Data I/O PSV5000 Owner's Manual
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Data I/O PSV5000 Owner's Manual

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Automated Programming and Handling
096-0465-001C
Owner's Manual
N
OW WITH
P
ROGRAMMERS
Snapshot of Features
page 10
Specifications
page 18
Setting Up Security
page 65
Maintenance Schedule
& Sign-Off Chart
page 92 and 150

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Summary of Contents for Data I/O PSV5000

  • Page 1 Owner’s Manual Automated Programming and Handling OW WITH ROGRAMMERS Snapshot of Features page 10 Specifications page 18 Setting Up Security page 65 Maintenance Schedule & Sign-Off Chart page 92 and 150 096-0465-001C...
  • Page 2 Data I/O product. Any algorithms, adapters or other Data I/O products provided or sold by Data I/O to you must first be tested and verified by you for use in your application prior to use in a production environment. Data I/O does...
  • Page 3 Using this Manual•- 1 - Warnings and Cautions•- 1 - Safety Symbols•- 2 - Symbols for Specific Models & Options•- 3 - Precautions for Safe Operation•- 4 - Contacting Data I/O•- 6 - Repair Service•- 7 - 1 — •9 HAPTER Introduction•9...
  • Page 4 Handler Computer•129 Troubleshooting•131 Tape Output System Maintenance•140 The Tray Feeder•148 Electrical Equipment Disposal Notice•148 Maintenance Sign-off Chart•150 Index•152 Electrical Schematics for PSV5000 and Equipment•157 ■ 096-0465-001C Data I/O...
  • Page 5 Service information Using this Manual Knowing the conventions used in this manual helps make it easy find information, as well as to make the PSV5000 machine easy-to-use and keep the operator safe. Warnings and Cautions Special paragraphs with red lines are safety warnings as follows:...
  • Page 6 ADVERTENCIA de colisión Collision Warning Laser Hazard Warning ADVERTENCIA de peligro del laser Laser-Hazard Warning Compressed Air Warning ADVERTENCIA de aire comprimido Druckluft‐Warnung Electrostatic Discharge Warning (ESD) ADVERTENCIA de descarga electrostática Elektrostatische Entladung Warnung - 2 - Data I/O ■ 096-0465-001C...
  • Page 7 This Symbol Adjacent information is limited to this optional equipment: Means… Tape-In Module (Tape Feeder) Only Tape Output Systems Only Auto‐Tray Feeder Fiber Laser Marking System. FlashCORE (FC) programmers Lumen™X (LX) programmers PSV5000 Owner’s Manual - 3 -...
  • Page 8 Precaution List ENERAL RECAUTIONS  Do not use the PSV5000 System for any purpose other than its WARNING: intended use.  Personal injury could be caused from high leakage electrical current from the main power cable. An Earth (ground) connection is Pinch hazard.
  • Page 9 Jump Right In Thanks for reading about the safety symbols, notes, and icons. If your PSV5000 System is already set up and you want to skip ahead: Safety Systems on page 12. Be safe —see Machine Components on page 19 Where’s the _____? —see...
  • Page 10 Preface ■ Contacting Data I/O Contacting Data I/O Contact Data I/O for technical assistance visit www.dataio.com and click the Technical Support button. Log-in to our Support Portal. For first time use, we recommend that customers enter a generic user name and email for a distribution group so that multiple people in your company can access Data I/O Service requests.
  • Page 11 Technical support > Representative Search. http://www.dataio.com/Contact-Us/Representative-Search Warranty Information Data I/O Corporation warrants this product will be free from defects in materials and workmanship for one (1) year from delivery. This warranty and any third party warranties are in lieu of all other...
  • Page 13 Controllers, Serial EEPROM, and the latest e-MMC memories. The PSV5000 System refers to the machine, The modular design of PSV5000 creates flexibility, allowing you to accessories, and the optimize to the level of production required by your facility. software. The word...
  • Page 14 Number Server relocation. Module Figure 1: Features of PSV5000. For a more detailed image with components labeled, see the Operator’s Manual. For component descriptions see Component Descriptions on page19. Setting the Language Several other languages are available for the application interface. To...
  • Page 15 □ ■ Snapshot of PSV5000 Setting the Language 1. Opent the ini file in Notepad or UltraEdit. (Do not use Microsoft Word or other word processor.) 2. Find “Language Settings” section. 3. Add a semicolon to the line for the current language.
  • Page 16 MERGENCY UTTONS Two large, red Emergency Stop buttons are located near the top of the PSV5000 System, one on either side of the machine. When an E-Stop button is pressed, the gantry stops moving immediately. See caution notice below. Right Side...
  • Page 17 (ground) exists between a static-sensitive device or component, its environment, and the operator. Operators should wear an antistatic wrist strap (Data I/O part number 440-0021-001) connected to one of the grounding connections on the PSV5000 Owner’s Manual...
  • Page 18 Laser Marking Fume Extractor on page 126. Machine Axes The PSV5000 System gantry operates on three primary axes: X, Y, Z. An additional axis, called the R-axis (theta), is used by the PNP head to change device orientation (rotation).
  • Page 19 TaskLink™, or Job Creator or Job Runner software, and Automated Handler software (CH700) running on the system’s Handler Computer direct the PSV5000 System to perform a series of processes, including automatic handling, programming, marking, and placement of devices to the output media of your choice.
  • Page 20 The manuals that came with any optional equipment on your system contain additional, more in-depth information. Some of the manuals came in hard copy format with your PSV5000 System. Others are PDFs installed on the Handler computer. - 16 -...
  • Page 21 □ ■ System Description Manuals for Optional Equipment Figure 6: Some of the optional equipment manuals, from left to right: Laser Marker; Automatic Tray Feeder CB (Tray Stacker). PSV5000 Owner’s Manual - 17 -...
