taper Tab. Press the right Arrow button to advance to the second Taper screen. Press Trigger to manually trigger an inspection of the part under the camera. The green PASS message should appear.
  • Page 129 Next trigger inspections with parts which are incorrectly oriented, badly marked or Vision with an empty pocket to ensure that they generate a red FAIL message. Setup CONFIGURE COMPUTER The TM-401 is now ready for operation. Select the Run Tab to run the job. D292104.16.fm Configure Inspection...

  • Page 130: Configure Keyence Monitor

    5-28 TM-403 User’s Guide Configure Keyence Monitor Step 2: Vision Setup CONFIGURE Monitor Display: Menu OFF MONITOR Title: Displays the device name, the program number and the program name. Tool name: Displays the tool number and the tool name of the tool selected. The selected tool can be switched.
  • Page 131 Chapter 5: Setup 5- 29 Monitor Display: Menu ON Step 2: Vision Setup CONFIGURE MONITOR Title: Displays the device name, the program number and the program name. Tool name: Displays the tool number and the tool name of the tool selected. The selected tool can be switched.
  • Page 132 5-30 TM-403 User’s Guide Step 2: Sensor Image Memory button: Displays the Sensor Image Memory screen. Vision USB memory button: Displays the USB memory screen. Setup CONFIGURE Sensor setup button: Stops running mode and displays the Sensor setup menu MONITOR screen.
  • Page 133 Chapter 5: Setup 5- 31 Setup Image Optimization Step 2: Vision Setup Touch Trigger Options. CONFIGURE MONITOR Select the External Trigger type. Touch OK. D292104.16.fm Configure Inspection...
  • Page 134 5-32 TM-403 User’s Guide Step 2: Touch Auto Brightness Adjustment. Touch OK. Vision Setup CONFIGURE MONITOR Touch Focus Adjustment. If Auto focusing is selected, the focus position is adjusted automatically. If Manual focusing is selected, the focus indicator will be displayed.
  • Page 135 Chapter 5: Setup 5- 33 Register Master Image Step 2: Vision Setup After setting the image optimization, press Register Live Image as Master. CONFIGURE MONITOR Image the target and touch the Trig button. Check the image displayed on the monitor and touch the Register button. Touch Touch Next to proceed to “STEP3”....
  • Page 136 5-34 TM-403 User’s Guide Setup Outline Detection Tool Step 2: Vision Setup Touch the Add Tool button. CONFIGURE MONITOR Select Outline. Touch Edit Window. Configure Inspection D292104.16.fm...
  • Page 137 Chapter 5: Setup 5- 35 Step 2: Set the position, size, and the angle of the tool window. The detected outline will be Vision displayed in green. After the setting is completed, touch OK. Setup CONFIGURE MONITOR Touch the Limit Adjustment button. D292104.16.fm Configure Inspection...
  • Page 138 5-36 TM-403 User’s Guide Step 2: Set the threshold to judge OK and NG. Vision Setup CONFIGURE MONITOR The display will return to the main screen for the Outline tool. Touch OK, then touch Next to proceed to “STEP4”. Setup Area Detection Tool Touch the Add Tool button.
  • Page 139 Chapter 5: Setup 5- 37 Step 2: Touch Edit Window button. Vision Setup CONFIGURE MONITOR Set the position, size, and the angle of the tool window. After the setting is completed, touch OK D292104.16.fm Configure Inspection...
  • Page 140 5-38 TM-403 User’s Guide Step 2: Touch the Brightness Extraction button. Vision Setup CONFIGURE MONITOR Touch the brightness area to be the reference of judgment for the Area tool, then touch OK. Configure Inspection D292104.16.fm...
  • Page 141 Chapter 5: Setup 5- 39 Step 2: Touch the Limit Adjustment button. Vision Setup CONFIGURE MONITOR Set the threshold to judge OK and NG, then touch OK. The display will return to the main screen for the Color Area/Area tool. Touch OK, then touch Next to proceed to “STEP4”.
  • Page 142 5-40 TM-403 User’s Guide Setup Position Adjust Detection Tool Step 2: Vision Setup Touch the Add Tool button. CONFIGURE MONITOR Touch the Pos.Adj. button. Touch the Edit Window button. Configure Inspection D292104.16.fm...
  • Page 143 Chapter 5: Setup 5- 41 Step 2: Set the position, size, and the angle of the tool window. The detected outline will be Vision displayed in green. Touch OK. Setup CONFIGURE MONITOR Touch the Limit Adjustment button. D292104.16.fm Configure Inspection...
  • Page 144 5-42 TM-403 User’s Guide Step 2: Set the threshold to judge OK and NG. Vision Setup CONFIGURE MONITOR After the setting is completed, touch OK. The display will return to the main screen for Position Adjustment tool. Touch OK again, then touch Next to proceed to “STEP4”. Setup Output Touch the output line to assign the output function.
  • Page 145 Chapter 5: Setup 5- 43 Step 2: Vision Setup CONFIGURE MONITOR Set the output functions as follows: • OUT1 = Busy • OUT2 = Total Status • OUT3 - OUT8 = OFF After the setting is completed, touch Complete, then touch Yes. D292104.16.fm Configure Inspection...
  • Page 146 5-44 TM-403 User’s Guide Configure Inspection D292104.16.fm...

