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V-TEK TM-500 User Manual

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TM-500
User's Guide
Original Instructions
CE Certified, ISO 9001:2008 Certified
V-TEK, Incorporated
(P) 507-387-2039
751 Summit Avenue
(F) 507-387-2257
Mankato, Minnesota 56001
service@vtekusa.com
USA
www.vtekusa.com
User's Guide # D292142D

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  • Page 1 TM-500 User’s Guide Original Instructions CE Certified, ISO 9001:2008 Certified V-TEK, Incorporated (P) 507-387-2039 751 Summit Avenue (F) 507-387-2257 Mankato, Minnesota 56001 service@vtekusa.com www.vtekusa.com User’s Guide # D292142D...
  • Page 2 European Representative QNET BV Hommerterweg 286 6436 AM Amstenrade The Netherlands Vendor Provided Material Significant portions of this documentation were provided by: SCANNERTECH LLC 5026 S. Roosevelt St. Tempe, Arizona 85282 Tel: (480) 540-4154 Fax: (480) 505-2253 info@scannertech.com www.scannertech.com...
  • Page 3   EC Declaration of Conformity  Manufacturers Name:   V‐TEK Incorporated  Manufacturers’ Address:  751 Summit Avenue                                                                         Mankato, MN 56001 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. If a request is received documentation  will be delivered on a CD or by post.  TM 500 Tape Machine Description:    Model Number:  TM 500   Specification:  Load measuring range and sizes of sealed carrier tape.  Serial Number/s:   …………..  The following standards have either been referred to or been complied with in part or in full as relevant:   EN ISO 12100:2010  Safety of machinery  ‐   Safety of machinery ‐ General principles for design ‐    ...
  • Page 4 Introduction Contents Introduction ..........ii Theory of Operation .
  • Page 5 Introduction Thank you for purchasing the TM-500 Component Handling Machine. The TM 500 is a multiple input, pick and place, test, inspection and taping machine designed for high mix/low volume pro- duction environments for electronic devices. The flexibility of multiple inputs reduces the need for additional machines, simplifies and speeds set up and operations, thus delivering a fast ROI.
  • Page 6 When the TM-500 is set in motion, the pick head picks an individual part from the installed input module. The part can then be placed directly into a carrier tape pocket or positioned for 3D inspection or electrical testing prior to placement.
  • Page 7 Note: The TM-500 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-500 can also handle other voltage levels seen in other parts of the world including voltages from 208V-240V @ 50/60 Hz.
  • Page 8 Intended Use The intended use of the TM-500 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-500 is designed to accommodate a full range of electronic devices. Input options vary with the type of input module installed.
  • Page 9 The intended electrical environment is Pollution Degree 2 and Over Voltage Category II. Misuse The TM-500 weighs approximately 1,200 lb. (545 Kg) and requires a forklift or other lifting equip- ment to be raised off the floor. It’s built so its legs can be raised to engage four wheels on its bot- tom.
  • Page 10 Power/Emergency Stop Button. This position allows the oper- ator to view all parts of the TM-500 while it is in operation. When loading or unloading the TM-500 or changing input modules, the operator may also need to access the front and side enclosure...
  • Page 11 OFF position. Emergency Stop Switches There are three Emergency Stop Switches on the TM-500. One is located on the front of the machine below the Upper Enclosure. Two are located on the back of the machine under the Upper Enclosure.
  • Page 12 Open Doors Stop Operation All automated motion stops when an enclosure cabinet door is opened. The only exception to this is the Tape Advance function which allows the user to load and unload the taper. The pick head, nozzle, tape and trays can only be moved manually as long as the doors are open. Once a job has been selected or programmed, it can be started and stopped from the HMI or by pressing the Start and Stop buttons.
  • Page 13 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-500 is ready for the next process. Safety Features...
  • Page 14 Safety Warning Labels The following warning labels have been placed in various places on the machine to bring safety issues to the attention of operators and technicians working with or near the machine. Attention Indicates an adjustment or danger zone requiring attention. Electrical Hazards Indicates that hazardous voltage levels are present.
  • Page 15 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 16 Unpacking the TM-500........

  • Page 17: Table Of Contents

    Table of Contents (continued) Chapter 3: The Human Machine Interface ........3-1 Introduction .
  • Page 18 Table of Contents (continued) Chapter 5: Vision Setup ..........5-1 Vision Options .
  • Page 19 Table of Contents (continued) Chapter 8: Maintenance ..........8-1 Safe Maintenance Steps .
  • Page 20 Assembling the TM-500 ........

  • Page 21: Preparing The Work Area

    Work Space Requirements The TM-500 is an automated pick & place machine which needs to be placed on a flat, stable surface in a well lit area. It requires a minimum work area of 7’ high x 13.5’ wide x 9‘deep (2.2m x 3.7m x 2.7m) to provide sufficient space for the assembled machine when it is fully loaded with a...
  • Page 22 Arm and Carrier Arm positions to avoid tripping. Power Requirements The TM-500 will also require access to a 85-110 PSI air pressure system and a 230/240 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 23: Unpacking The Tm-500

    TM-500 User’s Guide Unpacking the TM-500 The TM-500 is partially disassembled, then shrink wrapped, placed in a crate for shipping and strapped to the crate floor. The disassembled TM-500 parts, which include the Carrier Tape Arm, the Take-up Assembly, the Monitor Arm, the Monitor, Mouse and Keyboard and various Input Module options, are individu- ally bubble-wrapped and packed around the base machine.

  • Page 24: Assembling The Tm-500

    Hex wrench set (provided with machine) 85-110 PSI air pressure system Note: Read the TM-500 User’s Guide before assembling the TM-500. Unpack the Crate. a. Remove the smaller items one at a time from the crate and place on a flat, stable sur- face for assembly.
  • Page 25 Position the TM-500 in the work area so there is at least 3 feet of clearance on the front. left and right sides. (See the Preparing the Work Area section earlier in this chapter for details.)
  • Page 26 Connecting the Take-up Arm a. Use an 1/4” hex wrench to connect the Take- up Arm. b. Plug the power cord into the power recepta- cle on the front of the machine. D292142.4.fm Assembling the TM-500...
  • Page 27 TM-500 User’s Guide Setting up the Monitor Arm. a. Attach the Monitor Arm to the to the front right corner of the machine using the pro- vided bolts. b. Attach the Keyboard/Mouse Tray to the Monitor Arm. c. Place the Monitor on the Monitor Arm.
  • Page 28 V-TEK. The TM-500 is fully tested before shipping. No further grounding or testing is required during re-assembly and installation. The TM-500 is ready to power up. Follow the instructions in Chapter 3: Machine Setup to setup the machine for operation.

  • Page 29: Installing Modules

    Installing Modules Installing the Bowl Feeder Note: Bowl feeders are specific to part types. TM-500 bowls vary depending on the type of part they are intended to process. The bowl pictured below may appear different from the module that you selected.
  • Page 30 Use a 5mm hex wrench to screw the (2) shoul- der bolts which are provided through the base of the Bowl Feeder and into the TM-500 base- plate, attaching the module securely to the machine.