  • Page 22 Since the monitor arm rotates, length and width dimensions can be adjusted inversely, up to 10 cm (4 inches). For example, if you sub‐ tract 10 cm from length, then add 10 cm to width. - 18 - Data I/O ■ 096-0465-001C...
  • Page 23 Refer to the figure below to locate primary components. Safety Systems IGHT OWER Allows monitoring the status of the PSV5000 System from a distance while the system is processing devices. See Light Tower Interpretation in the Operator’s Manual for a complete description of lamp colors and significance.
  • Page 24 Left: A FlashCORE Programmer (next to the reject bin), and Right: a LumenX Programmer. ISION YSTEM PSV5000 uses an upward camera for precise picking and placing. TATIC OUNT Using positioning pins and a magnetic bracket, JEDEC and non-JEDEC standard trays are held firm for the PNP head to pick devices and return them after processing.
  • Page 25 CPU that runs Microsoft Windows 7 Operating System (at time of release). CAUTION: Possible machine damage! Adding software to the PSV5000 System can cause damage or cause the system to operate improperly. Adding software without specific instruction from Data I/O Customer Support will void the warranty and may incur service charges if subsequent service is required.
  • Page 26 Power Panel (Facilities Panel) on the back of the machine. The Serial Number is there, also (arrow). Optional Equipment Descriptions IRCUIT REAKERS There is a toggle switch on the power panel which allows shutting off power to only the programmers. - 22 - Data I/O ■ 096-0465-001C...
  • Page 27 For additional safety information, see Laser Safety on page 27. PTIONAL UTOMATIC EEDER Designed to automatically supply trays full of devices to the PSV5000 System, the Tray Feeder CB accepts up to twenty thin or thick JEDEC trays. Figure 11: The Tray Feeder.
  • Page 28 Introduction ■ Machine Components empty pockets on the carrier tape. The carrier tape advances through either a heat seal or pressure seal unit that applies cover tape to the carrier tape. - 24 - Data I/O ■ 096-0465-001C...
  • Page 29 Windows 7. CAUTION: Possible machine damage! Adding software to the PSV5000 System can cause damage or cause the system to operate improperly. Adding software without specific instruction from Data I/O Customer Support will void the warranty and may incur service charges if subsequent service is required.
  • Page 30 TaskLink online Help. It includes update instructions. Job Creation Software for LumenX Job Runner and Job Creator are Data I/O’s latest applications for creating and managing jobs to run on the PSV5000 with LumenX programmers. The software resides on the Handler Computer. Updates and Algorithm Support Updates, includes algorithm updates, are generally acquired through our APS Agreement (Annual Programmer Support).
  • Page 31 ® ® application for setting up and programming integrated circuits (devices) on PSV5000 Systems. It offers a selection of many PSV5000 System options such as input/output configurations, labeling options, and statistical feedback methods. The CH700 application software resides in the Handler Computer.
  • Page 32 WARNING: Possible eye and skin injury! The laser will fire even when safety doors are open. If equipped with Laser Marking, do NOT interfere with, or work on, the Laser Module while the Laser PC key-switch is ON. - 28 - Data I/O ■ 096-0465-001C...
  • Page 33 Summary-Regarding ventilation, the minimum room size for any PSV5000 System is 3 x 3 meters x 2.4 meters high (10 x 10 x 8 feet). However, access space for some machines requires a larger room; see Access Space below.
  • Page 34 2.9 m x 0.87m 4.9 m x2 .87m + Tape Out Module with Large reel For example, a PSV5000 System with a Tray Feeder requires a minimum physical area of 4.1 meters wide x 2.87 meters deep for easy access. - 30 -...
  • Page 35 □ ■ Room Consideration Access Space Figure 15: Maximum envelope of PSV5000 without optional equipment such as marking, Tape-In or Tape Output Modules. (Dimensions in mm. Reduced scale). PSV5000 Owner’s Manual - 31 -...
  • Page 37 For the intended area for PSV5000 installation see Room Considerations on page 29. Leveling When the PSV5000 is at the desired location, adjust the feet to level it. WARNING: Possible machine damage or personal injury! Instability such as vibrating, walking, or rocking, may occur if fewer than four of the installed feet make suitable contact with PSV5000 Owner’s Manual...
  • Page 38 Setup ■ Machine Installation the floor, or if the leg locknuts are not tightened against the frame. Only the adjustable feet provided on the PSV5000 Machine should be used for leveling. Do not use shims to assist in leveling. Connecting Facilities The PSV5000 requires two external services: pressurized air and electrical power.
  • Page 39 When air pressure is within range, the regulator readout is green. If air pressure is above or below the acceptable range, the readout displays red. If it is red (out of range), contact Data I/O Support or a qualified service If there is low air pressure the monitor technician.
  • Page 40 2-1. (Optional) Network Settings on page 38 Network settings are described in CAUTION: Possible PC virus hazard! The PSV5000 System has no antivirus software installed from the factory. Prior to connecting to a network, Data I/O recommends installing antivirus software.
  • Page 41 ■ Applying Power for the First Time □ (Optional) Connecting an Ethernet Cable Applying Power for the First Time Before the PSV5000 System is turned on for the first time, ensure the following: The external air line is connected, and the main air valve is open.
  • Page 42 (on the Power Panel) counterclockwise to the OFF (vertical) position. If the PSV5000 Machine will not be used for several days, the shop air should also be removed or turned off at the Power Panel. (Optional)
  • Page 43 If you need the IP Address for communicating with other Data I/O software, they are available via TaskLink. The Port numbers are also displayed. (Port numbers are the same for all programmers on a PSV5000 Machine.) Addresses and Port numbers can be found as follows.
