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V-TEK TM-403 User Manual

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TM-403 User's Guide
V-TEK, Inc.
751 Summit Avenue
Mankato, MN 56001
(P) 507-387-2039
www.vtekusa.com
User's Guide # D292106G

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  • Page 1 TM-403 User’s Guide V-TEK, Inc. 751 Summit Avenue Mankato, MN 56001 (P) 507-387-2039 www.vtekusa.com User’s Guide # D292106G...
  • Page 2 Vendor Provided Material Significant portions of this documentation were provided by: KEYENCE CORPORATION OF AMERICA 1100 North Arlington Heights Road, Suite210, Itasca, IL 60143 1-888-KEYENCE (1-888-539-3623) www.keyence.com...
  • Page 3 EC Declaration of Conformity Manufacturers Name: V-TEK Inc. Manufacturers’ Address: 751 Summit Avenue, Mankato, Minnesota 56002, USA Declare that the machinery described below complies with applicable health and safety requirements of Part 1 of Annex 1 of the Machinery Directive 2006/42/EC and EMC Directive 2004/108/EC. Confidential technical documentation has been compiled in accordance with Part A of Annex VII of Machinery Directive 2006/42/EC and is available to European national authorities on written request only.
  • Page 5 Introduction Contents Introduction ..........ii Theory of Operation .
  • Page 6 Introduction Thank you for purchasing the TM-403 Component Handling Machine. The TM-403 is a table- top pick and place tape and reel machine with vision, designed for use in production environ- ments for electronic devices. This machine accepts devices loaded in trays. It features a 2D over tape vision system for component verification.
  • Page 7 As the tape advances, it passes sensors which detect jams in tape. Once the carrier tape reaches the TM-403 sealer assembly, cover tape is applied. The part is then sealed in the pocket with either a Heat Seal or Pressure Sensitive Adhesive (PSA) cover tape. When the sealing pro- cess is complete, the finished tape is routed onto a take-up reel.
  • Page 8 Note: The TM-403 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-403 can also handle other voltage levels seen in other parts of the world including voltages from 208V-240V @ 50/60 Hz.
  • Page 9 Intended Use The intended use of the TM-403 Taping Machine is to produce taped reels of individually sealed and consistently orientated components. It can also be used to move parts from one tray to another, combining partial trays. Use of this equipment in any other way is not recommended.
  • Page 10 The enclosure doors may be left open during basic set-up procedures such as positioning the pick head at place or pick locations. If the enclosure doors are left open during setup the TM-403 automatically reduces the speed of the pick head to a fraction of its normal operating speed to prevent operator injury due to collision, etc.
  • Page 11 Power/Emergency Stop Button. This position allows the oper- ator to view all parts of the TM-403 while it is in operation. When loading the TM-403 Tray Feeder or changing Taper reels, the operator may also need to access the side and back of the machine...
  • Page 12 HMI. Reset Button The TM-403’s blue Reset button is located on the left side of the machine above the Emergency Stop Switch. When the machine is powered up, it...
  • Page 13 The enclosure doors may be left open during basic set-up procedures such as positioning the pick head at place or pick locations. If the enclosure doors are left open during setup the TM-403 automatically reduces the speed of the pick head to a fraction of its normal operating speed to prevent operator injury due to collision, etc.
  • Page 14 A blinking red light and a solid amber light indicates the machine is at the end of a job, the leader creation sequence is complete and the TM-403 is ready for the next process. Safety Features...
  • Page 15 Consult User’s Guide for proper procedure. Disconnect power and air supplies and refer to Chapter 8: Maintenance of this manual before performing maintenance on the TM-403. Note: Do not remove or obstruct any of the warning or instruction labels on the TM-403.
  • Page 16 Contact Information V-TEK, Inc. 751 Summit Ave Mankato, MN 56001 TEL: (507) 389-2039 FAX: (507) 387-2257 email:service@vtekusa.com website: http://www.vtekusa.com For customer service, please refer to the Customer Service Contact Sheet at the back of this manual. European Representative: QNET BV...
  • Page 17 Table of Contents EC Declaration of Conformity Introduction Introduction ............i-ii Theory of Operation .

  • Page 18: Table Of Contents

    Table of Contents (continued) Chapter 3: The Human Machine Interface ........3-1 Introduction .
  • Page 19 Table of Contents (continued) Chapter 6: Operation ........... . .6-1 Quick Start: Running a Job .
  • Page 20 Table of Contents (continued) Chapter 8: Maintenance ..........8-1 Safe Maintenance Steps .
  • Page 21 Assembling the TM-403 ........

  • Page 22: Preparing The Work Area

    Space Requirements The TM-403 is a table-top machine which needs to be placed on a flat, stable surface in a well lit work area that is a minimum of 7’ high x 11’ wide x 9‘deep (2.2 m x 3.5 m x 2.7 m) to provide suf- ficient space for the assembled machine when it is fully loaded with a variety of tape reel sizes.
  • Page 23 1- 3 Table Requirements The TM-403 should be placed on a user-supplied table or bench that is capable of supporting a minimum of 260 lb. (118 kg). An optional 80/20 frame (pictured above) is also available for mounting the TM-403.

  • Page 24: Power Requirements

    Power Requirements The TM-403 will also require access to a 85-110 PSI air pressure system and a 120/240 VAC, 50/60 Hz power supply. Locate the machine so electrical power cables can be routed away from areas where personnel are expected to move.

  • Page 25: Unpacking The Tm-403

    1- 5 Unpacking the TM-403 Prior to shipment, the TM-403 is partially disassembled, then shrink wrapped, placed in a crate, and strapped to the crate floor. The disassembled TM-403 parts, which include the Carrier Tape Arm, the Take-up Assembly, the Tower Light and the Spare Parts Kit, are individually bubble- wrapped and packed around the base machine.

  • Page 26: Assembling The Tm-403

    Note: Read the TM-403 User’s Guide before assembling the TM-403. Unpack the TM-403 Crate Move the Crate to the Work Area. Use a fork lift to move the TM-403 crate to the pre- pared work area. Ensure the fork is centered under the crate before lifting.
  • Page 27 Lift the machine from the crate and place it onto the prepared work table/bench. Position the TM-403 in the work area so there is at least 3 feet of clearance on all sides. (See the Preparing the Work Area section earlier in this chapter for details.) The TM-403 is shipped with zip ties securing the pick head, the 2D Camera, the Tray Feeder and any mobile portions of the machine.
  • Page 28 Re-assemble the TM-403 Position the Tower Light Lift Tower Light, snapping it in place in an upright position perpendicular to the TM-403. Connect the Carrier Tape Arm a. Remove the black knob from the right side of the Track Support Bracket.
  • Page 29 45 degree angle from the baseplate assembly. Engage the dowel pin into the desired posi- tion and secure it into place with the black knob. b. Plug the electrical connector into the take-up motor receptacle. D292106.4a.fm Assembling the TM-403...
  • Page 30 V-TEK. The TM-403 is fully tested before shipping. No further grounding or testing is required during re-assembly and installation. The TM-403 is ready to power up. Follow the instructions in Chapter 3: Machine Setup to setup the machine for operation.
  • Page 31 Chapter 2: Machine Overview Contents Front View ........... . 2-2 Right Side View .