  • Page 31: Installing The Ultravim 2D System

    1-12 TM-500 User’s Guide Installing the UltraVim 2D System UltraVim 2D Vision (2D over Tape shown above.) Vision installation may only be performed by qualified V-TEK Service personnel. Installing the UltraVim 2D System D292142.4.fm...

  • Page 32: Chapter 2: Tm-500 Overview

    Chapter 2: TM-500 Overview Contents Front View ........... . 2-2 Right Side View .

  • Page 33: Front View

    TM-500 User’s Guide Front View A. Reset/Off/On Control Buttons H. Taper B. Pick Head Bridge I. Computer Monitor/HMI C. Cover Tape Arm J. Monitor Arm Tray with Keyboard & Mouse D. Pick & Place Head Assembly K. Emergency Stop Button E.

  • Page 34: Right Side View

    Chapter 2: TM-500 Overview 2- 3 Right Side View A. Tower Light F. Monitor/HMI B. Main Power Switch G. Monitor Arm Tray, Keyboard & Mouse C. Pick & Place Head Assembly H. Air Pressure Regulator D. Payout Arm I. Taper Output Module E.

  • Page 35: Left Side View

    TM-500 User’s Guide Left Side View A. Tower Light F. Taper B. Pick & Place Head Assembly G. Takeup Arm C. 2D Camera over Tape H. Monitor/HMI D. Cover Tape Arm I. Payout Arm E. Bowl Input Module Left Side View...

  • Page 36: Back View

    Chapter 2: TM-500 Overview 2- 5 Back View A. Computer Monitor/HMI E. Electrical Tester B. Pick & Place Head Assembly F. Bowl Input Module C. Pick & Place Head Bridge G. Air Pressure Regulator D. Taper Output Module H. Emergency Stop Buttons D292142.5.fm...

  • Page 37: Enclosure Interior

    TM-500 User’s Guide Enclosure Interior The interior of the lower cabinet is pictured on this page. The photo above shows the front sec- tion of the cabinet. Note: Before opening the lower front, right door, the Input Carrier Tape Reel must be removed from the Carrier Arm before loosening the bolt to raise the Carrier Arm.

  • Page 38: Controls, Connections & Labeling

    Emergency Stop Switch The TM-500 has three Emergency Stop switches. One is located above the Lower Enclosure on the front of the machine. Two are located above the Lower Enclosure on the back of the machine.
  • Page 39 TM-500 User’s Guide Input Module Connections There are three connectors located on the lower left side of the Pick Head Bridge. These are used to connect the Bowl Input Module. Power Pneumatic Data A. Power Connection B. Pneumatic Connection C. Data Connection There are two connectors located on the baseplate underneath the Pick Head Bridge.

  • Page 40: The Taping Module

    Chapter 2: TM-500 Overview 2- 9 The Taping Module A. Carrier Tape Feed Reel B. Take-up Reel C. Cover Tape Reel D. Sealer E. Idler Wheel F. Tape Cutter G. Drive Sprocket H. Sealer Shoe Temperature Controls I. Seal Pressure Control & Gauge J.
  • Page 41 2-10 TM-500 User’s Guide Seal Position Adjustments Figure 1.1 A. Inner Seal Position Lock F. Outer Seal Position Adjuster B. Inner Seal Position Adjuster G. Cover Tape Guide Width Thumb Screw C. PSA Seal Rollers H. Cover Tape Guide Width Inner Adjuster D.

  • Page 42: Taper Connections & Controls

    2- 11 Taper Connections & Controls Take-up Connection The Take-up connection is located under the Take-up Arm on the front of the TM-500. Sealer Air Pressure Gauge & Control A. Inside Heat Seal Shoe Temperature Control B. Outside Heat Seal Shoe Temperature Control C.
  • Page 43 2-12 TM-500 User’s Guide Pick & Place Assembly Pick & Place Head A. Nozzle B. Nozzle Vacuum Sensor C. Nozzle Vacuum Filter Pick & Place Controls A. Blow-off Air Pressure Gauge & Control B. Nozzle Vacuum Sensor Pick & Place Assembly...

  • Page 44: Bowl Input Module

    Chapter 2: TM-500 Overview 2- 13 Bowl Input Module A. Bowl B. Track Full Sensor C. Linear Track D. Part Present Sensors E. Nest Assembly F. Sensor Amplifiers G. Bowl Connectors H. Lift Handles I. Track Width Adjust J. Bowl Sorting & Bowl Trigger Sensors Note: The Bowl Feeder Assembly’s appear-...

  • Page 45: Optional Modules

    2-14 TM-500 User’s Guide Optional Modules Keithley Electrical Tester E F G A. Micrometers B. Position Lock Set Screws C. Reject Bin D. Tester Blades E. Source Hi Connection F. Sense Hi Connection G. Sense Low Connection H. Source Low Connection E F G H Note: See the Keithley 2002 Multimeter User’s Guide for detailed Keithley Electrical Tes-...

  • Page 46: Ultravim 2D Vision System

    2- 15 UltraVim 2D Vision System The ScannerTech UltraVim 2D Vision System for in-tape Mark and Orientation Inspection is pictured at right. It is one of the inspection options V-TEK offers. A. ScannerTech UltraVim 2D Camera B. Lens C. Support Bracket D.
  • Page 47 Chapter 3: Human Machine Interface Contents Introduction ..........3-2 Menus .

  • Page 48: Introduction

    The user interacts with the TM-500 through a Human Machine Interface (HMI) which runs on a Windows PC. The TM-500 HMI features a touch screen. Touching it has the same effect as a left click with the mouse. The Job Screen of the HMI is pictured above. Although only lightly touching the buttons or data fields is necessary for activation, the action is referred to as “pressing”...
  • Page 49 Each tab also includes a variety of drop-down menus on the top of the screen and a Connection Status indicator on the bottom of the screen. The Tray Tab from a TM-500 with the Tray Input Module installed is pictured below.
  • Page 50 Note: When the TM-500 is powered off or if the E-Stop is pressed, the Test Module will disconnect and the connection status will change to N/A. The Test Module will automati- cally attempt to reconnect upon restart of the TM-500. If the message continues to be displayed, click it to connect to the Test Module.

  • Page 51: Menus

    Open: Opens an existing job. Save: Save changes to the current job settings. Save As: Create a new job using the current settings. Exit: Exit out of the TM-500 HMI. User Menu The User Menu allows the user to Login, Log Off and Change Passwords for the Admin and Super User access levels.
  • Page 52 TM-500 User’s Guide Change Password: Is used to change/update the current user password for the Admin and Super User access levels. The screen on the right is used to change the Admin Password only. It can be accessed in User and Admin Modes and .

  • Page 53: System Menu

    Chapter 3: Human Machine Interface System Menu The System Menu provides access to Job Statistics, Homing Motors and Documentation. If the operator is logged in at the Super User level, they can also customize Accessibility for the User and Admin levels. Note: The System Menu will not appear if System Menu access has been disabled by the Super User for User Mode or Admin Mode.
  • Page 54 • To use a different logo, name the new logo image Logo.jpg and save it under C:\V- Tek\TM-500\AppData\Statistics Settings, replacing the current logo file. Note: Changing the logo image file will change the logo for all printed reports and labels.