  • Page 147: Chapter 6: Operation

    Chapter 6: Operation Contents Quick Start: Running a Job ........6-2 Preparing to Run a Pre-programmed Job .

  • Page 148: Quick Start: Running A Job

    The following is an outline of the basic steps required to run a pre-programmed job. More detailed instructions follow in the next section of this chapter. Caution: Users should always wear protective eye wear when operat- ing or maintaining the TM-401. Power up. • Power up the machine by turning on the Main Power Switch.
  • Page 149 • On the HMI, select the Run Tab then press Run. • Load/unload parts and reels as needed. Caution! V-TEK® Incorporated takes no responsibility for the safety of TM-401 if it is used for any purpose other than the intended purpose as specified in this User’s Guide.

  • Page 150: Preparing To Run A Pre-Programmed Job

    Press the blue Reset button on the left side of the machine. Step 2: Home Motors Home Note: The TM-401 only needs to be homed once after each power up or emer- Motors gency stop. Once the motors have been homed, they remain homed until the machine is powered down.

  • Page 151: Home Motors

    Chapter 6: Operation 6- 5 Step 2: Press the Home All Motors button. Home Motors The motor homing sequence begins with the nozzle moving slowly upwards (Z Axis movement). After about a three second delay, the pick head will begin to move slowly to the right towards the taper (X Axis movement).

  • Page 152: Setup The Manual Tube Input Device (Mtid)

    Adjust feeder position on Slotted Plate Y Axis Clamping Bolts Load filled tubes into feeder.. Note: The TM-401 is designed to work with one or two MTIDs installed. Follow the setup procedures for both MTIDs if the optional second feeder is installed.

  • Page 153: Setup The Taper

    Chapter 6: Operation 6- 7 Setup the Taper Step 4: Setup Load the correct carrier tape and cover Taper tape, adjusting the track width as necessary. Select PSA or Heat seal. Align cover tape with carrier tape. Run a pull test and adjust seal strength as needed.

  • Page 154: Select Job

    TM-401 User’s Guide Select Job Step 5: Select When a job is already set up and saved in the machine’s memory, the first step in running the job is to call it up with the Job Select screen. On the HMI, select the Job Tab Browse through the Job Library to locate the desired job by using the up and down Arrow buttons.

  • Page 155: Setup The Pick Head

    Chapter 6: Operation 6- 9 Setup the Pick Head Step 6: Setup Ensure the correct Nozzle and Nozzle Tip are installed for the job that will be run.: Pick Head Note: See the Chapter 4: Setup for nozzle change procedures. Open the Head Tab on the HMI.