  • Page 44 Media There are many options for device input and output. One option for input and one for output must be set up on the PSV5000 Machine for your target job. Further, the setup must correspond with the current software, such as the Job file, winAH400.ini file.
  • Page 45 ■ Setting Up Input and Output Media □ Install the Reject Bin EQUIREMENTS Metric hex key set. To remove a Static Tray Platform: Shut OFF the PSV5000 System. See Shutting Down the PSV5000 System on page 38. Disconnect the tray sensor- Remove two sensor bracket screws (2.5 mm).
  • Page 46 Common locations for the reject tray and bin with Tape Input and Tape Output. Only one is necessary. The reject bin that comes with the PSV5000 should be placed as shown. Note: On the Gantry window, the reject bin or tray is associated with a yellow position label that reads RTr.
  • Page 47 Setting Up an Automatic Tray Feeder The PSV5000 System can be configured with an Automatic Tray Feeder. The Tray Feeder must be level to the Gantry and square to the PSV5000 Machine. For general information about setting it up, see the Tray Feeder Owner’s Manual that came with your system.
  • Page 48 ModelTray1=STD. NSTALLING THE EEDER The Tray Feeder can only be installed if your PSV5000 was set up for it at the factory or by a Data I/O Service Technician. EQUIREMENTS Two people to lift it •...
  • Page 49 Two people are required to lift it. A third person is needed to attach fasteners. Use caution. 7. With two people lifting the Tray Feeder, slide the nose into the shield opening and far enough in to accommodate the mounting holes on the machine base plate. PSV5000 Owner’s Manual - 45 -...
  • Page 50 9. Plug in the three utilities: air, electrical, signal cable. figure for Tray Feeder The air connection has One-Touch fittings. connections. The electrical connector can be rotated until it slides into the socket, and then screw the knurled ring up. - 46 - Data I/O ■ 096-0465-001C...
  • Page 51 71. The Tape Output Setup and Operation The PSV5000 System can be configured with an optional Tape Output System. The Tape Output System receives programmed devices directly from the PSV5000 System via the PNP head. The Tape Output System advances PSV5000 Owner’s Manual...
  • Page 52 Figure 25: Tape Output Module on PSV5000 Note: For additional information, refer to the TM-50 Tape Output System User’s Guide that came with your Tape Output System.
  • Page 53 Approximate weight: 47.63 kg (105 lbs.). A third person may be required to bolt it into place. 3. Install the Tape Output Module onto the plate in the PSV5000 workspace and screw it down with six screws (5 mm hex key). See the figure below.
  • Page 54 Locate the line: TapeOutPutInstalled=FALSE and change it to True: TapeOutputInstalled=TRUE Save the winAH400.ini file and exit Windows Explorer. The Tape Output Module gets power and air from the PSV5000 System. Connect the compressed air, electrical power, and communication (Just right below the Tape Output System).
  • Page 55 Place a reel of cover tape of the correct width to match the carrier tape on the cover tape spindle. The tape should unwind to the right from the bottom of the reel. Set the width of the cover tape guide assembly for your size tape. PSV5000 Owner’s Manual - 51 -...
  • Page 56 Adjust the heat shoe air pressure to the appropriate setting. This setting controls the amount of force applied when the sealer shoes drop. - 52 - Data I/O ■ 096-0465-001C...
  • Page 57 RIOR TO UNNING Mount an empty take-up reel on the spindle. Perform a Peel Force Test Perform as many peel force tests as needed while adjusting the sealer controls to obtain the required seal strength. PSV5000 Owner’s Manual - 53 -...
  • Page 58 Note: Use the counter on the Tape output system if desired. However, we recommend setting this counter to zero and using the pass quantity on the PSV5000 System to monitor quantity. Note: When starting a job that uses Tape Output, pull the red “E-Stop/On”...
  • Page 59 AND CUP2 IN Y DIRECTION Start ‘MarkingMate.exe.’ Click a blank space on work area, and then at the Property Table, click Work Area tab, and click Lens Correction to open the Lens Setup dialog. PSV5000 Owner’s Manual - 55 -...
  • Page 60 Laser Software Instruction 1. Copy Template.ezm and rename it for your job, or start the MarkingMate.exe to create a new blank file and then add a text string into the work area for marking. - 56 - Data I/O ■ 096-0465-001C...
  • Page 61 The Preview button. 3. Save the file and exit the software. CH700 Configuration 1. Make a backup of the winAH400.ini file. 2. In the winAH400.ini file make the following changes: Set MarkerSystem=UPRHAND to enable the laser. PSV5000 Owner’s Manual - 57 -...
  • Page 62 20%, here set to 10% means power is 30% for cup2. d. After setting the proper positions, click Laser Mark to check real marking results. - 58 - Data I/O ■ 096-0465-001C...
  • Page 63 ■ Setting Up the Laser Marking Module □ CH700 Configuration Figure 35: The Laser tab in the Gantry window. See instructions in step 3 above for descriptions of controls on the Laser tab. PSV5000 Owner’s Manual - 59 -...
  • Page 64 3 — Chapter Three Administrative Functions The two primary levels of operation of PSV5000 are • Operator functions, and • Administrator functions. Only Administrator functions are covered in this manual. Operator functions are covered in the separate PSV5000 Operators Manual, although Administrators should be familiar with all operator functions.
  • Page 65 Setting Up the Laser Marking Module ≡ CH700 Configuration Creating a Job—Administrator Functions at a Glance Figure 36: Detailed Administrator Functions begin on the next page. Shaded boxes are activities that are performed once per package type. PSV5000 Owner’s Manual - 61 -...
  • Page 66 - 1 - (in the Preface) for symbols and fonts used for safety messages. Safety Systems on page 12 Refer to for safety regarding Emergency Stops, the safety doors, and ESD. - 62 - Data I/O ■ 096-0465-001C...