  • Page 32: Front View

    TM-403 User’s Guide Front View A. Take-up Arm H. Vision System B. Air Regulator I. Taper Track C. Idler Wheel J. Pick & Place Head Assembly & Bridge D. Drive Sprocket K. Touch Screen HMI E. Cover Tape Arm L. Tower Light F.

  • Page 33: Right Side View

    Chapter 2: TM-403 Overview Right Side View A. Tower Light E. Taper Input B. Pick & Place Head Enclosure F. Tray Feeder C. Carrier Tape Arm G. Main Power Switch D. Carrier Tape Arm Adjustment Knob D292106.5b.fm Right Side View...

  • Page 34: Left Side View

    TM-403 User’s Guide Left Side View A. Pick & Place Head Assembly G. Take-up Arm B. Enclosure Doors (3) H. Cover Tape Arm C. Tray Feeder I. Tower Light D. Air Regulator J. Heat/PSA Sealer E. Take-up Motor Connection K. Reset Button F.

  • Page 35: Back View

    Chapter 2: TM-403 Overview Back View A. Carrier Tape Arm J. Pick Head Jog Buttons B. Carrier Arm Adjustment Knob K. Heat/PSA Sealer C. Fuse Holders (Bowl application only) L. Tray Feeder D. Pick Head Enclosure M. Ethernet Connection E. Tower Light N.

  • Page 36: Controls, Connections & Labeling

    TM-403 User’s Guide Controls, Connections & Labeling Reset Button The TM-403’s blue Reset Button is located on the left side of the machine below the Take-up Arm. (pictured below) Emergency Stop Switch The Emergency Stop Switch is located on the left side of the machine below the blue Reset Button.
  • Page 37 Chapter 2: TM-403 Overview Main Power Switch The Main Power Switch is located on the right side of the machine behind the Carrier Tape Arm on the lower sheet metal enclosure. Serial Plate This is an example of the Serial Plate which is permanently affixed to the back of the TM- 403.

  • Page 38: The Taper

    TM-403 User’s Guide The Taper A. Take-up Arm H. Sensor Amplifiers B. Take-up Guide I. Cover Tape Guide C. Drive Sprocket J. Heat/PSA Sealer D. Idler Wheel K. Tape Jam Sensor E. Sealer Controls & Pressure Gauge L. Adjustable Width Track F.
  • Page 39 Chapter 2: TM-403 Overview Taper: Sealer A. Idler Wheel G. Heat Sealer B. Drive Sprocket H. PSA Pressure Wheels C. Outer Seal Lock I. PSA Pressure Adjustment Screws D. Outer Seal Adjuster J. Cover Tape Guide E. Inner Seal Lock K.

  • Page 40: Pick & Place Assembly

    2-10 TM-403 User’s Guide Pick & Place Assembly Pick & Place Head A. Nozzle D. Pick Actuator Adjustment Screw B. Nozzle Vacuum Sensor E. Place Actuator Adjustment Screw C. Nozzle Vacuum Filter Pick & Place Controls A. Blow-off Air Pressure Gauge & Control B.

  • Page 41: Tray Feeder

    Chapter 2: TM-403 Overview 2-11 Tray Feeder A. Pick Area B. Stationary Tray Clamps C. Side & Center Clamps D. Safety Enclosure Door E. Tray 1 F. Tray 2 G. Spring loaded Tray Clamps D292106.5b.fm Tray Feeder.

  • Page 42: 2D Vision System

    J. Dome Light Option (not shown) Note: For advanced Vision configuration, a computer or Keyence Monitor is required. These can be purchased as an option from V-TEK, Inc or the user can provide their own computer. System requirements for the vision computer follow: •...
  • Page 43 Chapter 3: Human Machine Interface Contents Introduction ..........3-2 Touch Screen .

  • Page 44: Introduction

    Operation for instructions on how to run a job. Touch Screen The user interacts with the TM-403 through a touch screen HMI which is located on the front of the machine below the Taper. Touching the HMI screen has the same effect as a left click with the mouse.

  • Page 45: Hmi Tabs

    Chapter 3: Human Machine Interface HMI Tabs When the TM-403 is powered on, the user interface opens to the Job Tab. The Job Tab is pictured above as it appears when the motors have been homed. There are five tabs on the TM-403 HMI: Job, Taper, Head, Tray and Run.

  • Page 46: Job Tab

    TM-403 User’s Guide Job Tab When the TM-403 is initially powered up, the HMI will open to the Job Tab with a red Home Required button at the top of the Tab Menu and the other tab buttons grayed out.
  • Page 47 Chapter 3: Human Machine Interface Press the Home All Motors button to begin the homing sequence. Homing progress is displayed in the Pick Axis Motor Status Bar and the Tray Axis Motor Status Bar. As the homing sequence is completed, the bars gradually turns from black to green. A Homing Succeeded! message appears at the end of the sequence.
  • Page 48 TM-403 User’s Guide Pressing the Left Arrow button in the Homing Screen will open the Run Tab. Select the Job Tab from the Tab Menu to navigate back to the Job Tab. Job Tab D292106.6b.fm...
  • Page 49 Chapter 3: Human Machine Interface Job Tab Overview The Job Tab allows the user to select a pre-programmed job, change job information and move to the other tab screens. It also features an easy-to-use Job Wizard which leads the user through the job set-up process.

  • Page 50: Job Wizard

    TM-403 User’s Guide Job Wizard Pressing the Job Wizard button in the Job Tab opens the Job Wizard. The Job Wizard has 16 screens that lead the user through the job set-up process. Instructions at the top of each Job Wizard screen explain each step. The Arrow buttons on the bottom of the window move the user forward and backwards through the process.
  • Page 51 Chapter 3: Human Machine Interface In the first Job Wizard screen the user resets the job to initialize the system. Press Reset Job Wizard Step 1 Arrow Buttons Job, then press the right Arrow key to move to the next Job Wizard screen. In the second Job Wizard screen the user enters the Quantity of parts that will be run and a brief Description of the job.
  • Page 52 Arrow Key to move to the next Job Wizard screen. Note: The TM-403 accommodates a wide range of carrier tapes and cover tapes. Set- tings may vary from one tape product to another. The recommended starting point is 90°...
  • Page 53 Chapter 3: Human Machine Interface 3-11 The fourth Job Wizard screen enables or disables the tape Leader.. Job Wizard Step 4 Leader State toggles between Enabled and Disabled. Pressing the Leader Length field will open a keypad. Type in the desired value, then press the right Arrow Key to move to the next Job Wizard screen.
  • Page 54 3-12 TM-403 User’s Guide Enter the number of tray rows in the tray that will be processed. Note: Columns run parallel to the front of the machine. Rows run perpendicular to the front of the machine. In the example below, each tray has 5 columns and 12 rows. The number of rows will always be greater than the number of columns in a tray.
  • Page 55 Chapter 3: Human Machine Interface 3-13 Press the right Arrow Key to move to the next Job Wizard screen. Job Wizard Step 6 Center the Pick Head over Pocket 1 using the HMI Head & Tray Jog buttons or the Pick Head Jog Buttons on top of the Sealer enclosure and the Tray Carriage Jog Buttons on the back of the machine.
  • Page 56 3-14 TM-403 User’s Guide Press the right Arrow to move to the next Job Wizard screen. Job Wizard Step 7 Center the Pick Head over Pocket 2 using the Jog buttons or the Pick Head Jog Buttons on top of the Sealer enclosure and the Tray Carriage Jog Buttons on the back of the machine.
  • Page 57 Chapter 3: Human Machine Interface 3-15 The next seven Job Wizard screens are used to set the Nozzle positions at the Pick and Place locations. The first is shown below. Job Wizard Step 8 Press Move to Origin to move the Pick Head to the Tray Feeder’s Tray 1, Pocket 1 position.
  • Page 58 3-16 TM-403 User’s Guide Press Pick Extend to lower the Nozzle to the tray pocket. The button will change to Pick Retract. Note: Follow the directions in Chapter 4: Setup for manually adjusting the Pick Actuator to set the correct Nozzle Height.
  • Page 59 Chapter 3: Human Machine Interface 3-17 Press the right Arrow Key to move to the next Job Wizard screen. Job Wizard Step 11 The Arrow keys allow the user to jog the Pick Head and Carrier Tape forward or backward in small preset increments. This is useful for centering the Nozzle in the pick and place positions.
  • Page 60 3-18 TM-403 User’s Guide Press the right Arrow Key to move to the next Job Wizard screen.. Job Wizard Step 12 Press Place Extend to lower the Nozzle to the Carrier Tape Pocket. Note: The Place Extend button toggles between Place Extend and Place Retract.
  • Page 61 Chapter 3: Human Machine Interface 3-19 Enter the placement angle which was manually set in Step 8. The options are 0, - 90 and +90. In the photo below, a part is shown at the pick position as viewed from the front of the machine.
  • Page 62 If adjustment are required, use the left Arrow key to return to the desired step and adjust settings until the TM-403 picks and places parts as desired. Press the right Arrow Key to move to the next Job Wizard screen.
  • Page 63 Chapter 3: Human Machine Interface 3-21 Press the right Arrow Key to move to the final Job Wizard screen. Job Wizard Step 16 Browse through the Job Library using the Up/Down Arrow keys to move up or down through the list. To select a Job Name from the list, press the Enter key. Note: The Save function will overwrite the information stored for the currently selected job.