  • Page 55: End Of Job Reporting

    Chapter 3: Human Machine Interface The System Options screen has two tabs: End of Job Reporting and Bar Code Settings. End Of Job Reporting The End of Job Reporting Tab allows the user to choose between Manually saving the Job Sta- tistics Report and Auto-saving the report.
  • Page 56 • To use a different logo, name the new logo image Logo.jpg and save it under C:\V- Tek\TM-500\AppData\Statistics Settings replacing the current logo file. • To resize the report logo, click and stretch the logo until it reaches the desired size.

  • Page 57: Home All Motors

    Documentation Like the System Documentation button on the Main Screen, selecting Documentation from the System Menu opens a directory with PDF versions of the TM-500 User’s Guide and other supporting materials. D292142.6.fm Menus...

  • Page 58: Accessibility

    There are tabs for Menus and for any input, output and vision modules that have been installed on the TM-500. These may include: Head, Job, Taper, Bowl, Tray, Tube, Test and Inspection options.
  • Page 59 Chapter 3: Human Machine Interface 3-13 User Mode User Mode allows the Super User to determine which fields will be accessible to operators with User Access in the various setup screens. The Menu Tabs allow the Super User to select which setup screen they wish to configure.
  • Page 60 3-14 TM-500 User’s Guide Advanced Mode Advanced Mode allows the Super User to enable Auto Logoff and set Logoff Time in minutes. Auto Logoff automatically returns the HMI to User Mode after a defined period of time. To regain access to Admin or Super User Mode, the user must login once again.

  • Page 61: The Setup Screens

    The Tab Menu, which is located to the left of the active screen, allows the user to access the var- ious TM-500 setup screens. Note: Setup Tabs appear greyed out and cannot be accessed when the TM-500 is run- ning. If in the process of running a job, press Stop, then select the desired Setup Tab from the Tab Menu.
  • Page 62 3-16 TM-500 User’s Guide 4. Inspection Display When the 2D Tape, the Upwards 2D and/or the 3D Inspection modules are installed, the Pre Place Inspection and Taper Vision buttons appear. These buttons allow the user to toggle between the two active inspection options. In the example above, Pre Place Inspection is dis- played.

  • Page 63: Head Setup Tab

    Chapter 3: Human Machine Interface 3-17 Head Setup Tab The Head Setup Tab allows the user to set pick, place and inspect head positions and dwell times and set head speed and acceleration. There are also buttons that allow the user to manu- ally rotate, pick, test, place and reject parts 1.
  • Page 64 3-18 TM-500 User’s Guide 2. Head Settings Speed is a percentage of the maximum velocity. It can be set between 1-100. Acceleration is how rapidly the head will accelerate to reach Head Speed. It can be set between 1-100. The lower the value of this setting, the more gradual the acceleration will be.
  • Page 65 Chapter 3: Human Machine Interface 3-19 5. Rotation Settings Speed is the velocity at which the nozzle rotate components. It can be set between 1-100. Acceleration is how rapidly the head will accelerate to reach Rotation Speed. It can be set between 1-100. The lower the value of this setting, the more gradual the acceleration will be.
  • Page 66 3-20 TM-500 User’s Guide 7. Nozzle Settings Speed is the velocity at which the nozzle extends or retracts. It can be set between 1-100. Acceleration is how rapidly the nozzle will accelerate to reach Nozzle Speed. It can be set between 1-100. The lower...

  • Page 67: Taper Setup Tab

    Chapter 3: Human Machine Interface 3-21 Taper Setup Tab 1. Tape Settings Speed is a percentage of the maximum velocity the carrier tape can be advanced at. It can be set between 1-100. Pitch is determined by the carrier tape selected. Use the Pitch Setting Guide on the taping module to determine the correct pitch.
  • Page 68 3-22 TM-500 User’s Guide 2. Taper Controls The Pocket Advance button advances the tape one pocket at a time. The Continuous Advance button advances the tape through the taper and onto the take-up reel. It will continue to advance until the Stop button is pressed or the Continuous Advance is pressed a second time.
  • Page 69 Once cut the user can press start to finish processing the remaining trailer. 5. Sensor Settings The TM-500 is equipped with five sen- sors: Tape Jam, Cover Low, Carrier Low, Carrier Motion, and Empty Pocket Detect (EPD).
  • Page 70 3-24 TM-500 User’s Guide The Carrier Low button turns the Carrier Tape Low Sensor on and off. The Carrier Tape Low Sensor detects when the carrier tape reel is running low. When the Carrier Tape Low Sensor is activated, an error message appears at the bottom of the HMI screen. The recommended setting for the Carrier Motion Sensor is ON.
  • Page 71 HMI. If the user is working in the Vision program software, this may be inconvenient. Check the Disable Alarm Window checkbox to disable the alarm window so it only appears in the TM-500 HMI. The Trigger Camera button manually triggers the camera to inspect the part that is currently under the camera.

  • Page 72: Bowl Setup Tab

    3-26 TM-500 User’s Guide Bowl Setup Tab 1. Vibratory Controls The Vibratory Controls button toggles the bowl vibratory ON and OFF (I/O). The Bowl Vibration and Linear Vibration slide controls set the amplitude of the vibration for the Bowl and the Linear Track. The higher the setting, the stronger the vibration amplitude.
  • Page 73 Chapter 3: Human Machine Interface 3-27 2. Track Options The Bowl Nest has a sensor which detects when parts are present. The Empty Nest Timer set- ting is the time in milliseconds the Empty Nest Timer should wait before it beeps to indicate parts are not loading in the nest.

  • Page 74: Test Setup Tab

    3-28 TM-500 User’s Guide Test Setup Tab 1. Test Settings The Pre-Place Test button toggles the Test Module ON and OFF (I/O). 2. Test Control The Test Part button manually trigger the Test Module to test the part which is currently in the test position.

  • Page 75: Job Setup Tab

    Chapter 3: Human Machine Interface 3-29 Job Setup Tab Job Information Name refers to the job name that was assigned when the job was saved. Quantity refers to the number of parts to be run in the job. Part Number refers to the part number of the device that is being processed. Lot Number refers to the unique lot number assigned to this job.

  • Page 76: Chapter 4: Machine Setup

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

  • Page 77: Quick Start: Setup

    Quick Start: Setup Quick Start The following is an outline of the basic steps required to setup the TM-500 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-500.
  • Page 78 Chapter 4: Machine Setup 4- 3 Quick Setup Output. Start • For Taper Output: • Ensure Track is setup for correct tape • Load Carrier Tape, Cover Tape and an empty Take-up Reel. • Adjust Sealer settings to ensure a good seal. •...

  • Page 79: Power Up The System

    ON position. Confirm that the E-Stop button is released. The E-Stop button on is located on the front of the TM-500 in the top right corner. Press the blue Reset Button on the front of the machine.
  • Page 80 4- 5 Activate the HMI Step 2: Activate Open the TM-500 application by clicking the TM-500 icon on the computer desktop. To configure the HMI settings, the user must be logged into the Super User level of the HMI. Go to the User Menu and select Login.
  • Page 81 Home Motors Step 3: Home Note: The TM-500 only needs to be homed once after each power up. Once the Motors motors have been homed, they remain homed until the machine is powered down. Click on the System drop-down menu in the program bar at the top of the page.