  • Page 156: Setup Vision

    Step 7: Setup Vision Setup The TM-401 Vision System will automatically revert to the previous inspection. If the Vision same part is being run, there is no need to retrain the camera. Proceed to Step 8. If a dif- ferent job/inspection is being run, follow the setup instructions in Chapter 4: Setup.

  • Page 157: Run The Job

    2D Inspection. Otherwise no other adjustments are required for a job that has already been defined properly. When the preset number of parts has been run, the TM-401 will automatically stop operation. Cut the sealed tape at the cut point and use a piece of blue Permacel tape to secure the finished reel.
  • Page 158 6-12 TM-401 User’s Guide Preparing to Run a Pre-programmed Job D292104.8a.fm...

  • Page 159: Chapter 7: Troubleshooting

    Chapter 7: Troubleshooting Contents Emergency Stop..........7-2 Activating an Emergency Stop .

  • Page 160: Emergency Stop

    If emergency stop condition occurs, follow the steps below to resolve the failure. Press the red E-Stop button to place the TM-401 into an Emergency Stop state. The Tower Light will switch to red and all operations will cease and the HMI will power off.
  • Page 161 Chapter 7: Troubleshooting Press the blue Reset button. The Boot Screen will appear on the HMI Monitor and display a loading progress message. This process typically takes about 90 seconds to complete. Once the system has finished booting, the HMI will open to the Job Tab with the Home Required button displayed.
  • Page 162 TM-401 User’s Guide The Homing Status window will open. Press Home All Motors When the homing sequence is completed, the bar will turn from black to green and a Hom- ing Succeeded! message will appear. Emergency Stop D292104.9a.fm...
  • Page 163 Chapter 7: Troubleshooting Once homing is complete, press the Left Arrow button will open the Run Tab. Press the Run button on the HMI Run Tab to resume operation. D292104.9a.fm Emergency Stop...

  • Page 164: System Alarm Messages

    System Alarm Messages contain a description of the problem and suggestions for resolving the problem. They also include an illustration of the TM-401 with the area of interest indicated by a flashing red outline.
  • Page 165 Chapter 7: Troubleshooting Note: There are a variety of error conditions which could cause the machine to stop. See the Error Message Table at the end of this section for an explanation of the various error messages and their suggested solutions. An illustration and description of each System Alarm Message follows.
  • Page 166 TM-401 User’s Guide Part Lost System Alarm If a part falls off the nozzle and is lost during the Pick process, the Part Lost system alarm will be activated. When this happens, operation stops, a beep sounds, and a warning appears on the HMI.
  • Page 167 Chapter 7: Troubleshooting No Part To Place System Alarm If the user attempts to place a part in tape when there is no part on the Nozzle, the No Part To Place System Alarm will be activated. When this happens, operation stops, a beep sounds, and a warning appears on the HMI.
  • Page 168 7-10 TM-401 User’s Guide Tape Jam Sensor System Alarm The Tape Jam Sensor is located on the Taper Track just before the Sealer. It detects when parts are protruding above the top of the pocket due to a misplaced part or tape jam.
  • Page 169 Chapter 7: Troubleshooting 7-11 Vision Error System Alarm The 2D Inspection System is mounted on the Taper between the place point and the Sealer. It inspects parts for mark and orienta- tion. It also detects empty pockets If the 2D Inspection System detects an inspection error, the 2D Inspection System Alarm will be activated.
  • Page 170 7-12 TM-401 User’s Guide Vision Timeout System Alarm If the 2D Inspection System fails to inspect a part within a preset time period, the Vision System Timeout System Alarm will be activated. Tape advance stops, a beep sounds and a warning appears on the HMI.
  • Page 171 Chapter 7: Troubleshooting 7-13 Temperature Out of Range System Alarm When Heat Seal is enabled and the Heat Shoe temperatures are either too hot or too cold, a Heat Seal Temperature Out of Range system alarm will activate. When this occurs, tape advance stops, a beep sounds and a warning appears on the HMI. To clear the Heat Seal Temperature Out of Range System Alarm, wait for the heat shoes to reach their set point and then press CONTINUE to clear the alarm and resume operation.
  • Page 172 7-14 TM-401 User’s Guide Heat Sealer Inactivity System Alarm If the Taper is inactive for 40 minutes or longer, the Heat Sealer is automatically disabled. Once that occurs, if a user attempts to run a job, or use Continuous Advance, Pocket Advance or Man- ual Seal a Heat Sealer Inactivity system alarm will activate.
  • Page 173 START again to continue with the current level of cover tape. Note: The Low Cover Tape warning will only appear once during a job. If the user ignores the message and continues operation, the TM-401 will continue taping until the job is fin- ished or the cover tape is empty.
  • Page 174 7-16 TM-401 User’s Guide Job Quantity Inadequate System Alarm If during the course of a job, the operator changes the job quantity to less than the amount of parts that have already been processed a Job Quanity Inadequate message will appear on the HMI.
  • Page 175 Chapter 7: Troubleshooting 7-17 Job Completed System Alarm If the operator completes a job and then attempts to run the same job again without resetting the job, a Job Completed System Alarm will appear on the HMI. The operator can resolve the alarm by resetting the job. Push Continue to clear the alarm mes- sage and resume processing.
  • Page 176 7-18 TM-401 User’s Guide Halted State Error Condition If the E-Stop button is pressed or the system is started up and the Reset button is not pressed, the following message will appear on the HMI. To resolve the error message, clear the emergency stop condition, then twist and release the E-Stop button.
  • Page 177 To resolve the error condition in this instance, enter an acceptable value into the field. If this message persists, it indicates that the Ethernet connection to the PLC may have been lost. Contact V-TEK Service for support. D292104.9a.fm System Alarm Messages...