  • Page 64: Taper Tab

    3-22 TM-403 User’s Guide Taper Tab The Taper Tab allows the user to adjust taper settings by leading them through four Taper Setup screens. The first screen of the Taper Tab is shown below. Taper Screen 1 Press the Taper tab in the Tab Menu to open that tab window.
  • Page 65 PASS message or a red FAIL message. Note: For more detailed inspection configuration and procedures, see the Cognex Checker User’s Guide which was included with the TM-403. Pressing the right Arrow button opens the next Taper Setup screen.
  • Page 66 The Measured field shows the current Heat Sealer temperature in degrees Cel- sius. Note: The TM-403 accommodates a wide range of carrier tapes and cover tapes. Set- tings may vary from one tape product to another. The recommended starting point is 90°...
  • Page 67 The Leader Length field is only active when Leader State is Enabled. Enter the desired leader length in millimeters in the field. Note: The TM-403 will use these settings for the current job. To save Taper Settings for future jobs, go to the Job Tab, select a job name and Save.

  • Page 68: Head Tab

    3-26 TM-403 User’s Guide Head Tab The three Head Setup Tab screens allow the user to set pick and place head positions, head speed, and blow off time. There are also buttons that allow the user to manually pick, place and rotate parts.
  • Page 69 Chapter 3: Human Machine Interface 3-27 Press the right Arrow button to open the second Head Setup screen (shown below). Head Screen 2 This section includes a Location Field for entering the desired place position, the Set Place Position button and a Status button. The status button will appear green if the place position has been learned and if it has not been learned.
  • Page 70 3-28 TM-403 User’s Guide Press the right Arrow button to open the third Head Setup screen (shown below). Head Screen 3 The Pick Extend/Pick Retract button actuates the pick solenoid to enable the operator to set the pick height. The Rotate Part button rotates the pick head to the preset rotation angle.
  • Page 71 Tab Menu to move to a new tab. Note: The TM-403 will use these settings for the current job. To save Head Settings for future jobs, go to the Job Tab, select a job name and Save.

  • Page 72: Tray Tab

    3-30 TM-403 User’s Guide Tray Tab The Tray Setup Tabs allows the user to manually index the tray and configure tray size and pitch. The user can also utilize the Pitch Wizard to calculate pick position. Tray Screen 1 allows the user to position the trays as desired..
  • Page 73 Chapter 3: Human Machine Interface 3-31 Tray Screen 2 allows the user to enter tray parameters and set Pocket 1 and Pocket 2 positions if they are known. The user can also select the Pitch Wizard to automatically calculate this information. Tray Screen 2 Press the Tray tab in the Tab Menu to open that tab window.
  • Page 74 3-32 TM-403 User’s Guide Press the Help Icon to see an illustration of X1, Y1 and X2, Y2 posi- tions in relation to the X and Y axis. The current Row Pitch and Column Pitch settings are displayed at the bottom of the screen.
  • Page 75 Chapter 3: Human Machine Interface 3-33 Press the right arrow key to advance to the second Pitch Wizard screen. Pitch Wizard 2 The Jog buttons are used to jog the head forward or backward along the X Axis (left/right) until the nozzle is centered over the first tray pocket (X1, Y1).
  • Page 76 3-34 TM-403 User’s Guide Tray Jog Step is the distance in millimeters that the tray will move when Jog is pressed. The Head Position indicates where the pick head is located in relation to the Home position. The Learned Position indicates the current Pick position.
  • Page 77 Press the Finish button to calculate tube pitch and return to the Tray Feeder Tab. Note: The TM-403 will use these settings for the current job. To save Tray Feeder Set- tings for future jobs, go to the Job Tab, select a job name and Save.
  • Page 78 3-36 TM-403 User’s Guide Pressing the Tray Options Screen in the first Tray screen opens the Tray Options Screen which allows the user to select output to Tape or to Tray. The screen below shows the screen with the Tape Output selected.
  • Page 79 Chapter 3: Human Machine Interface 3-37 Note: Rows run perpendicular to the front of the machine. Columns run parallel to the front of the machine. The number of rows will always be greater than the number of col- umns in a tray. The Place Position section allows the user to designate which row and column to place to on Tray 2.

  • Page 80: Run Tab

    3-38 TM-403 User’s Guide Run Tab When Run is selected from the Tab Menu, the Run Tab opens. It includes job information, current job statistics, Status messages and Run control buttons. The Run Screen with all status mes- sages displayed appears below.
  • Page 81 Chapter 3: Human Machine Interface 3-39 When Reset Job is pressed, the following message appears. • The System Homing button allows the user to home the motor. Homing motors should be done once following every system power up. When System Homing is selected, the Homing Status window will appear.
  • Page 82 3-40 TM-403 User’s Guide As the homing sequence is completed, the bar gradually turns from black to green. A Homing Succeeded! message appears at the end of the sequence. If a problem arises during homing for the motor, the status bar will turn and a Homing Error message will appear.
  • Page 83 • If the preset quantity of parts has been processed, the End Of Job message will appear. • If the doors are open, the Doors Open message will appear and the TM-403 will make a chirping sound. • The current software version is displayed in the center of the bottom of the screen.
  • Page 84 3-42 TM-403 User’s Guide Run Tab D292106.6b.fm...
  • Page 85 Chapter 4: Machine Setup Contents Quick Start: Setup ......... . .4-2 Power Up the System .

  • Page 86: Quick Start: Setup

    TM-403 User’s Guide Quick Start: Setup The following is an outline of the basic steps required to setup the TM-403 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-403.