  • Page 67: Table Of Contents

    Installing Socket Adapters and Actuator Plates Installing the Correct Probe (Optional) Installing the Correct Shuttle Cups Turning PSV5000 System Power ON Selecting a Job (Starting CH700 via TaskLink or Job Runner) (Optional) Preselecting Programmers Setting Media and Options—the Setup window Starting Programming PSV5000 Owner’s Manual...

  • Page 68: Editing The Winah400.Ini File

    —After Starting a Job... Stopping the System Light Tower Interpretation (Optional) Changing Programmer Status Turning PSV5000 System Power OFF (Optional) Operating the Tray Feeder Editing the winAH400.ini File The winAH400.ini file can be edited to add or remove options which determine their availability in the CH700 Setup window.

  • Page 69: Creating Security Profiles

    FlashCORE When CH700 starts, programmers that are not used for a particular job Jobs. can be turned off to improve efficiency; see the PSV5000 Operators Job Creator for Manual for more. Note that operators also have access to this feature.

  • Page 70: (Optional) Do A First Article Test

    RIOR TO REATING A ACKAGE Outlined below is a suggested test process using Data I/O’s desktop programmer called FlashPAK III. This method allows testing without first having to create the Package File required for PSV5000. Create a new Job for FlashPAK—...
  • Page 71 Administrator Functions ≡ (Optional) Do a First Article Test If the job passed the tests, in TaskLink Task Manager, select the Task and click Duplicate. Enter a name and click Edit the Task so that it can be used on your PSV5000 System as follows: Select the Task,...

  • Page 72: (Optional) Setting Tasklink To Operator Mode

    If different input media (tape or tray) is desired, the winAH400.ini file may need to be edited. See the online Help for instructions editing the WinAH400.int file or contact Data I/O support or an authorized technician. Dry Run (Ignore Programmers)

  • Page 73: Teaching The Workspace Locations

    A primary device has been selected. Figure 37: Run window shown with static Trays. O TEACH LOCATIONS 1. Run the job in TaskLink/Job Creator/Job Runner that uses your new (renamed) Package File. 1a. Select a Task/Job and click Run. PSV5000 Owner’s Manual - 69 -...

  • Page 74: Optimize Movetimes

    2. To continue, see the CH700 on-screen Help (Teaching Locations > Printable list of the steps). It covers teaching workspace locations for all media options. Note: The PSV5000 System can have static trays or a Tray Feeder. Teaching tray locations is the same for both. RRORS Please Refer to CH700 on-screen Help.

  • Page 75: Monitoring Statistics

    Sort-on-Error-Code separates devices that fail specific, customer specified processes. In addition, Data I/O offers additional utilities for enhancing yield and reducing errors. These include the Automotive Performance Pak (see page 89) and several other software packages and hardware such as Factory Integration Software (FIS) and Serial Number Server (SNS).
  • Page 76 • For example, if a Socket Adapter was replaced, reset all rows for HPS Socket Adapters are designed to that programmer. accommodate replacement of individual sockets on the - 72 - Data I/O ■ 096-0465-001C adapter board. For LumenX, Socket Adapters only have one socket.
  • Page 77 A (customer-supplied) Statistical Control SW can be used to import and process data output by the CH700. Or use Data I/O’s Enhanced Statistical Software that comes with the CH700; refer to page 89. CAUTION: File corruption hazard! Before making any changes to your winAH400.ini file, save a backup copy.
  • Page 78 17 OrderNumber - Job Name and or number 18 Package - A Package File used for the job If the Automotive Performance Pak is installed, an extended SPC log file (with APP enabled) would have the following delimited fields: TimeStamp - 74 - Data I/O ■ 096-0465-001C...
  • Page 79 DevicesInserted-Socket SocketYield ProgrammerYield ProgSysYield DevicesProcessed-Marker DevicesMarked DevicesInputSystem SystemYield SystemThroughputExcWait SystemTotalThroughputIncWait DevicesOutputSystem MachineID ProgTime *Inspection quality contains a 4 number record divided by the pipe[|], such as 1|2|3|4. 100.0-> vision pass or XXX.X->vision error code PSV5000 Owner’s Manual - 75 -...
  • Page 80 Administrative Functions ■ Administrator Functions XAMPLE 100.0|85.0|-152.4|-1022.4 dX,dY are recorded in μm, dR is in microdegree (μdeg) Figure 42: Sample SPC Log File line entry defined. - 76 - Data I/O ■ 096-0465-001C...