  • Page 82: Creating A New Job

    Chapter 4: Machine Setup 4- 7 Creating a New Job Step 4: Create Once the input, test and output modules have been setup and the pick head positions New Job have been taught, a new job can be created. Select JOB from the HMI tab menu to open the Job Settings tab.

  • Page 83: Nozzle Setup

    TM-500 User’s Guide Nozzle Setup Step 5: Nozzle Installing Nozzle & Nozzle Tip Setup INSTALL Open the enclosure doors to stop operation and allow manual manipulation of the nozzle. Manually move the Pick & Place Head to the left side of the bridge so it is easily accessible from the left side doors.
  • Page 84 Chapter 4: Machine Setup 4- 9 Step 5: Use a 1.5mm hex wrench to tighten the set Nozzle screw, holding the Nozzle in place. Setup INSTALL Select the correct nozzle cup size and press the new nozzle cup onto the Nozzle Shaft. Store the unused nozzle cups with the spare parts kit.
  • Page 85 Step 6: Setup Input The TM-500 consists of three areas which require setup when a new job is created: the OPTIONS Input area, the Testing area and the Output area. Each area may be configured in a vari- ety of ways, depending on the modules chosen for the TM-500.

  • Page 86: Bowl Setup

    Note: For Bowl installation instructions, see Chapter 1: Assembly & Installation. Input BOWL The TM-500 Tooling Sets are customized to meet the user’s needs. The illustrations below refer to the 2512 Tooling, but the procedure is the same for all tooling sizes. G H I J A.

  • Page 87: Removing Tooling

    Assembly. Set the screws aside. Allow the sensors to hang to the side of the track. Note: The sensor screws are very small and easy to lose. V-TEK recom- mends using a tweezers to safely remove the screws. Remove the (2) M2.5 SHCS from the Nest Assembly.

  • Page 88: Install Tooling

    Nest Assembly. Insert the (4) M2 Phillips screws and tighten the Nest Assembly in place. Note: The sensor screws are very small and easy to lose. V-TEK recom- mends using a tweezers to safely remove the screws. D292142.7.fm...
  • Page 89 4-14 TM-500 User’s Guide Loosen the (2) #10 SHCS on the Bowl Track on the right side of the Bowl assembly. Insert a group of the parts which will be run into the track and spread the parts along the length of the track (B). Adjust the track width until there is only about 1/64”...

  • Page 90: Tune Sensors

    Chapter 4: Machine Setup 4- 15 Tune Sensors Step 6: Setup There are four sensors on the Bowl Assembly. They are the Part Present Sensor, the Input Track Full Sensor, the Bowl Trigger Sensor and the Bowl Sorting Sensor. After changing BOWL the Bowl Tooling, the sensors need to be tuned to ensure they are configured for the part which will be processed.
  • Page 91 4-16 TM-500 User’s Guide Tuning a Through-Beam Sensor The through-beam sensors detect when parts are present in the Nest, Linear Track and Bowl Track. This alerts the user if there are no parts in the sensor location due to a jam or the need to reload parts.

  • Page 92: Load Bowl

    Chapter 4: Machine Setup 4- 17 Load Bowl Step 6: Setup Load the Bowl with parts. Input Linear Track BOWL Bowl On the HMI, select Bowl from the Setup tabs list to open the Bowl Setup screen In the Vibratory Controls section, turn the Bowl Vibratory ON (I) by pressing the ON/OFF control in the top left corner.

  • Page 93: Taper Setup

    4-18 TM-500 User’s Guide Taper Setup Step 7: Setup Output TAPER 1. Take-up Reel 2. Cover Tape Reel 3. Take-up Dancer Arm 4. Sprocket & Pinch Wheel 5. Sealer 6. 2D Camera System 7. Tape Track 8. Carrier Tape Motion Sensor 9.

  • Page 94: Loading Tape

    32mm. Tapes wider than 32mm have holes on both Carrier Tape Reel sides. Caution! Operators should use caution when working in front of the TM-500. Be aware of Takeup Arm and Carrier Arm positions to avoid tripping. D292142.7.fm Taper Setup...
  • Page 95 4-20 TM-500 User’s Guide Step 7: Trim the end of the carrier tape so it is clean and straight. Setup Output Guide the carrier tape under the input tape CARRIER guide and then feed it through the carrier tape channel under the taper.
  • Page 96 Chapter 4: Machine Setup 4- 21 Step 7: Use your fingertips to continue to Setup guide the carrier tape forward Output through the loading track and the CARRIER sealer until it reaches the sprocket. TAPE Lift the idler wheel and place the carrier tape onto the sprocket so that the holes engage the teeth.
  • Page 97 4-22 TM-500 User’s Guide LOAD COVER TAPE Step 7: Remove the reel lock mechanism and place Setup a reel of cover tape of the correct width to Output match the carrier tape on the cover tape COVER spindle. The tape should unwind counter-...
  • Page 98 Chapter 4: Machine Setup 4- 23 Step 7: The position of the cover tape guide can be Setup adjusted using the Cover Tape Position Output Adjuster (B). Loosen the thumb screw (C), COVER then turn the position adjuster clockwise to move the cover tape position toward the TAPE sprocket side of the tape.
  • Page 99 Mechanical Hazard! Avoid placing fingers between the carrier tape and the Take-up Reel when the TM-500 is in operation. Pinching or entrapment may occur if safety precautions are not observed. Taper Setup D292142.7.fm...

  • Page 100: Heat Sealer Setup

    Chapter 4: Machine Setup 4- 25 SEALER SETUP Step 7: Setup Output HEAT SEALER A. Inside Heat Seal Shoe Temperature Control B. Outside Heat Seal Shoe Temperature Control C. Heat Shoes - Seal Pressure Control D. Heat Shoes - Seal Pressure Gauge Heat Sealer Setup Open the HMI Taper Setup Screen.
  • Page 101 Turn the heat sealer on and set the temperature Setup controls for 120 degrees. Output HEAT Note: The TM-500 accommodates a wide range of carrier tapes and cover tapes. Settings may SEALER vary from one tape product to another. The suggested starting point is 120 degrees Cel- sius.
  • Page 102 Chapter 4: Machine Setup 4- 27 Step 7: After the initial adjustment, run the tape out again and observe whether the cover Setup tape aligns itself satisfactorily. If it is still misaligned, continue adjusting the cover Output tape guide until it is aligned properly. HEAT Once the cover tape and sealer are aligned with the carrier tape, perform a pull SEALER...

  • Page 103: Psa Sealer Setup

    4-28 TM-500 User’s Guide PSA Sealer Setup Step 7: Setup Open the HMI Taper Setup Screen. Select PSA Seal Type and ensure Tape Output Settings and Sealer Settings are appropriate for the current job. Engage the Tape Cutter if desired.
  • Page 104 Chapter 4: Machine Setup 4- 29 Step 7: Seal Roller Pressure The second Setup factor in PSA seal strength is the Output pressure applied to the cover tape PSA Seal as it is sealed to the carrier tape. SEALER The seal should appear as a solid Pressure stripe and it should not show any Adjustment...