  • Page 87: Power Up The System

    Press the blue Reset Button on the left side of the machine. There will be a brief popping sound as the Air Dump Valve releases air to the machine. As the TM-403 powers up the PLC, Servo Drivers and HMI Monitor will boot up. On top of the machine, the Tower Light will flash red indicating the machine is on but not running.

  • Page 88: Home Motors

    TM-403 User’s Guide Home Motors Step 2: Note: The TM-403 needs to be homed once after each power up or Emergency Home Stop activation. The HMI will prompt the operator to home the motors whenever it Motors is required. Once the motors have been homed, they remain homed until the machine is powered down or the E-Stop is activated.

  • Page 89: Load The Tray Feeder

    Chapter 4: Setup 4- 5 Load the Tray Feeder Step 3: Load the Tray Feeder To prepare the Tray Feeder for operation, load it with trays. On the HMI, select Tray from the tab menu on the left to open the Tray Setup Tab. Press the Eject Tray button to bring the Tray Module to the front of the machine so it is easily accessible.
  • Page 90 TM-403 User’s Guide A. Turn the side Tray Clamps and center Tray Clamp 90 degrees to allow the trays to be placed in the feeder. B. Pull the Spring Loaded Tray Clamps back to slide the trays into position. Ensure the tray...

  • Page 91: Nozzle Installation

    Chapter 4: Setup 4- 7 Nozzle Installation Step 4: Nozzle Installation The TM-403’s is shipped with the following nozzles and nozzle tips: SELECT Convum Quad NOZZLE • (1) Quad Nozzle Shank (Part # 267090) • (1) Small Precision Tool (SPT) Nozzle Shank (Part # 267091) •...

  • Page 92: Installing Nozzle & Nozzle Tip

    TM-403 User’s Guide Installing Nozzle & Nozzle Tip Step 4: Nozzle Move the Pick & Place Head to the Place position Installation so it is easily accessible from the front. . INSTALL NOZZLE Remove the air line from the Nozzle Shank, sup- porting the Nozzle with one hand while gently pull- ing the tube off the Nozzle Barb.

  • Page 93: Taper Setup

    Chapter 4: Setup 4- 9 Taper Setup Step 5: Setup Taper Loading Tape The Taper must be loaded with carrier and cover tapes and configured for operation. Begin by preparing the Taper, then move to the HMI to adjust settings. (Step 7) Load Carrier Tape Step 5: Setup...
  • Page 94 4-10 TM-403 User’s Guide Step 5: Mount the bulk carrier tape reel on the spindle, ensuring that there is sufficient tape Setup for the batch to be run. Taper CARRIER The carrier tape should roll off to the left, unwinding from the top so it will feed right side up into the carrier tape channel underneath the Pick Head Enclosure.

  • Page 95: Load Cover Tape

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

  • Page 96: Load Take-Up Reel

    Mechanical Hazard! Avoid placing fingers between the carrier tape and the Take-up Reel when the TM-403 is in operation. Pinching or entrapment may occur if safety precautions are not observed. Taper Setup...

  • Page 97: Configure Hmi Settings

    4- 13 Configure HMI Settings Step 6: Setup The TM-403’s Job Wizard leads the user through the HMI setup process. OPEN JOB WIZARD a. Open the HMI Job Screen. b. Press the Job Wizard button to open the Job Wizard.
  • Page 98 4-14 TM-403 User’s Guide b. Press the right Arrow key to open the next Job Wizard screen. ENTER JOB PARAMETERS. Arrow Buttons a. Enter Job Quantity b. Enter Job Description. Press the right Arrow key to open the next Job Wizard screen.
  • Page 99 Settings. Allow the heat sealer to reach operating temperature before continuing. Note: The TM-403 accommodates a wide range of carrier tapes and cover tapes. Set- tings may vary from one tape product to another. The recommended starting point is 90° C. The maximum recommended operat- ing temperature is 160°...
  • Page 100 (leader) and the end (trailer) of the finished reel of placed parts. Therefore, when the reel is being taped on the TM-403, 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 101 Chapter 4: Setup 4- 17 Step 6: ENABLE LEADER. Setup HMI TAPER a. Select Leader State and enter Leader Length in millimeters if enabled. b. Press the right Arrow key to move to the next screen. D292106.7b.fm Configure HMI Settings...
  • Page 102 4-18 TM-403 User’s Guide Step 6: Tray Feeder SETUP The next three Job Wizard screens are used to detect Tray Setup HMI Pitch. TRAY FEEDER a. Enter the number of tray rows and tray columns in the tray that will be processed.
  • Page 103 Chapter 4: Setup 4- 19 Step 6: c. Center the Pick Head over the Pocket 1 using the HMI Jog Setup HMI buttons or the Jog buttons on top of the Sealer enclosure. To see TRAY an illustration of the correct head placement, push the Help icon. FEEDER An illustration of a tray with Pocket 1 and Pocket 2 identified will appear.
  • Page 104 Head in an accessible position so the pick height can be adjusted. a. Use the Index arrow keys to move the Nozzle to the last column of Tray 2. b. Open the TM-403 enclosure doors to access the pick head. Configure HMI Settings...
  • Page 105 Chapter 4: Setup 4- 21 c. Press Rotate to turn the nozzle so the set screw is accessible. d. Use a 2.5mm hex wrench to hold the Actuator Adjustment Screw in place from the bottom, while loosening the Jam Nut on top of the Actuator Adjustment Screw with an 8mm open ended wrench.
  • Page 106 4-22 TM-403 User’s Guide Nozzle Setup: Manual Rotation a. Place a part in the Pocket 1 position. Press Pick Part to activate the Pick Head and pick a part from the pick location. b. If the part needs to be rotated before it is placed in tape, press Rotate Part.
  • Page 107 Chapter 4: Setup 4- 23 a. Use the Arrow keys to position the Pick Head and Carrier Tape so the Nozzle is centered over the carrier tape placement position. The Up/Down Arrow keys move the Pick Head forward and backward. The Left/Right Arrow keys move the tape left and right in the Taper Track.
  • Page 108 4-24 TM-403 User’s Guide Step 6: a. To manually set the Place Actuator to Setup HMI the correct nozzle height, press Place NOZZLE Extend b. Use a 2.5mm hex wrench to hold the Actuator Adjustment Screw in place from the bottom, while loosening the...
  • Page 109 Chapter 4: Setup 4- 25 Step 6: • If rotation is set at 0, Setup HMI the part will be placed Rotation Options NOZZLE in the same orientation as it was picked. • If rotation is set at -90, the part will be rotated 90 degrees clockwise prior to placement.
  • Page 110 4-26 TM-403 User’s Guide Step 6: Vision Settings Setup HMI VISION a. Set Camera State to Enabled or Disabled. b. If camera is enabled, enter number of Parts Until Inspection (do not include part at Pick point.). Press the right Arrow Key to move to the final Job Wizard...
  • Page 111 Chapter 4: Setup 4- 27 Note: The Save function will overwrite the information stored for the currently selected job. Therefore, it is important to select the desired job prior to pressing the Save button. b. Press the Save button to save job settings to the selected job name, then press Finish to close the Job Wizard and return to the main Job Tab.