  • Page 178: Error Message Table

    7-20 TM-401 User’s Guide Error Message Table Error Condition Solution “The system was unable to suc- Nozzle is not picking parts from the Tube Feeder. Check cessfully pick from the feeder.” the following: - Feeder is empty. - Tube Feeder is jammed.
  • Page 179 - If an unacceptable value has been entered into a setup tion...” field, change the value to one that fits that field’s parame- ters. - If this message persists, the Ethernet connection to the PLC may have been lost. Contact V-TEK Service for sup- port. D292104.9a.fm System Alarm Messages...

  • Page 180: Adjusting Nozzle Vacuum Sensors

    If the TM-401 places “empty” pockets (i.e. places as though it held a part when it did not) or returns a picking part error when it picked a part, the vacuum sensor’s threshold point probably needs to be adjusted.

  • Page 181: Tips On Part Placement

    Chapter 7: Troubleshooting 7-23 Tips on Part Placement If components are not dropped properly, there are four variables that can be adjusted to correct the problem. Note: Each part is different and may require a different combination of adjustments to obtain proper place performance.
  • Page 182 7-24 TM-401 User’s Guide Press the Right Arrow to move to the next Head Tab.. Jog the head up or down until the nozzle is centered correctly over the place location. When the nozzle is positioned correctly, press the Set Place Position button.
  • Page 183 If Nozzle Blow Off is set too high, the excess air may cause the part to bounce back out of the pocket. Adjust the Nozzle Blow Off value until the TM-401 consistently and accurately places parts in the carrier tape.

  • Page 184: Sensor Adjustments

    7-26 TM-401 User’s Guide Sensor Adjustments Adjusting the Low Cover Sensor The Low Cover Sensor alerts the operator at the begin- ning of a job if there is not enough cover tape loaded on the Cover Tape Reel to complete the job.

  • Page 185: Adjusting Heat Seal Quality

    Note: Generally it is best practice to adjust the temperature to achieve the desired peel force. The TM-401 accommodates a wide range of carrier tapes and cover tapes. Settings may vary from one tape product to another. The suggested starting point is 90 degrees Cel- sius.

  • Page 186: Seal Pressure

    7-28 TM-401 User’s Guide Seal Pressure This control is located on the front of the Taper. It controls the amount of force applied when the sealer shoes drop. Turning the Seal Pressure control clockwise will increase the pressure, while turning it counter-clockwise will decrease the pressure.