  • Page 105: Leader/Trailer

    (leader) and the end (trailer) of the finished reel of placed parts. Therefore, TRAILER when the reel is being taped on the TM-500, 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 106: Setup The Pick Head

    Setup Pick Head If this it the first time the TM-500 has been powered up or if a new Input or Output Module has been loaded, the Pick & Place Head must be configured. Setting the pick, test and place positions teaches the head where to position the nozzle for each part of the pro- cess.
  • Page 107 4-32 TM-500 User’s Guide Step 8: If the part needs to be rotated before it is placed Setup in tape, select the correct Rotation Angle from Pick Head the Rotation Settings section. The options are 0, 90, 180 and -90 degrees.

  • Page 108: Setup Electrical Test (Optional)

    Chapter 4: Machine Setup 4- 33 Setup Electrical Test (Optional) Step 9: Setup Test See the Keithley 2002 Multimeter User’s Guide for detailed Test Setup instructions. Ensure correct Tester Blades are inserted. Ensure the Reject Bin is empty and ready for operation.

  • Page 109: Configure End Of Job Options

    4-34 TM-500 User’s Guide Configure End of Job Options Step 11: Configure End of Job Options Job Statistics Report Select Job > Statistics from the System Menu to configure end of job options. The Job Statistics screen will appear. Check the data field boxes on the left side of the screen to select what data will be included in the Job Statistics Report/Chart.
  • Page 110 Chapter 4: Machine Setup 4- 35 Step 11: Select a Data Source for Configure Report/Chart. End of Job options are Machine Data Options or Machine Stops. Note: Only the selected data in the Job Statistics screen (with boxes checked on the left) will be tracked in the chart.
  • Page 111 4-36 TM-500 User’s Guide Step 11: If Manual is selected, the user must use the Report Configure Options Save button to save the Job Statistics Report at End of Job the end of the job. If this setting is selected and the user Options fails to manually save the report, the data will be lost.
  • Page 112 Save to save printer settings for future labels. To use a different logo, name the new logo image Logo.jpg and save it under C:\V-Tek\TM-500\AppData\Statistics Settings replacing the current logo file. To resize the report logo, click and stretch the logo until it reaches the desired size.

  • Page 113: Chapter 5: Vision Setup

    Chapter 5: Vision Setup Contents Vision Options ..........5-2 Vision Resources .

  • Page 114: Vision Options

    On the HMI the UltraVim 2D Vision System is referred to as 2D Tape. The 2D Inspection System must be enabled within the TM-500 HMI and then configured in the UltraVim HMI. Vision Resources A PDF version of the TM-500 User’s Guide and the Ultra-...

  • Page 115: Ultravim Hmi

    Chapter 5: Vision/Test Setup & Inspection UltraVim HMI Main Screen The main screen of the UltraVim software is shown below. A. Command Bar B. Part File, Units, Position and Cycle Time C. Lot Summary, Pass, Rework, and Fails Totals D. Camera Image D292142.8.fm UltraVim HMI...
  • Page 116 TM-500 User’s Guide COMMAND BUTTONS Antenna: The antenna icon shows the state of the software communications. When it is green the software is ready to communicate with another application. When the icon shows a red and white plug communication has stopped. A user may click on a green antenna and it will turn purple.

  • Page 117: Select Part Screen

    Chapter 5: Vision/Test Setup & Inspection Zoom In: Click on the Zoom button to view the image in full screen mode. Print: Print the Lot Summary Report. Note: All command buttons may not be displayed in the command bar based on the screen resolution of your computer, your hardware and the type of part file you have selected.

  • Page 118: Inspect Part

    TM-500 User’s Guide Inspect Part When the user clicks the Inspect Part button the UltraVim performs the following steps: • Acquires Images • Sends a Move Response (Optional) • Computes the Results • Sends a Result Response • Displays Results...

  • Page 119: Data Screen

    Chapter 5: Vision/Test Setup & Inspection Data Screen To view data, click on the Data button and the Data Screen will open. Select a report by clicking on the report type then selecting the OK button, or simply double click the report.

  • Page 120: Options Screen

    TM-500 User’s Guide Options Screen The Options Screen allows the user to customize the UltraVim software settings. Graphics: Set Debug graphics or select Locate to display only the graphics used to locate the position of the device. Language: Select the language you want displayed.
  • Page 121 Chapter 5: Vision/Test Setup & Inspection Reference: Select the golden unit reference files. Golden QFP files end with *.CRQ and golden BGA files end with *.CRB. These files are located in the \Files or \Library directory. Setup: This determines how the software will respond to host commands. You may select a COMM port, an Ethernet port or an optional Digital I/O device.

  • Page 122: Edit

    5-10 TM-500 User’s Guide Edit When Edit is selected, the Edit Screen will display. Click on the icon of the part type, then click OK OR double-click on the part type to open the edit screen for that device. Note: Part types may be disabled in the Config.ini file. For example, if “UseMRK=0” is set, the MRK part types cannot be selected.

  • Page 123: Passwords Screen

    Chapter 5: Vision/Test Setup & Inspection 5-11 Passwords Screen The Passwords Screen shows the software version, the license code, the hardware ID, the com- puter name, and the camera, Digital I/O and LED driver names. The user can enter a password to change user level, show additional screens, exit the program, or update the license code.

  • Page 124: Inspection Setup & Configuration

    Inspection Setup & Configuration This section explains the setup and configuration procedure for the Ultra- Vim 2D Vision System. Configure the TM-500 with Input, Output and Test criteria for the job to be run before programming vision. 2D Vision Setup & Inspection...
  • Page 125 Open the Run Tab. Enter the job Quantity and Name. Press Run to begin operation. Since the TM-500 automatically inspects for the last job that was run, the first part in the new job will trigger an Inspection Fail.
  • Page 126 Select Part File screen will be those used during V-TEK installation and testing. If unable to find an exact match select the part that most closely resembles the part to be inspected and click New.
  • Page 127 Chapter 5: Vision/Test Setup & Inspection 5-15 The Edit Screen will open. Customize the part as needed and then save it as a new part. Note: You must be in Password Level 3 to edit an inspection. Press Inspect to display a pink Inspection Criteria Selection Box and delete it.
  • Page 128 The Edit Tolerances Screen will open. Customize the part inspection as needed, then click Press Inspect to re-inspect the part and verify inspection criteria is correct. Press Alt + Tab to toggle back to the TM-500 HMI. Close the enclosure doors, then press Run. Inspection Setup & Configuration...
  • Page 129 Chapter 5: Vision/Test Setup & Inspection 5-17 Selecting an Existing 2D Part Inspection Follow the Setup Instructions in Chapter 4: Machine Setup to set up the Input and Taper Modules and prepare to run a job. On the desktop, double-click the UltraVim icon to open the UltraVim software.
  • Page 130 TM-500 User’s Guide Open the Run Tab. Enter job Quantity and Name. Press Run to begin operation. Since the TM-500 automatically inspects for the last job that was run, when the first part in the new job will trigger an Inspection Fail.
  • Page 131 Press Inspect to manually inspect the part and verify inspection criteria is correct. If the part passes inspection, the vision system is configured correctly. Press Alt + Tab to toggle back to the TM-500 HMI. Close the enclosure doors, then press Run. D292142.8.fm...