  • Page 112: Test Seal

    4-28 TM-403 User’s Guide Test Seal Step 7: Seal Test Perform a Seal Test to ensure a good seal. Adjust Sealer settings in the HMI Taper tab as necessary. Run the tape through the taping module by pressing the Continuous Advance button in the HMI Taper Tab.
  • Page 113 Position Locks to secure them. Perform a Seal Test. The V-TEK PT-55 Peel Force Tester is pictured above. (Sold separately.) Proceed to Chapter 5: Vision Setup to configure the Vision System for operation. If processing from tray to tray, see the next section of this chapter.

  • Page 114: Tray-To-Tray Output Option

    TM-403 User’s Guide Tray-to-Tray Output Option If desired, the TM-403 can combine two partially filled trays by picking from Tray 1 and placing to Tray 2. Follow the procedure below to configure Tray-to-Tray placement. Note: The intended use for the Tray-to-Tray function is to pick from Tray 1, which is the tray located closest to the front of the machine, and place to Tray 2.
  • Page 115 Chapter 4: Setup 4- 31 Pull the Spring Loaded Tray Clamps back to slide the trays into position. Ensure the trays are placed so that the front lip of the trays is under the Stationary Tray Clamps and the side of the tray is pressed against the center datums.
  • Page 116 4-32 TM-403 User’s Guide Note: Rows run perpendicular to the front of the machine. Columns run parallel to the front of the machine. The number of rows will always be greater than the num- ber of columns in a tray.

  • Page 117: Chapter 5: Vision Setup

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

  • Page 118: Quick Start: Vision Setup

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

  • Page 119: Connect Vision

    Step 1: Vision Setup Note: The TM-403 vision system can be run with a computer or a Keyence IV-G CONNECT Monitor. These options are not included with the TM-403. They can be purchased separately from V-TEK, Inc. or the user may provide their own computer.
  • Page 120 Keyence IV-G Monitor. If using one of these options, skip this step and proceed to Configure Inspection. On the TM-403 HMI, select the Taper Tab, then press the Right Arrow key to advance to the second Taper screen.

  • Page 121: Connect Computer

    Chapter 5: Setup 5- 5 Connect Computer Step 1: Vision Follow the steps below to connect the Keyence IV-G Camera to the vision computer. Setup (Proceed to the next section if using the Keyence Monitor instead of a computer.) CONNECT LAPTOP Open the Control Panel, then select Network and Sharing Center.
  • Page 122 TM-403 User’s Guide Step 1: Double click Internet Protocol version4 (TCP/IPv4) Vision Setup CONNECT LAPTOP Ensure Obtain an IP address automatically is selected. Click OK. Connect Vision D292106.16c.fm...
  • Page 123 Chapter 5: Setup 5- 7 Step 1: To select a stored inspection or configure a new inspection, open the Keyence Inspection System software by double-clicking on Vision the IV Navigator icon on the desktop. Setup CONNECT LAPTOP Select Direct Connection. The following pop-up will appear.
  • Page 124 TM-403 User’s Guide Step 1: A Connecting to Sensor status window will open. Vision Setup CONNECT LAPTOP Once the connection is complete, the Run/Program window will open. Connect Vision D292106.16c.fm...

  • Page 125: Connect Keyence Monitor

    Connect the Monitor's power cable to the power connection on the back of the TM- 403 (B). Turn the TM-403 ON. The Keyence Monitor will automatically start and open the Keyence software program. Select Direct Connection, then press Connect to establish a connection between the Keyence Monitor and the Keyence Camera.

  • Page 126: Configure Inspection

    America. In order to use the Keyence IV Vision System, the camera must be configured and set to Run Mode in the Keyence HMI as well as being enabled on the TM-403 HMI. Please complete the following instructions to cor- rectly configure the vision system.
  • Page 127 Chapter 5: Setup 5- 11 Step 2: Click Trigger ON, then center a part under the camera. Vision Setup CONFIGURE COMPUTER Select or create a program from the Program drop-down menu. A yellow Selection Box will appear over the part image. Click NAVI Sensor Setup.
  • Page 128 5-12 TM-403 User’s Guide Step 2: The Image Optimization window will open. Vision Setup CONFIGURE COMPUTER Select the Trigger Options button on the right. Configure Inspection D292106.16c.fm...
  • Page 129 Chapter 5: Setup 5- 13 Step 2: Adjust Trigger Options to External Trigger with a 0ms Trigger Delay. Vision Setup CONFIGURE COMPUTER Select the Brightness Adjustment button on the right Set the Imaging Mode to High Gain, then click the Automatic Brightness Adjustment button.
  • Page 130 5-14 TM-403 User’s Guide Step 2: Vision Setup CONFIGURE COMPUTER Select the Focus Adjustment button on the right. Click the Automatic Focus Adjustment button. One or more yellow dots may appear above the Undo button, representing the best focus point(s). Click on the yellow dot(s) to jump to the associated focus point and select the best one.
  • Page 131 Chapter 5: Setup 5- 15 Step 2: Vision Setup CONFIGURE COMPUTER Select the Extended Functions button on the right. Click on the Imaging Area tab (not shown) and adjust the selection box so it captures the minimum area needed to achieve the desired inspection. D292106.16c.fm Configure Inspection...
  • Page 132 5-16 TM-403 User’s Guide Step 2: Vision Setup CONFIGURE COMPUTER Click on the Lighting tab and select ON and Flash. Then click the Next to STEP2 button which is located in the bottom right corner of the window. The Save Master window will open.
  • Page 133 Chapter 5: Setup 5- 17 Step 2: Select Register Live image as master. Vision Setup CONFIGURE COMPUTER Select Register the image. Once the image has been registered, click OK. Then click Next to STEP3. D292106.16c.fm Configure Inspection...
  • Page 134 5-18 TM-403 User’s Guide Step 2: The Tool Settings window will open. Vision Setup CONFIGURE COMPUTER Select Add Tool. Configure Inspection D292106.16c.fm...
  • Page 135 Chapter 5: Setup 5- 19 Step 2: Select the Outline tool, then click OK. Vision Setup CONFIGURE COMPUTER A green outline will now appear around the selected mark. Click OK. D292106.16c.fm Configure Inspection...
  • Page 136 5-20 TM-403 User’s Guide Step 2: The Tool Settings Options will now appear as below. Vision Setup CONFIGURE COMPUTER Configure Inspection D292106.16c.fm...
  • Page 137 Chapter 5: Setup 5- 21 Step 2: Adjust the yellow Selection Box so it surrounds the selected mark. Vision Setup CONFIGURE COMPUTER In the Fine Tune Outline section, click the Remove Outline button. D292106.16c.fm Configure Inspection...
  • Page 138 5-22 TM-403 User’s Guide Step 2: The Eraser Settings window will open. Vision Setup CONFIGURE COMPUTER The Eraser appears as a white square on the image. Adjust eraser size as needed, then click and drag it over any unwanted data that is outlined in green on the image.
  • Page 139 Chapter 5: Setup 5- 23 Step 2: Vision Setup CONFIGURE COMPUTER Click Live Adjustment and the sensor will continuously take measurements. Adjust the threshold to yield the highest difference between good and bad parts, then click OK. D292106.16c.fm Configure Inspection...
  • Page 140 5-24 TM-403 User’s Guide Step 2: The Output Assignment window will open. Set up the Outputs as shown below. Vision Setup CONFIGURE COMPUTER • Set OUT1 to Total Status. • Set OUT2 to Tot.StatusNG. • Set OUT3 to Busy. • Set OUT4 - OUT8 to OFF.
  • Page 141 Chapter 5: Setup 5- 25 Step 2: Click Complete to return to the Run/Program window. Select Run. Vision Setup CONFIGURE COMPUTER Click the Manual Trigger button which is located under the Program button to test the inspection criteria. The test results will appear on the right side of the window. D292106.16c.fm Configure Inspection...
  • Page 142 Vision Setup CONFIGURE COMPUTER On the TM-403 HMI, open the Taper Tab. Press the right Arrow button to advance to the second Taper screen. Press Trigger to manually trigger an inspection of the part under the camera. The green PASS message should appear.
  • Page 143 Next trigger inspections with parts which are incorrectly oriented, badly marked or with an empty pocket to ensure that they generate a red FAIL message. Vision Setup CONFIGURE COMPUTER The TM-403 is now ready for operation. Select the Run Tab to run the job. D292106.16c.fm Configure Inspection...