  • Page 81: Maximizing Programming Yields

    Maximizing Programming Yields Occasional declines in system yields may occur during day to day operation of the PSV5000 System. While overall yield levels can vary depending on device manufacture, any steep change in yields is sufficient reason for investigation of an immediate cause of variation.
  • Page 82  failures. System Maintenance that Affects Yield PSV5000 machine maintenance is critical to maintaining high yields. Periodic cleaning, adjustment and replacement of worn elements ensure the best possible performance. These periodic procedures are outlined in Maintenance Schedule on page 4-2 and should be followed closely.
  • Page 83 Using the wrong data file (selected in TaskLink/Job Creator).  Socket abuse, such as digging failed devices out with sharp  instruments. Changing to a questionable vendor source. Lower quality devices  tend to produce lower yields. PSV5000 Owner’s Manual - 79 -...

  • Page 84: (Optional) Creating A Data File From A Master Device

    Administrative Functions ■ (Optional) Creating a Data File from a Master Device (Optional) Creating a Data File from a Master Device The PSV5000 System can read data from a master device and create a data file (also called a PC File) that can then be used in programming jobs.
  • Page 85 Installing the Laser Shuttle Module OOLS EQUIRED Metric Hex Key set To install the Laser Shuttle Module: 1. On the left side of the machine prepare the small clear safety covers for receiving the Laser Shuttle Module. PSV5000 Owner’s Manual - 81 -...
  • Page 86 2. Unscrew the five screws that secure large fixed safety shield (4 mm hex key). 3. Install the Laser Shuttle Module onto the plate in the PSV5000 workspace and screw it down with two screws (5 mm hex key) from the underside of the plate .
  • Page 87 4. Connect the air tube to the machine, two connectors are shown below. 5. Connect the communications cable to the left side of the machine. Figure 48: Left: the Laser Shuttle air connection (circled). Right: connected. PSV5000 Owner’s Manual - 83 -...

  • Page 88: Creating A Laser Marking File (If Marking)

    • An image file is in the MarkingMate SW application. To verify that the laser is marking as expected: 1. Put one device on the expected marking position. 2. At the Laser window, click Laser Marker. This device will be marked. - 84 - Data I/O ■ 096-0465-001C...
  • Page 89 2. Turn off the Laser Switch in the Laser power control panel. WARNING: Serious injury hazard to eyes and skin! Do not open or work on the Laser Module when the Laser Switch is in the ON position. Always make sure it is OFF. PSV5000 Owner’s Manual - 85 -...
  • Page 90 4. Click preview icon in the MarkingMate software. Figure 51: The preview icon in the MarkingMate software 5. Another operator open the PSV5000 front left safety door and unscrew the two screws on the inspection door of the Laser Module. - 86 -...
  • Page 91 7. Use arrow key on the keyboard to move the laser position (red rectangle) to the desired position, lift the door open and recheck. Note: If the rectangle can’t move, make sure the laser pattern in the MarkingMate software is selected. PSV5000 Owner’s Manual - 87 -...
  • Page 92 10. Turn off the Laser Switch in the Laser power control panel. 11. Retry marking device. Refer to the previous heading. If all appears correct and still there is no mark, contact Data I/O Customer Support. Note: The Laser rotor has been leveled at the factory. If you experience trouble, contact Data I/O Customer Support.

  • Page 93: Automotive Performance Pak

    Data I/O offers several utilities that are especially useful to certain industries. These utilities, labeled the Automotive Performance Pak (AP Pak), are described below. If your PSV5000 System does not have this feature, it can be ordered and installed. Contact Data I/O Sales.
  • Page 94 RDERING AND NSTALLING Ordering the AP Pak involves sending Data I/O a number from the Setup window in CH700 with your purchase order. Data I/O will send a security file via return e-mail. Complete instructions along with the installation procedure are in the CH700 online Help: find Automotive Performance Pak in the online Help index.
  • Page 95 Note: Only individuals trained on these procedures by Data I/O or its representatives are qualified to perform maintenance on the PSV5000 System. This section describes the preventive maintenance schedule for the...
  • Page 96 Every day Input air pressure page within specifications and that it is constant, that is the Nm3/min. [Normal Cubic Meter/min.] (SCFM ) must be stable. For specifications, see Connecting Air on page 34. - 92 - Data I/O ■ 096-0465-001C...
  • Page 97 CAUTION: Possible damage to programmers and devices! DO NOT TURN AIR OR POWER OFF to the PSV5000 Machine while a job is running. A job must be Finished before turning OFF compressed air or electrical power. Wait for the Continued- gantry to park before turning OFF.
  • Page 98 DO NOT USE alcohol or industrial chemical cleaners. Clean with damp cloth. Every Safety doors Quarter Replace the O-Ring on the probe stem. Every Probe stem O-Ring page Quarter - 94 - Data I/O ■ 096-0465-001C...
  • Page 99 Every year Vacuum Generator Page necessary. silencers PNP head * Denotes optional equipment Materials Required for Preventive Maintenance To perform preventive maintenance procedures on the PSV5000 System, in general you need the following materials. PSV5000 Owner’s Manual - 95 -...
  • Page 100 • Self-Serve Spares Kit (page 97) Turning off the Systems When the PSV5000 System will not be used for several days, or before performing a service procedure, turn OFF the system. See Shutting Down the PSV5000 System on page 38.
  • Page 101 Self-Service Spares Kit  Turning off the Systems Self-Service Spares Kit The Self-Service Spares Kit, Data I/O part number 952-0508-001 or higher, can be purchased at any time. 910-2200-00d or higher: Diagnostics Adapter Board (DAB) only for FC programmer calibration...