  • Page 132: Chapter 6: Operation

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

  • Page 133: Quick Start: Running A Job

    Module. Power up. • Power up the machine. Press Reset. Close all doors. Activate the HMI. • Double-click the TM-500 HMI icon on the monitor. Home the motors. • Open the System Menu and select Home Motors. Select Job. • On the HMI, select the Job Tab. Go to the File Menu and select Open, then select the correct job.
  • Page 134 • On the HMI, select the Run Tab then press Run or press the Start button on the machine. • Load/unload parts and reels when prompted. Caution! V-TEK® Incorporated takes no responsibility for the safety of TM-500 if it is used for any purpose other than the intended purpose as specified in this User’s Guide. D292142.9.fm...

  • Page 135: Preparing To Run A Pre-Programmed Job

    Super User are grayed out and the operator only has access to buttons related to running a job. Caution: Users should always wear protective eye wear when operating or maintaining the TM-500. Step 1: Setup Input and Output modules Setup Ensure the correct Input, Output and Test modules are installed.
  • Page 136 The tape normally can be attached by inserting it into the reel hub or with adhesive tape. Caution! Operators should use caution when working in front of the TM-500. Be aware of the Takeup Arm and Carrier Arm positions to avoid tripping. D292142.9.fm...

  • Page 137: Power Up The System

    Home Motors Step 4: Home Note: The TM-500 only needs to be homed once after each power up. Once the Motors motors have been homed, they remain homed until the machine is powered down. Click on the System drop-down menu in the program bar at the top of the page.

  • Page 138: Select Job

    Chapter 6: Operation 6- 7 Select Job Step 5: Select If 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 Run Tab.

  • Page 139: Setup End Of Job Options

    TM-500 User’s Guide Setup End of Job Options Step 6: Setup If a job is already set up and saved in the machine’s memory, the first step in running the End of Job job is to call it up with the Job Select screen.

  • Page 140: Setup Pick Head

    Chapter 6: Operation 6- 9 Setup Pick Head Step 7: Setup Open the Head Tab on the HMI. Pick Head Press Move To Pick, then press Pick Part. Observe the vacuum sensor which is located on top of the head to see if it is set correctly for the current part.
  • Page 141 6-10 TM-500 User’s Guide Return to the Head Setup Tab. Press Move To Place, then press Place Part. Check that the Blow-off Pressure is set correctly for the current part. The Blow-off Pressure Gauge is located on the left side of the Pick Head Bridge.

  • Page 142: Setup Electrical Test

    Chapter 6: Operation 6- 11 Setup Electrical Test Step 8: Setup See the Keithley 2002 Multimeter User’s Guide for detailed Electrical Test Setup instructions.. Test Ensure correct Tester Blades are inserted. Ensure the Reject Bin is empty and ready for operation.

  • Page 143: Setup 2D Vision

    If desired, disable the Alarm Window. Open the Run Tab. Enter the job Name and Quantity. Press Run to begin operation. Since the TM-500 automatically inspects for the last job that was run, when the first Preparing to Run a Pre-programmed Job D292142.9.fm...
  • Page 144 Chapter 6: Operation 6- 13 part in the new job will trigger an Inspection Fail. Right-click the Pre Place Inspection button to switch to the UltraVim Software Main Screen. To load new inspection criteria, press Select to open the Select Part Screen. D292142.9.fm Preparing to Run a Pre-programmed Job...
  • Page 145 Press Inspect to manually inspect the part and verify inspection criteria is correct. If the part passes inspection, the vision system is configured correctly. Press Alt + Tab to toggle back to the TM-500 HMI. Preparing to Run a Pre-programmed Job D292142.9.fm...

  • Page 146: Run The Job

    During operation, the operator will add additional parts to the Input Module and unload packaged parts from the Output Module and Reject Area as necessary. When the preset number of parts has been run, the TM-500 will automatically stop operation.

  • Page 147: Creating A New Job

    6-16 TM-500 User’s Guide Creating a New Job Once the input, test and output modules have been setup and the pick head positions have been taught, a new job can be created. Select JOB from the HMI tab menu to open the Job Settings tab.

  • Page 148: Chapter 7: Troubleshooting

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

  • Page 149: Emergency Stop

    Activating an Emergency Stop If a malfunction occurs, follow the steps below to resolve the failure. Press the red E-Stop button to place the TM-500 into an Emergency Stop state. A brief alarm will sound, the Tower Light will switch to flash- ing red and all operations will cease.

  • Page 150: System Alarm Messages

    Alarm alerts the user so the situation can be resolved and operation can begin. System Alarm Messages contain a description of the problem and suggestions for resolving the problem. They also include an illustration of the TM-500 with the area of interest indicated by a flashing red outline.
  • Page 151 TM-500 User’s Guide 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.
  • Page 152 Chapter 7: Troubleshooting Part Present (Empty Nest) System Alarm The Part Present Sensors are located at the pick posi- tions on the Bowl Input Module. They detect when no parts are available in the Nest. When the Part Present sensor is on and no part is detected in the Nest, operation stops, a beep sounds and a warning appears on the HMI.
  • Page 153 TM-500 User’s Guide Part Not Picked System Alarm If the nozzle is unable to pick a part from the Bowl Input Module, the Part Not Picked system alarm will be activated. When this happens, operation stops, a beep sounds, and a warning appears on the HMI.
  • Page 154 Chapter 7: Troubleshooting Track Jam Sensor System Alarm The Track Jam Sensor is located on the Bowl Input Modules’ Linear Track. The Track Jam Sen- sor detects when no parts are in the track and activates the Input Feeder. If the track remains empty after the feeder is activated, the sensor times-out and raises a Track Jam System Alarm.
  • Page 155 TM-500 User’s Guide Carrier Tape Low System Alarm If the Taper’s Low Carrier Tape Sensor detects that the carrier tape supply has fallen below the preset minimum level, it will trigger a Low Carrier Tape system alarm. Sensor When the Low Carrier Tape system alarm is activated, tape advance stops, a beep sounds and a warning appears on the HMI.
  • Page 156 Chapter 7: Troubleshooting 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. When the Tape Jam sensor is enabled and a jam occurs, operation stops, a beep sounds and a warning appears on the HMI.
  • Page 157 7-10 TM-500 User’s Guide Carrier Motion System Alarm If the Taper’s Carrier Motion Sensor detects that carrier tape is not moving through the track, it will trigger a Carrier Motion Tape system alarm. When the Carrier Tape Motion system alarm is activated, tape advance stops, a beep sounds and a warning appears on the HMI.
  • Page 158 Chapter 7: Troubleshooting 7-11 Heat Seal Temperature Out of Range System Alarm The Heat Seal Temperature Controls are controlled through the HMI Taper Tab. When Heat Seal is enabled and the Heat Shoe temperatures are either too hot or too cold, a Heat Seal Tempera- ture Out of Range system alarm will activate.
  • Page 159 7-12 TM-500 User’s Guide Low Cover Tape System Alarm The Low Cover Tape sensor is located on the Cover Tape Arm. It detects when the cover tape supply on the Cover Tape Reel is below a preset minimum. If an operator attempts to start a job when the cover tape level is below the sensor, operation will not begin.
  • Page 160 Chapter 7: Troubleshooting 7-13 Visual Inspection Fail System Alarm The 2D Vision System is located over the Taper Track to the right of the Sealer. When Vision is enabled and a placed part fails inspection, a Visual Inspection Fail system alarm will activate. When this occurs, tape advance stops, a beep sounds and a warning appears on the HMI.
  • Page 161 Press OK, then press Start to resume operation. Doors are Open Message The TM-500 will not operate if the enclosure doors are open. If the doors are open, the following message will appear on the screen: Close all enclosure doors, then press OK to continue.
  • Page 162 7-15 Air Pressure Too Low Message The TM-500 cannot operate at optimum levels if the air pressure is too low. If the air pressure needs to be adjusted, the following message will appear on the screen: Adjust the air pressure to between 80 and 100 PSI. The suggested incoming air pressure value is 100 psi.
  • Page 163 7-16 TM-500 User’s Guide Electrical Test Time-out Message When the optional Electrical Tester is installed, the following message will appear on the screen if the inspection times out. To clear the Electrical Test Time-Out message, ensure the tester is installed, connected and enabled on the HMI.