  • Page 144: Configure Keyence Monitor

    5-28 TM-403 User’s Guide Configure Keyence Monitor Step 2: Vision Setup CONFIGURE Monitor Display: Menu OFF MONITOR Title: Displays the device name, the program number and the program name. Tool name: Displays the tool number and the tool name of the tool selected. The selected tool can be switched.
  • Page 145 Chapter 5: Setup 5- 29 Monitor Display: Menu ON Step 2: Vision Setup CONFIGURE MONITOR Title: Displays the device name, the program number and the program name. Tool name: Displays the tool number and the tool name of the tool selected. The selected tool can be switched.
  • Page 146 5-30 TM-403 User’s Guide Step 2: Sensor Image Memory button: Displays the Sensor Image Memory screen. Vision USB memory button: Displays the USB memory screen. Setup Sensor setup button: Stops running mode and displays the Sensor setup menu CONFIGURE MONITOR screen.
  • Page 147 Chapter 5: Setup 5- 31 Setup Image Optimization Step 2: Vision Setup Touch Trigger Options. CONFIGURE MONITOR Select the External Trigger type. Touch OK. D292106.16c.fm Configure Inspection...
  • Page 148 5-32 TM-403 User’s Guide Step 2: Touch Auto Brightness Adjustment. Touch OK. Vision Setup CONFIGURE MONITOR Touch Focus Adjustment. If Auto focusing is selected, the focus position is adjusted automatically. If Manual focusing is selected, the focus indicator will be displayed.
  • Page 149 Chapter 5: Setup 5- 33 Register Master Image Step 2: Vision Setup After setting the image optimization, press Register Live Image as Master. CONFIGURE MONITOR Image the target and touch the Trig button. Check the image displayed on the monitor and touch the Register button. Touch Touch Next to proceed to “STEP3”....
  • Page 150 5-34 TM-403 User’s Guide Setup Outline Detection Tool Step 2: Vision Setup Touch the Add Tool button. CONFIGURE MONITOR Select Outline. Touch Edit Window. Configure Inspection D292106.16c.fm...
  • Page 151 Chapter 5: Setup 5- 35 Step 2: Set the position, size, and the angle of the tool window. The detected outline will be Vision displayed in green. After the setting is completed, touch OK. Setup CONFIGURE MONITOR Touch the Limit Adjustment button. D292106.16c.fm Configure Inspection...
  • Page 152 5-36 TM-403 User’s Guide Step 2: Set the threshold to judge OK and NG. Vision Setup CONFIGURE MONITOR The display will return to the main screen for the Outline tool. Touch OK, then touch Next to proceed to “STEP4”. Setup Area Detection Tool Touch the Add Tool button.
  • Page 153 Chapter 5: Setup 5- 37 Step 2: Touch Edit Window button. Vision Setup CONFIGURE MONITOR Set the position, size, and the angle of the tool window. After the setting is completed, touch OK D292106.16c.fm Configure Inspection...
  • Page 154 5-38 TM-403 User’s Guide Step 2: Touch the Brightness Extraction button. Vision Setup CONFIGURE MONITOR Touch the brightness area to be the reference of judgment for the Area tool, then touch OK. Configure Inspection D292106.16c.fm...
  • Page 155 Chapter 5: Setup 5- 39 Step 2: Touch the Limit Adjustment button. Vision Setup CONFIGURE MONITOR Set the threshold to judge OK and NG, then touch OK. The display will return to the main screen for the Color Area/Area tool. Touch OK, then touch Next to proceed to “STEP4”.
  • Page 156 5-40 TM-403 User’s Guide Setup Position Adjust Detection Tool Step 2: Vision Setup Touch the Add Tool button. CONFIGURE MONITOR Touch the Pos.Adj. button. Touch the Edit Window button. Configure Inspection D292106.16c.fm...
  • Page 157 Chapter 5: Setup 5- 41 Step 2: Set the position, size, and the angle of the tool window. The detected outline will be Vision displayed in green. Touch OK. Setup CONFIGURE MONITOR Touch the Limit Adjustment button. D292106.16c.fm Configure Inspection...
  • Page 158 5-42 TM-403 User’s Guide Step 2: Set the threshold to judge OK and NG. Vision Setup CONFIGURE MONITOR After the setting is completed, touch OK. The display will return to the main screen for Position Adjustment tool. Touch OK again, then touch Next to proceed to “STEP4”.
  • Page 159 Chapter 5: Setup 5- 43 In the Sensor Advanced screen, touch I/O Settings. In the I/O Settings screen, ensure Polarity is set to PNP. Next, touch the Output Settings button. D292106.16c.fm Configure Inspection...
  • Page 160 5-44 TM-403 User’s Guide In the Output Settings screen, touch the Common Output Settings button. In the Common Output Settings screen, adjust settings as follows: • One-Shot ON Time = 100 ms • ON-Delay Time = 0 ms Configure Inspection...
  • Page 161 Chapter 5: Setup 5- 45 Setup Output Touch the output line to assign the output function. Step 2: Vision Setup CONFIGURE MONITOR Set the output functions as follows: • Set OUT1 = Total Status. • Set OUT2 = Tot.StatusNG. • Set OUT3 = Busy. •...
  • Page 162 5-46 TM-403 User’s Guide • Set Trigger Error Output = OFF. After the setting is completed, touch Complete, then touch Yes. Configure Inspection D292106.16c.fm...

  • Page 163: Chapter 6: Operation

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

  • Page 164: Quick Start: Running A Job

    The following is an outline of the basic steps required to run a pre-programmed job. More detailed instructions follow in the next section of this chapter. Caution: Users should always wear protective eye wear when operat- ing or maintaining the TM-403. Power up. • Power up the machine by turning on the Main Power Switch.
  • Page 165 • On the HMI, select the Run Tab then press Run. • Load/unload parts and reels as needed. Caution! V-TEK® Incorporated takes no responsibility for the safety of TM-403 if it is used for any purpose other than the intended purpose as specified in this User’s Guide.

  • Page 166: Preparing To Run A Pre-Programmed Job

    Press the blue Reset button on the left side of the machine. Step 2: Home Motors Home Note: The TM-403 only needs to be homed once after each power up or emer- Motors gency stop. Once the motors have been homed, they remain homed until the machine is powered down.