  • Page 102: Workspace, Head And Gantry

    Prior to turning off the input air, ensure that no job is running. CAUTION: Possible damage to programmers and devices! DO NOT TURN AIR OR POWER OFF to the PSV5000 Machine while a job is - 98 - Data I/O ■ 096-0465-001C...
  • Page 103 ROGRAMMERS Socket Actuators are built into the FlashCORE programmers on PSV5000. Socket actuation is controlled by air pressure. If Socket Actuators are slamming up and down loudly, or devices are bouncing, the air pressure may be too high. If the PNP head does not properly pick or place a device in a socket because the socket is not opening completely, the air pressure might be set too low.
  • Page 104 THE SOCKET ACTUATOR SPEED WAS SET AT THE FACTORY AND SHOULD NOT NEED ADJUSTMENT. If it is determined that adjustment is necessary, this procedure requires a Data I/O trained technician since it requires having an access door open while the machine power is on.
  • Page 105 If it is too slow it will look slow. Click Actuate Socket OFF. Adjust the flow controls as necessary and repeat the test. Perform the same procedure for the other flow control if necessary. PSV5000 Owner’s Manual - 101 -...
  • Page 106 Maintenance ■ Workspace, Head and Gantry Cleaning the PSV5000 Machine ENERAL ACHINE LEANING General cleaning should be performed on a weekly basis. General cleaning includes, but is not limited to, the following listed item. WARNING: Vision hazard! Pressurized air or debris blown into the eyes or skin could cause bodily damage.
  • Page 107 Gantry window. The Tool position is recommended. 2. Open the safety door. 3. Wipe the tip with alcohol wipes (Data I/O PN 570-0410-001) or a damp cloth. PSV5000 Owner’s Manual - 103 -...
  • Page 108 4. Click Blow-off to the ON position. Figure 60: Vacuum and Blow-off on the I/O Interface window. WARNING: Possible collision hazard! The high speed and force of the gantry can seriously harm anyone working inside the - 104 - Data I/O ■ 096-0465-001C...
  • Page 109 Ensure that a job is Paused or Finished, or the system power is OFF prior to opening any safety doors. 5. Locate the actual vacuum generator (Data I/O PN 815-0047-001) on the right side of the PNP head. Find the blow-off adjustment set-screw.
  • Page 110 Vacuum sensors on the PSV5000 System are adjustable. The I/O Interface window displays a list of the sensors in the PSV5000 System and the status of each sensor. Note: The number of sensors on the PSV5000 System depends on the options installed.
  • Page 111 3. Unscrew the air contamination collection bowl housing. 4. Pull off the clear collection bowl. Clean out any dirt, oil, or water. 5. Unscrew the black knob below the filter. 6. Pull off the filter. Clean or replace as necessary. PSV5000 Owner’s Manual - 107 -...
  • Page 112 1. Finish a job if one is running. 2. Use the Gantry window to move the PNP head to an accessible location such as the Tool position. 3. Properly shut OFF the PSV5000 System. See Shutting Down the PSV5000 System on page 38. - 108 -...
  • Page 113 7. Remove the filter housing and ensure that the O-Ring doesn’t fall. 8. Remove the filter from the housing. It should be white or nearly white. If dirty or clogged, replace with new filter (Data I/O PN 294-0219-001). See the figure below.
  • Page 114 Maintenance ■ Pick and Place Probe 3. Properly shut OFF the PSV5000 System. See Shutting Down the PSV5000 System on page 38. WARNING: Shock hazard! Opening the safety doors stops motion of the gantry only. It does not remove electrical power from the machine or any optional equipment.
  • Page 115 UBRICATION 1. Move the PNP head to the Park position. 2. Properly shut OFF the PSV5000 sub-systems and machine power. See Shutting Down the PSV5000 System on page 38. 3. The guard on the back linear guide must slide out to the left or right.
  • Page 116 (2 mm hex key). 11. Remove the screw covering the grease duct. 12. Apply grease to the grease duct on each end of the slide block. Wipe off any excess. See figure below. - 112 - Data I/O ■ 096-0465-001C...
  • Page 117 1. Open the front and rear safety doors and remove the four screws securing the guard of the Y-axis linear guide (2 mm hex key). 2. Slide the guard out from either the front or back after pulling slightly to clear the end cap. PSV5000 Owner’s Manual - 113 -...
  • Page 118 1. End a job and move the PNP head to the PARK position (click System > Gantry > Tool) to move it to an accessible position. 2. Properly shut down the PSV5000 System; refer to Shutting Down the PSV5000 System on page 38.
  • Page 119 3. Remove the probe from the Probe stem. Refer to Installing the Correct Probe in the PSV5000 Operator’s Manual. 4. Disconnect the air hose form the vacuum generator (shown in the figure below) by pushing on the collar while pulling the tubing.
  • Page 120 Refer to Figure 71: (A long 2.5 mm hex key is required.) 9. Disconnect and remove the Z-axis retention spring (front side of assembly). 10. Remove two wire connectors from the back of the motor. See Figure 74: . - 116 - Data I/O ■ 096-0465-001C...
  • Page 121 Probe Assembly is removed with the tubing and wires still through the head mount. EINSTALLING THE ROBE SSEMBLY Generally, the reinstallation is in the reverse order of removal with these precautions: • Remember to thread the cables/tube through the head bracket. PSV5000 Owner’s Manual - 117 -...
  • Page 122 • Make sure tubes and wires are securely stowed and fixed to avoid being rubbed by any moving parts. • Remember to re-install the retention spring. - 118 - Data I/O ■ 096-0465-001C...