  • Page 164: Error Message Table

    Chapter 7: Troubleshooting 7-17 Error Message Table Error Condition Solution “The system Emergency Stop Release the E-Stop, then press the blue Reset button to has been pressed.” continue. “The system doors are open Close all doors. which disable the machine’s motors.”...
  • Page 165 7-18 TM-500 User’s Guide Error Condition Solution “The inspection process has This refers to the Upwards 2D Inspection Module or the timed out. No response was 2D Taper Inspection Module. Check the following: received from the 2D Inspec- - 2D Module is not enabled (Pre-Place Inspection ON or tion Module.”...

  • Page 166: Linear Track Jam Checklist

    Chapter 7: Troubleshooting 7-19 Linear Track Jam Checklist If a Part Not Present alarm or Track Jam alarm is due to a part jam somewhere in the Bowl Assembly’s Linear Track, there are three likely locations: A. Check the Bowl Output. B.

  • Page 167: Adjusting Nozzle Vacuum Sensors

    If the TM-500 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 168: Nozzle Positioning Tips

    Chapter 7: Troubleshooting 7-21 Nozzle Positioning Tips 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. Adjust Blow-off Pressure.
  • Page 169 7-22 TM-500 User’s Guide Adjust Place Position Z Open the Head Set-up Tab (see above). Jog the head up or down until the nozzle is extended the appropriate distance above the place location. Experiment with placing a part to determine what Z Axis height works best. When the nozzle is positioned correctly, press the Teach Place Positions button.

  • Page 170: Adjusting Seal Quality

    Under normal con- ditions and materials, changing the temperatures should suffice. The TM-500 accommodates a wide range of carrier tapes and cover tapes. Settings may vary from one tape product to another. The suggested starting point is 120 degrees.

  • Page 171: Psa Seal Adjustments

    7-24 TM-500 User’s Guide PSA Seal Adjustments 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. Materials Used For a PSA seal, seal strength is determined first by the nature of the materials used. It is nor- mally recommended to use the same brand of cover and carrier tapes together as the manufac- turers use the appropriate adhesive to match the material used to make the carrier tapes.

  • Page 172: Sensor Adjustments

    Adjusting the Low Cover Sensor The Low Cover Sensor is one of five sensor options that are included with the standard TM-500. It alerts the operator at the beginning of a job if there is not enough cover tape loaded on the Cover Tape Reel to complete the job.

  • Page 173: Adjusting The Tape Jam Sensor

    Adjusting the Tape Jam Sensor The Tape Jam Sensor is one of five sensor options that are included with the standard TM-500. It is located on the Taper track just before the Sealer. It detects if parts are doubled up or incorrectly placed in...

  • Page 174: Adjusting The Empty Pocket Detector

    Adjusting the Empty Pocket Detector Empty Pocket Detection is one of five sensors that come with the standard TM-500. The EPD alerts the operator if a carrier tape pocket is empty before the tape advances through the sealer, allowing the operator to manually fill the pocket.

  • Page 175: Testing Seal Strength

    Instructions for peel force test vary from one manufacturer to another. Follow the manufacturer’s instructions for the peel force tester selected to perform the test. A V-TEK PT-55 Peel Force Tes- ter is pictured below. Testing Seal Strength...

  • Page 176: Chapter 8: Maintenance

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

  • Page 177: Safe Maintenance Steps

    TM-500 User’s Guide Safe Maintenance Steps Follow the steps below when performing routine maintenance or cleaning on the TM-500. Turn the TM-500 OFF. Ensure the Main Power Switch is rotated to the OFF position. The Main Power Switch is Lock-out/Tag-out capable. Follow your com- pany’s Lock-out/Tag-out procedure to ensure safe maintenance.

  • Page 178: Routine Maintenance Schedule

    Chapter 8: Maintenance 8- 3 Maintenance Only maintenance personnel that have thoroughly read and understand the TM-500 User’s Guide and have several years experience operating and maintaining similar machines should be permitted to maintain the TM-500. Routine Maintenance Schedule The TM-500’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 179: Maintenance

    Caution! Operators should use caution when working in front of the TM-500. Be aware of Takeup Arm and Carrier Arm positions to avoid tripping. Caution! Users should always wear protective eye wear when operating or maintaining the TM-500.

  • Page 180: General Maintenance Tasks

    Lubrication No lubrication is required or desired on the TM-500 as all parts are no maintenance in this regard and the use of lubricants could interfere with components.

  • Page 181: Pick Head Maintenance

    TM-500 User’s Guide 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 indicate pneumatic problems such as loose fittings or seal problems.

  • Page 182: Taping Module Maintenance

    Chapter 8: Maintenance 8- 7 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. Loosen the track width lock knobs and slide the loading tracks all the way out.
  • Page 183 TM-500 User’s Guide PSA Sealer PSA Sealer Wheels The adhesive residues should be cleaned from the sealer assembly every 40 hours of operation. Wipe the entire assembly using a cloth soaked in alcohol. Using a cotton swab soaked in alcohol, clean between the sealer wheels.
  • Page 184 Chapter 8: Maintenance 8- 9 Remove/Replace Heat Shoes Remove heat shoes every four months and inspect and clean them. Replace if necessary. Ensure the heater is off and has cooled completely. Remove the outer heat sealer guard as described above. Use a 5/64 inch hex wrench to release the shoe from the heat sealer assembly.

  • Page 185: Lubricate Linear Bearing Block

    8-10 TM-500 User’s Guide Lubricate Linear Bearing Block Once a year, use a Needle Style Grease Gun to apply approxi- mately 6cc (cubic centimeters) of Super Lube Multi-Purpose Syn- thetic Grease to the grease fittings on the ends of the Linear Bearing Blocks.

  • Page 186: Check Actuator Belt Tension

    Use an inch/pound torque wrench to torque the tensioning bolt to 10 inch/pounds. Note: For additional information, see 292586 Idler Assembly Drawing in the Exploded Views section of this User’s Guide. Contact V-TEK Service for tensioning procedure if belt tension is outside tolerance.