  • Page 167: Home Motors

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

  • Page 168: Setup The Tray Feeder

    TM-403 User’s Guide Setup the Tray Feeder Step 3: Setup On the HMI, select Tray from the tab menu on the left to open the Tray Setup Tab. Tray Feeder Press the Eject Tray button to bring the Tray Module to the front of the machine so it is easily accessible.
  • Page 169 Chapter 6: Operation 6- 7 A. Turn the side Tray Clamps and center Tray Clamp 90 degrees to allow the trays to be placed in the feeder. B. Pull the Spring Loaded Tray Clamps back to slide the trays into position. Ensure the tray is placed so that the front lip of the trays is under the Stationary Tray Clamps and the side of the tray is pressed against the center...

  • Page 170: Setup The Taper

    TM-403 User’s Guide Setup the Taper Step 4: Setup Load the correct carrier tape and cover Taper tape, adjusting the track width as necessary. Select PSA or Heat seal. Align cover tape with carrier tape. Run a pull test and adjust seal strength as needed.

  • Page 171: Select Job

    Chapter 6: Operation 6- 9 Select Job Step 5: Select When a job is already set up and saved in the machine’s memory, the first step in running the job is to call it up with the Job Select screen. On the HMI, select the Job Tab Browse through the Job Library to locate the desired job by using the up and down Arrow buttons.

  • Page 172: Setup The Pick Head

    6-10 TM-403 User’s Guide Setup the Pick Head Step 6: Setup Ensure the correct Nozzle and Nozzle Tip are installed for the job that will be run.: Pick Head Note: See the Chapter 4: Setup for nozzle change procedures. Open the Head Tab on the HMI.

  • Page 173: Setup Vision

    Setup Vision The TM-403 Vision System will automatically revert to the previous inspection. If the same part is being run, there is no need to retrain the camera. Proceed to Step 8. If a dif- ferent job/inspection is being run, follow the setup instructions in Chapter 4: Setup.

  • Page 174: Run The Job

    2D Inspection. Otherwise no other adjustments are required for a job that has already been defined properly. When the preset number of parts has been run, the TM-403 will automatically stop operation. Cut the sealed tape at the cut point and use a piece of blue Permacel tape to secure the finished reel.

  • Page 175: Chapter 7: Troubleshooting

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

  • Page 176: Emergency Stop

    If emergency stop condition occurs, follow the steps below to resolve the failure. Press the red E-Stop button to place the TM-403 into an Emergency Stop state. The Tower Light will switch to red and all operations will cease and the HMI will power off.
  • Page 177 Chapter 7: Troubleshooting Press the blue Reset button. The Boot Screen will appear on the HMI Monitor and display a loading progress message. This process typically takes about 90 seconds to complete. Once the system has finished booting, the HMI will open to the Job Tab with the Home Required button displayed.
  • Page 178 TM-403 User’s Guide When the homing sequence is completed, the bar will turn from black to green and a Hom- ing Succeeded! message will appear. Once homing is complete, press the Left Arrow button will open the Run Tab. Press the Run button on the HMI Run Tab to resume operation.

  • Page 179: System Alarm Messages

    System Alarm Messages contain a description of the problem and suggestions for resolving the problem. They also include an illustration of the TM-403 with the area of interest indicated by a flashing red outline.
  • Page 180 TM-403 User’s Guide An illustration and description of each System Alarm Message follows. Unable to Pick System Alarm If the nozzle is unable to pick a part from the Tray Feeder, the Unable to Pick system alarm will be activated. When this happens, operation stops, a beep sounds, and a warning appears on the HMI.
  • Page 181 Chapter 7: Troubleshooting Part Lost System Alarm If a part falls off the nozzle and is lost during the Pick process, the Part Lost system alarm will be activated. When this happens, operation stops, a beep sounds, and a warning appears on the HMI.
  • Page 182 TM-403 User’s Guide No Part To Place System Alarm If the user attempts to place a part in tape when there is no part on the Nozzle, the No Part To Place System Alarm will be activated. When this happens, operation stops, a beep sounds, and a warning appears on the HMI.
  • Page 183 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.
  • Page 184 7-10 TM-403 User’s Guide Vision Error System Alarm The 2D Inspection System is mounted on the Taper between the place point and the Sealer. It inspects parts for mark and orienta- tion. It also detects empty pockets If the 2D Inspection System detects an inspection error, the 2D Inspection System Alarm will be activated.
  • Page 185 Chapter 7: Troubleshooting 7-11 Inspection Time-out System Alarm If the 2D Inspection System fails to inspect a part within a preset time period, the Inspection Time-out System Alarm will be activated. Tape advance stops, a beep sounds and a warning appears on the HMI.
  • Page 186 7-12 TM-403 User’s Guide Temperature Out of Range System Alarm When Heat Seal is enabled and the Heat Shoe temperatures are either too hot or too cold, a Heat Seal Temperature Out of Range system alarm will activate. When this occurs, tape advance stops, a beep sounds and a warning appears on the HMI.
  • Page 187 Chapter 7: Troubleshooting 7-13 Heat Sealer Inactivity System Alarm If the Taper is inactive for 40 minutes or longer, the Heat Sealer is automatically disabled. Once that occurs, if a user attempts to run a job, or use Continuous Advance, Pocket Advance or Man- ual Seal a Heat Sealer Inactivity system alarm will activate.
  • Page 188 START again to continue with the current level of cover tape. Note: The Low Cover Tape warning will only appear once during a job. If the user ignores the message and continues operation, the TM-403 will continue taping until the job is fin- ished or the cover tape is empty.
  • Page 189 Chapter 7: Troubleshooting 7-15 Job Quantity Inadequate System Alarm If during the course of a job, the operator changes the job quantity to less than the amount of parts that have already been processed a Job Quantity Inadequate message will appear on the HMI.
  • Page 190 7-16 TM-403 User’s Guide Job Completed System Alarm If the operator completes a job and then attempts to run the same job again without resetting the job, a Job Completed System Alarm will appear on the HMI. The operator can resolve the alarm by resetting the job. Push Continue to clear the alarm mes- sage and resume processing.
  • Page 191 To resolve the error condition in this instance, enter an acceptable value into the field. If this message persists, it indicates that the Ethernet connection to the PLC may have been lost. Contact V-TEK Service for support. D292106.9b.fm System Alarm Messages...

  • Page 192: Error Message Table

    7-18 TM-403 User’s Guide Error Message Table Error Condition Solution “The system was unable to suc- Nozzle is not picking parts from the Tray Feeder. Check cessfully pick from the feeder.” the following: - Feeder is empty. - Tray Feeder is jammed.
  • Page 193 - If an unacceptable value has been entered into a setup tion...” field, change the value to one that fits that field’s parame- ters. - If this message persists, the Ethernet connection to the PLC may have been lost. Contact V-TEK Service for sup- port. D292106.9b.fm System Alarm Messages...

  • Page 194: Adjusting Nozzle Vacuum Sensors

    If the TM-403 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 195: Tips On Part Placement

    Chapter 7: Troubleshooting 7-21 Tips on Part Placement If components are not dropped properly, there are four variables that can be adjusted to correct the problem. Note: Each part is different and may require a different combination of adjustments to obtain proper place performance.
  • Page 196 7-22 TM-403 User’s Guide Press the Right Arrow to move to the next Head Tab.. Jog the head up or down until the nozzle is centered correctly over the place location. When the nozzle is positioned correctly, press the Set Place Position button.
  • Page 197 If Nozzle Blow Off is set too high, the excess air may cause the part to bounce back out of the pocket. Adjust the Nozzle Blow Off value until the TM-403 consistently and accurately places parts in the carrier tape.