  • Page 123: Programmers

    Annual programmer Compliance Verification (CV) can be performed by Data I/O at customer sites. This on-site visit is included if you have an APS (Annual Programmer Support) contract (customer pays travel costs). Optionally, customer can purchase a Diagnostic Adaptor Board (DAB) and perform the compliance diagnostics themselves.
  • Page 124 Socket Adapter, discharge static electricity from yourself by touching a common ground or an unpainted metal surface. When at the PSV5000 Machine, always wear a wrist strap containing a 1 The wrist strap Data I/O PN is 440-0021-001.
  • Page 125 (on the Handler Computer). If any of the tests show Fail in the TaskLink display, contact your nearest Data I/O Service Center for repair options. To help our service personnel diagnose the problem, please e-mail both the eventlog.txt and diaglog.txt files.
  • Page 126 • Access door key that came with your PSV5000 WARNING: Electric shock hazard! Injury or death may result from contact to parts inside the machine. Shut off the PSV5000 System by turning OFF the main power switch before working on or near the gantry, before opening any access doors or removing any cabinet panels.
  • Page 127 7. Follow and mark the Ethernet cable to the router : on the right mounting plate (FlashCORE programmers). mounted nearby (LumenX programmers). 8. Disconnect the Ethernet cable by pinching the clip and pulling up. Refer to Figure 76: . PSV5000 Owner’s Manual - 123 -...

  • Page 128: The Laser Module

    Replacement is in the reverse order of removal. The Laser Module and Shuttle [Laser Marking only] Laser Marker System is optional equipment on your PSV5000 Programming System. The Laser Module employs a laser shuttle (except when using Tape Output) and includes a fume extractor. The Laser Module The Laser shuttle transports devices to and from the lasing area.
  • Page 129 Wear safety goggles and disposable protective gloves. 1. Properly shut off the PSV5000 sub-systems and machine power. See Shutting Down the PSV5000 System on page 38. 2. Wear eye protection and put on disposable protective gloves.
  • Page 130 TART CAUTION: Possible health hazard! Dust from the main filter may be expelled on start-up after PSV5000 transportation. Turn the system ON in a room with appropriate ventilation or wear dust respirator and goggles. The Fume Extractor starts automatically when the PSV500 Machine is started (unless the extractor has been manually turned off).
  • Page 131 Perform the following procedure only if you have training regarding laser etching processes or handling hazardous materials. Wear safety goggles and disposable protective gloves.. For both these procedures contact Data I/O Customer Support or a local Data I/O approved service representative. EPLACING THE...
  • Page 132 Maintenance ■ The Laser Module and Shuttle Figure 77: The Fume Extractor inside the front of the PSV5000. 4. To continue, see the replacement instructions and part numbers of the UpperHand pre-filter and main filter in the UpperHand Fume Extractor Operation Manual (that came with PSV5000).

  • Page 133: Handler Computer

    Handler Computer  Handler Computer Air Filter Handler Computer The main PSV5000 Machine computer, or Handler Computer, is at the left side of the machine and requires little maintenance. Handler Computer Air Filter The Handler Computer has an air filter that requires periodic cleaning or replacing.
  • Page 134 CDs than the CH700 updates. For more information, see the online Help for TaskLink or Job Runner or Job Creator. NOTE: PSV5000 System algorithms are updated periodically and are An APS is our available depending on your maintenance plan. For more information...

  • Page 135: Troubleshooting

    PSV5000. Troubleshooting for the Tape Output System is covered in a separate heading; see Tape Output System Maintenance on page 140. Also, see PSV5000 on-screen Help for a more detailed Troubleshooting chart. EADINGS BELOW COVER THESE TOPICS...
  • Page 136 Maintenance ■ Troubleshooting Yellow • Tray not present PSV5000 does not detect the tray and when you click Run, you get error message Tray Not Present; or the Run window shows a tray where there is none. • Re-install the tray.
  • Page 137 Collect all PSV5000 System Logs Collect PS Logs is a software utility on CH700 Software that collects all log files from PSV5000. It creates a ZIP file containing all the information that Data I/O or trained service technicians need to evaluate your PSV5000 Machine status.
  • Page 138 After starting Collect PS Logs from the Start menu, the main window appears where you can select which items you need to collected. 1. Select or clear check boxes for files as desired. - 134 - Data I/O ■ 096-0465-001C...
  • Page 139 Troubleshooting  Collect all PSV5000 System Logs 2. (Optional) Check additional SPC files if the error rarely appears or appeared a long time ago. 3. (Optional) In Collect PSV5000 Logs, to enter a text description to the Zip file: a. Click Add description.
  • Page 140 If a programmer is not performing and you cannot correct the error, you can continue to use other programmer sites after disabling the non-functional programmer. See Disabling Programmers in the PSV5000 Operators Manual or the CH700 on-screen Help. • All programmers fail to •...
  • Page 141 Also see Inspecting Gantry accurately. Parts on page 110. • Yellow/ • The probe experiences • Contact Data I/O Customer Support or a pick and/or place local Data I/O approved service errors regularly. representative. • None •...
  • Page 142 See Pick and Place Probe on page 103. • Determine if the PNP head probe is clogged. Clean if necessary. Refer to Removing and Installing a Probe in the PSV5000 Operator’s Manual. • Check the probe vacuum and Blow-off solenoids; see Adjusting the Vacuum Generator Sensors on page 105.
  • Page 143 If the Handler computer drive fails, its behavior or a message indicates that a computer has crashed. Your PSV5000 System is equipped with a mirror-backup system called RAID that creates a real-time ghost image. You will see an error message display for a few seconds at system start-up.