  • Page 187: Ethernet Networks

    8-12 TM-500 User’s Guide Ethernet Networks The Ethernet Network for the TM-500 is diagrammed below. Maintenance and Service personnel are cautioned to review the diagram and instructions that follow thoroughly before disconnecting any cables Ethernet Networks D292142.11a.fm...
  • Page 188 TM-500 computer without disturbing the machine network. The Customer Access Network allows networked access to the files on the TM-500 computer for data logging and tracking. IP Protocol: •...
  • Page 189 Appendix A: Sensors Contents Keyence FS-V20 Series Sensor Amplifiers ......A-2 Keyence FS-N40 Series Sensor Amplifiers ......A-5 Watlow EZ-Zone PM Express Temperature Controller .

  • Page 190: Keyence Fs-V20 Series Sensor Amplifiers

    Appendix A: Sensors Keyence FS-V20 Series Sensor Amplifiers The Keyence FS-V20 Series sensor amplifiers are used for both the low cover tape sensor and the empty pocket detector. Preset Value (PV) Output Selector Fiber Lock Lever Manual Button Set Button Mode Button Current Value (CV) Output Indicator Light...
  • Page 191 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 (M) button simultaneously for at least three seconds.

  • Page 192: Appendix A: Sensors

    Appendix A: Sensors Note: Portions of this procedure were provided by: KEYENCE CORPORATION OF AMERICA 500 Park Boulevard, Suite 200, Itasca, IL 60143, U.S.A. Phone: 1-888-KEYENCE (1-888-539-3623) For detailed instructions, visit www.keyence.com and download the Keyence Digital Fiberoptic Sensor FS-N40 Series Instruction Manual. Keyence FS-V20 Series Sensor Amplifiers D291511.18a.fm...

  • Page 193: Keyence Fs-N40 Series Sensor Amplifiers

    Press Mode (M) once. The Current Value (CV) Indicator will display the current mode. Press the Manual (I< >I) button to switch the output style. Select dark-ON. This mode is used for all TM-50 and TM-500 sensors. Keyence FS-N40 Series Sensor Amplifiers...
  • Page 194 Appendix A: Sensors Press Mode (M) three times. Note that the L/D ON indicator is now set to D-ON Fine Tune the Setting Value (Threshold) Use the Manual (< >) button to adjust the Threshold value as desired: • Press the left arrow to increase the setting value. •...
  • Page 195 Appendix A: Sensors Initialization To initialize all the settings and return the sensor to the original Keyence factory default settings, follow the procedure below. Hold down Set and ACT-R simultaneously for at least three seconds. Press Mode (M) once. Press down the right side of the Manual (< >) button once. Press Mode (M) once.

  • Page 196: Watlow Ez-Zone Temperature Controller

    • If the display reads AL.Li the temperature is too low. The TM-500 cannot operate when a temperature alarm is triggered. If the TM-500’s Start button is pressed when the temperature controllers are registering a Temperature Fail alarm, a “Temp Fail Alarm has been raised.”...
  • Page 197 Refer to the Watlow EZ-Zone PM Express Temperature Controller when necessary for more detailed technical information regarding the operation of the temperature controllers. The direc- tions below describe the factory settings set at the time the controllers are installed at V-TEK, Inc. Initial Settings Press and hold the Up and Down Arrow Keys for about 3 seconds to enter the Setup Menu.
  • Page 198 Appendix A: Sensors A-10 In the Function of Output 1 Menu (Fn1) select Heat (hEAt). Press Advance twice to skip the Output Type Menu and move on to the Function of Output 2 Menu. In the Function of Output 2 Menu (Fn2) select Alarm (ALM). Press Advance. In the Heat Algorithm Menu (h.Ag) select PID (Pid).
  • Page 199 A-11 Appendix A: Sensors Operations Menu Settings Upon power up of the temperature controllers, the Advance key will scroll through the Opera- tions Menu. Press the Infinity key to return to the default display. Press the green Advance button to scroll through the menu. Begin with the Autotune Menu (AUt).
  • Page 200 Appendix A: Sensors A-12 Use the Up and Down Arrow Keys to enter the correct offset value. Press the Infinity Key to return to normal operation. Watlow EZ-Zone PM Express Temperature Controller D291511.18a.fm...

  • Page 201: Smc Zse30 Vacuum Sensor

    A-13 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 202 Appendix A: Sensors A-14 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 203 TM-500 Suggested Spare Parts List Part Number Description Air Regulator 200430 Main Air Regulator Switches 102518 Start switch 102519 Stop switch 102586 Reset switch 102597 Digital pressure switch Take-up 105573 Take up Gear head 105695 Take up Motor 150027 Take up Tension control board...
  • Page 204 Pick & Place Timing belt 140 teeth 266807 SPT Nozzle Shank Bowl 267344 Part Present Sensor M2 Screws Caution! Only genuine spares should be used on the TM-500. Failure to use genuine spare parts could render the machine unsafe and void factory warranty. D292142.13.fm...
  • Page 205 TM-500 Exploded Views Document List Section Description File Name This document D291980.14a.fm TM-500 Base Machine 292600.slddrw Frame Assembly 292596.slddrw Baseplate Assembly 292595.slddrw Upper Enclosure 292594.slddrw Electrical Panel Assembly 292715.slddrw X Axis Assembly 292591.slddrw Monitor Arm Assembly 291529.slddrw Bridge Enclosure Assembly 292583.slddrw...
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  • Page 245 " 2 " 2 & : ) s...
  • Page 246 I S I & : ) s...
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  • Page 248 I S I & TM-500 CRATE ASSEMBLY & : ) s...
  • Page 249 751 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 250 Cover Sheet ....... Page 1 - 2 ..D292142.1d.fm EC Declaration of Conformity ....Page 1 of 1 ..TM-500 DOC.pdf Introduction .
  • Page 251 EXPRESS WARRANTY, EXCLUSION AND DISCLAIMER OF UNSTATED WARRANTIES AND LIMITATION OF LIABILITY    V‐TEK Inc (V‐TEK) manufactures equipment for the Royce Instruments and V‐TEK International brands. The following  warranty applies to both product lines.    1. V‐TEK warrants for one year from date of receipt by end user that equipment manufactured by V‐TEK will  be free of defects in workmanship and materials.   2. All  integrated  products  purchased  by  V‐TEK  and  integrated  on  to  V‐TEK  equipment  shall  be  covered  in  accordance with the manufacturer’s pass through warranty and limited in costs equal to the amount of the  manufacturer’s pass through warranty.   3. V‐TEK’s obligation under this warranty applies only to the original Customer and commences when V‐TEK is  notified of name, address of Customer, and date of receipt of equipment.   4. During the warranty period, V‐TEK will replace any defective non‐consumable parts returned for that purpose  to the designated V‐TEK Replacement Parts Center or at V‐TEK’s option, refund original cost of equipment.   5. Authorization to return Articles purchased from V‐TEK must be obtained by Customer before return shipping  commences.   6. Credit may be granted, less an appropriate restocking charge of 15 to 20% of invoice amount, depending on  the reason for the return and condition of the Articles.   7. Returns should always be carefully packed in original shipping carton and sent via ground service. V‐TEK does  not assume any liability for damage incurred during shipment. ...
  • Page 252 751 Summit Avenue Mankato, MN 56001 (507) 387-2039 FAX: (507) 387-2257 www.vtekusa.com Email: info@vtekusa.com...

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