  • Page 187: Adjusting Psa Seal Quality

    Chapter 7: Troubleshooting 7-29 Adjusting PSA Seal Quality If a Peel Force Test determines the PSA Sealer is not generating a satisfactory seal, try one of the adjustments below to improve seal strength. Check Sealer Settings Open the HMI Taper Tab. Review the settings on the four Taper Tab screens to ensure Tape Settings and Sealer Settings are appropriate for...
  • Page 188 7-30 TM-401 User’s Guide Adjusting PSA Seal Quality D292104.9a.fm...

  • Page 189: Chapter 8: Maintenance

    Chapter 8: Maintenance Contents Safe Maintenance Steps ........8-2 Maintenance .

  • Page 190: Safe Maintenance Steps

    TM-401 User’s Guide Safe Maintenance Steps Caution! It is dangerous to service or maintain the TM-401 while it is con- nected to air and power supplies. Before performing any maintenance tasks, ensure the machine is stationary and disconnect the electrical and pneumatic power supplies placing the unplugged cables in clear view.

  • Page 191: Maintenance

    Chapter 8: Maintenance 8- 3 Maintenance Only maintenance personnel that have thoroughly read and understand the TM-401 User’s Guide and have several years experience operating and maintaining similar machines should be permitted to maintain the TM-401. Routine Maintenance Schedule The TM-401’s simple, low-maintenance design keeps required maintenance to a minimum. The following schedule indicates common maintenance tasks and how frequently they should be per- formed.

  • Page 192: Lubrication

    Lubrication No lubrication is required or desired on the TM-401 as all parts are no maintenance in this regard and the use of lubricants could interfere with components.

  • Page 193: Pick Head Maintenance

    Chapter 8: Maintenance 8- 5 Pick Head Maintenance Nozzle Tip Inspect the nozzle tip daily for excessive wear or damage. Remove and replace as necessary. See Chapter 4: Machine Setup for instructions on changing the nozzle tip. Vacuum Levels Check Vacuum levels weekly. This recorded information on high/ low vacuum levels is useful on a week to week basis and can indi- cate pneumatic problems such as loose fittings or seal problems.
  • Page 194 TM-401 User’s Guide Remove the air line from the Nozzle Shank. Use a needle-nose pliers to remove the air line from the Upper Filter Fitting which is located at the top of the Vacuum Filter. Use a 2.5mm Hex wrench to remove the retaining screw that holds the Filter in place.

  • Page 195: Check Actuator Belt Tension

    Deflect the Belt 1/4" (6 mm) in either direction. The force gauge should read between 12 and 16 lbs. [53 - 62 N]. Deflect 1/4” Note: Contact V-TEK Service for tensioning procedure if belt tension is outside tolerance. D292104.10a.fm General Maintenance Tasks...

  • Page 196: Taping Module Maintenance

    TM-401 User’s Guide Taping Module Maintenance Heat Sealer Heat sealer maintenance consists mainly of cleaning built-up debris and adhesive residues from the heat shoes. It should be cleaned after every 120 hours of operation or as needed. To clean the heat shoes, follow the steps below.
  • Page 197 Chapter 8: Maintenance 8- 9 Clean the residues from the heat shoes by using a plastic or brass brush soaked in alco- Heat Shoe hol to remove any residue that has built up on the lip of the heat shoe. Note: Do not use a steel bristled brush.

  • Page 198: Loading Track

    8-10 TM-401 User’s Guide Loading Track The Loading Track should be cleared of dust and debris after every 40 hours of operation. Strip the machine, remove the cover tape guide, and brush the dust and debris from the track with a small, stiff bristled paint brush. Excessive build-up of dirt and debris can cause carrier tape jams.
  • Page 199 Appendix A: Sensors Contents Keyence FS-N11CVP/FS-N12CP Sensor Amplifiers ....A-2 SMC ZSE30 Vacuum Sensor........A-4...
  • Page 200 Appendix A: Sensors Keyence FS-N11CP & FSN12CP Sensor Amplifiers The Keyence FS-N11CPand FS-N12CP sensor amplifiers (shown in Figure A.1 below) are used on the TM-403 for the Low Cover Tape Sensor and the Tape Jam Sensor. Both amplifiers are mounted on the Cover Tape Arm. The Low Cover Tape amplifier (FS-N11CP) is located on the left.