  • Page 144: Tape Output System Maintenance

    Maintenance ■ Tape Output System Maintenance Your PSV5000 System will continue to operate as normal on the backup drive. However, the failed drive must be replaced for continued safety. After the failed drive is identified and replaced, the message on-screen will read REBUILDING.
  • Page 145 Tape Output System Maintenance  Cleaning the Pressure Seal To clean the Pressure Seal Tape Output System: 1. Turn ON the PSV5000 System power and air. 2. Start TaskLink. 3. Select a job that requires the use of the tape output.
  • Page 146 PSA mode for pressure seal cover tape. An asterisk indicates the current setting. Then press ESC. NOTE: The Heat Seal switch should be OFF. T THE UN MENU • select Run Mode. The run window displays all the - 142 - Data I/O ■ 096-0465-001C...
  • Page 147 CAUTION: O-Rings might be easily damaged. Handle gently to avoid breaking them. a. Gently remove the two O-Rings from the drive sprocket idler. b. Using a damp cloth or a commercial wipe, remove all grime from O-Rings. PSV5000 Owner’s Manual - 143 -...
  • Page 148 When the CH700 software displays the error message Tape Out Unit, one of the tape output system sensors has been triggered. The most likely sensors to trigger are the Device Jam and Device Tape sensors. See figure below. - 144 - Data I/O ■ 096-0465-001C...
  • Page 149 Tape Output System Maintenance  Troubleshooting the Tape Output System Front View  Right Side View  Figure 84: Optical Fiber Amplifiers: Cover Tape Present and Empty Pocket, respectively. Amplifier doors are open in the right side view. PSV5000 Owner’s Manual - 145 -...
  • Page 150 The Track Jam sensor The Cover Tape sensor detects when there is no cover tape on the reel. When the Cover Tape sensor is triggered, a red LED is illuminated in the Cover Tape Sensor Controller. - 146 - Data I/O ■ 096-0465-001C...
  • Page 151 D.ON by pressing the Mode button. (There may be an L/D ON button or toggle to change the mode.) 7. Press and release the SET button in the right amplifier. 8. Remove the device from the tape pocket. PSV5000 Owner’s Manual - 147 -...

  • Page 152: Tray Feeder

    European Union's WEEE Directive. You may also dispose of it yourself in accordance with the European Union's WEEE Directive. Data I/O will collect this equipment at no cost to the equipment owner and process it accordingly. (This includes auxiliary equipment that came with your PSV5000 System such as Tape-Out Module, and Tray Feeder.)
  • Page 153 Electrical Equipment Disposal Notice  Cleaning and Inspecting the Tray Feeder Contact your nearest Data I/O office to receive information about returning WEEE labeled products with no charge. PSV5000 Owner’s Manual - 149 -...
  • Page 154 May. Jun. Jul. Aug. Sep. Oct. Nov. Dec. Weekly programmer Jan. Feb. Mar. Apr. May. Jun. Self-test, (cycle power) Clean surfaces Clean probe tips. Check Tray Feeder* Jul. Aug. Sep. Oct. Nov. Dec. - 150 - Data I/O ■ 096-0465-001C...
  • Page 155 Semi-Annually Check PNP head connections & fasteners Clean Handler PC filter Enter initials and date: Annually 20__ Clean and lube Gantry guide rails Perform Programmer Performance Verification test Check vacuum generator silencers on head PSV5000 Owner’s Manual - 151 -...
  • Page 156 Dimensions•18 Auxiliary Tray•42 Disabled programmers•67 Disposal of equipment•148 disposal requirements•- 5 - Dry Run•68 Backup system•139 Duplicating a Job•66 Blow-Off, adjusting•104 Electrical Input Requirements•35 Calibration test, programmers•119 Electrical Schematics•158 CH700 Emergency Stop buttons•12 - 152 - Data I/O ■ 096-0465-001C...
  • Page 157 LumenX Home position•13 Job Folder•64 LumenX programmers•20 Ignore Programmers•68 Input/Output Modules Machine Axes•14 Automatic Tray Feeder•43 Machine Cleaning auxiliary tray•42 general•102 reject bin•41 Main Air Pressure•35 static trays•40 Maintenance tape output•47 sign-off chart•150 Install PSV5000 Owner’s Manual - 153 -...
  • Page 158 Pneumatic input requirement•34 PNP head descripiton•15 moving manually•115 PNP Probe Safety re-installing•117 doors•13 replacing•114 Emergency Stop•12 laser•27 Pocket empty sensor•146 Pocket Empty Sensor•144, 147 pinch hazard•- 4 - Port Numbers•38 precautions•- 4 - - 154 - Data I/O ■ 096-0465-001C...
  • Page 159 Task creation•64 updating SW;•130 TaskLink Workspace layout creating a Package file•66 auxiliary•42 modes•68 Tray to Tray•43 session data logging•71 Teaching the Package file•69 Technical support•- 6 - Tool position•13 Yield, considerations•78 Transfer devices only•68 PSV5000 Owner’s Manual - 155 -...
  • Page 161 Electrical Schematics for PSV5000 and Equipment...
  • Page 176 ROGRAMMABLE MEDIA EXPERTS...

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