  • Page 201: Appendix A: Sensors

    Appendix A: Sensors Locking the Keys It is sometimes desirable to lock the keys of the sensor amplifiers so that the currents settings are not inadvertently changed. Hold down the Manual button and the Mode button simultaneously for at least three sec- onds.

  • Page 202: Smc Zse30 Vacuum Sensor

    Appendix A: Sensors SMC ZSE30 Vacuum Sensor The SMC ZSE30 Vacuum Sensor functions as a Pick & Place Head part present sensor. It com- pares the vacuum pressure at the pick and place nozzle to a threshold point. When the vacuum pressure drops beneath this level the sensor sends an OFF signal to the machine (the LCD display will be green).
  • Page 203 Appendix A: Sensors one is present, set the threshold closer to the pressure reading when no part is on the nozzle. In this way, the optimum setting for each specific part can be reached. Initial Factory Settings If for some reason the sensor needs to be re-initialized to the default factory settings, follow the steps below: Press and hold the Set button for at least two seconds.
  • Page 204 Appendix A: Sensors SMC ZSE30 Vacuum Sensor D292104.11.fm...
  • Page 205 TM-401 Suggested Spare Parts List Part Number Description 102534 Reset Switch Contact 102597 Digital Pressure Switch 105786 Take-up Motor 200401 Sealer Air Regulator 200636 Solenoid Air Valve 201026 Pick & Place Vacuum Air Filter 201207 Convum Vacuum Cup 209250 Pick & Place Spring...

  • Page 206: Spare Parts List

    Spare Parts List TM-401 User’s Guide Caution! Only genuine spares should be used on the TM-401. Failure to use genuine spare parts could render the machine unsafe and void factory warranty. D292104.12.fm...
  • Page 207 TM-401 Exploded Views Document List Final Assembly Pages 1-6 291679.slddrw Base Assembly Pages 1-8 291672.slddrw Electrical Panel Pages 1-5 291670.slddrw Guard Assembly Pages 1-4 291671.slddrw Manual Tape Input Device (MTID) Page 1-2 291523.slddrw Pick & Place Assembly Pages 1-10 291822.slddrw Pick &...
  • Page 285 751 Summit Avenue Mankato, MN USA 56001 Website: www.vtekusa.com Email: service@vtekusa.com Phone: (507) 387-2039 For inquiries regarding spare parts, tape and reel supplies, or the ser- vice department, please call or write: Phone: (507) 387-2039 Email: service@vtekusa.com Please provide the machine model and serial numbers with all inquiries. NOTES ____________________________________________________________ ____________________________________________________________...
  • Page 286 Service and Parts Contacts 61053915.fm Page 2...
  • Page 287 TM-401 Document List Section Pages File Name Cover Sheet Pages 1 - 2 D292013.1b.fm EC Declaration of Conformity Page 1 of 1 TM-400 DOC.pdf Introduction Pages i - xii D292013.2.fm Table of Contents Pages 1 - 4 D292013.3b.fm Chapter 1: Installation & Assembly Pages 1-1 to 1-10 D292013.4.fm...
  • Page 288 TM-401 Document List D292104.15b.fm Page 2...
  • Page 289 12. The warranty applies only to normal use of the equipment and shall be void if V-TEK determines that defects in or failures of the equipment were caused by the Customer’s negligence including the lack of proper preventative maintenance, misuse or accident or by unauthorized repair, alteration or installation.
  • Page 292 751 Summit Avenue Mankato, MN 56001 (507) 387-2039 FAX: (507) 387-2257 www.vtekusa.com Email: info@vtekusa.com...

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