  • Page 198: Sensor Adjustments

    7-24 TM-403 User’s Guide Sensor Adjustments Adjusting the Low Cover Sensor The Low Cover Sensor alerts the operator at the begin- ning of a job if there is not enough cover tape loaded on the Cover Tape Reel to complete the job.

  • Page 199: Adjusting Heat Seal Quality

    Note: Generally it is best practice to adjust the temperature to achieve the desired peel force. The TM-403 accommodates a wide range of carrier tapes and cover tapes. Settings may vary from one tape product to another. The suggested starting point is 90 degrees Cel- sius.

  • Page 200: Seal Pressure

    7-26 TM-403 User’s Guide Seal Pressure This control is located on the front of the Taper. It controls the amount of force applied when the sealer shoes drop. Turning the Seal Pressure Control clockwise will increase the pres- sure, while turning it counter-clockwise will decrease the pres- sure.

  • Page 201: Adjusting Psa Seal Quality

    Chapter 7: Troubleshooting 7-27 Adjusting PSA Seal Quality If a Peel Force Test determines the PSA Sealer is not generating a satisfactory seal, try one of the adjustments below to improve seal strength. Check Sealer Settings Open the HMI Taper Tab. Review the settings on the four Taper Tab screens to ensure Tape Settings and Sealer Settings are appropriate for the current job.
  • Page 202 7-28 TM-403 User’s Guide On the top of each sealer block, there are three holes with a screw in the center hole. With carrier and cover tape loaded, spin the Sealer Wheel. While spinning the Sealer Wheel, turn the screw...

  • Page 203: Chapter 8: Maintenance

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

  • Page 204: Safe Maintenance Steps

    TM-403 User’s Guide Safe Maintenance Steps Caution! It is dangerous to service or maintain the TM-403 while it is con- nected to air and power supplies. Before performing any maintenance tasks, ensure the machine is stationary and disconnect the electrical and pneumatic power supplies placing the unplugged cables in clear view.

  • Page 205: Maintenance

    Chapter 8: Maintenance 8- 3 Maintenance Only maintenance personnel that have thoroughly read and understand the TM-403 User’s Guide and have several years experience operating and maintaining similar machines should be permitted to maintain the TM-403. Routine Maintenance Schedule The TM-403’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 206: Lubrication

    Lubrication No lubrication is required or desired on the TM-403 as all parts are no maintenance in this regard and the use of lubricants could interfere with components.

  • Page 207: Pick Head Maintenance

    Chapter 8: Maintenance 8- 5 Pick Head Maintenance Nozzle Tip Inspect the nozzle tip daily for excessive wear or damage. Remove and replace as necessary. See Chapter 4: Machine Setup for instructions on changing the nozzle tip. Vacuum Levels Check Vacuum levels weekly. This recorded information on high/ low vacuum levels is useful on a week to week basis and can indi- cate pneumatic problems such as loose fittings or seal problems.
  • Page 208 TM-403 User’s Guide Remove the air line from the Nozzle Shank. Use a needle-nose pliers to remove the air line from the Upper Filter Fitting which is located at the top of the Vacuum Filter. Use a 2.5mm Hex wrench to remove the retaining screw that holds the Filter in place.

  • Page 209: Check Actuator Belt Tension

    Deflect the Belt 1/4" (6 mm) in either direction. The force gauge should read between 12 and 16 lbs. [53 - 62 N]. Deflect 1/4” Note: Contact V-TEK Service for tensioning procedure if belt tension is outside tolerance. D292106.10a.fm General Maintenance Tasks...

  • Page 210: Taper Maintenance

    TM-403 User’s Guide Taper Maintenance Heat Sealer Heat sealer maintenance consists mainly of cleaning built-up debris and adhesive residues from the heat shoes. It should be cleaned after every 120 hours of operation or as needed. To clean the heat shoes, follow the steps below.
  • Page 211 Chapter 8: Maintenance 8- 9 Clean the residues from the heat shoes by using a plastic or brass brush soaked in alco- Heat Shoe hol to remove any residue that has built up on the lip of the heat shoe. Note: Do not use a steel bristled brush.

  • Page 212: Loading Track

    8-10 TM-403 User’s Guide Loading Track The Loading Track should be cleared of dust and debris after every 40 hours of operation. Strip the machine, remove the cover tape guide, and brush the dust and debris from the track with a small, stiff bristled paint brush. Excessive build-up of dirt and debris can cause carrier tape jams.

  • Page 213: Cover Tape Guide

    Chapter 8: Maintenance 8- 11 Wipe the entire assembly using a cloth soaked in alcohol. Using a cotton swab soaked in alcohol, clean between the sealer wheels. Also, clean the entire surface of the black polyurethane wheel. Note: Do not use solvents other than alcohol when cleaning the black polyurethane wheels.
  • Page 214 8-12 TM-403 User’s Guide General Maintenance Tasks D292106.10a.fm...

  • Page 215: Appendix A: Sensors

    Appendix A: Sensors Contents Keyence FS-N11CVP/FS-N12CP Sensor Amplifiers ....A-2 SMC ZSE30 Vacuum Sensor........A-4...
  • Page 216 Keyence FS-N11CP & FSN12CP Sensor Amplifiers The Keyence FS-N11CPand FS-N12CP sensor amplifiers (shown in Figure A.1 below) are used on the TM-403 for the Low Cover Tape Sensor and the Tape Jam Sensor. Both amplifiers are mounted on the Cover Tape Arm. The Low Cover Tape amplifier (FS-N11CP) is located on the left.
  • Page 217 Appendix A: Sensors Locking the Keys It is sometimes desirable to lock the keys of the sensor amplifiers so that the currents settings are not inadvertently changed. Hold down the Manual button and the Mode button simultaneously for at least three sec- onds.

  • Page 218: Smc Zse30 Vacuum Sensor

    Appendix A: Sensors SMC ZSE30 Vacuum Sensor The SMC ZSE30 Vacuum Sensor functions as a Pick & Place Head part present sensor. It com- pares the vacuum pressure at the pick and place nozzle to a threshold point. When the vacuum pressure drops beneath this level the sensor sends an OFF signal to the machine (the LCD display will be green).
  • Page 219 Appendix A: Sensors one is present, set the threshold closer to the pressure reading when no part is on the nozzle. In this way, the optimum setting for each specific part can be reached. Initial Factory Settings If for some reason the sensor needs to be re-initialized to the default factory settings, follow the steps below: Press and hold the Set button for at least two seconds.
  • Page 221 TM-403 Suggested Spare Parts List Part Number Description 102534 Reset Switch Contact 102597 Digital Pressure Switch 105786 Take-up Motor 200401 Sealer Air Regulator 200636 Solenoid Air Valve 201026 Pick & Place Vacuum Air Filter 201207 Convum Vacuum Cup 209250 Pick & Place Spring...
  • Page 222 Spare Parts List TM-401 User’s Guide Caution! Only genuine spares should be used on the TM-403. Failure to use genuine spare parts could render the machine unsafe and void factory warranty. D292106.12a.fm...

  • Page 223: Tm-403 Exploded Views

    TM-403 Exploded Views Document List TM-403 Final Assembly Pages 1 - 7 292381.slddrw Electrical Panel Pages 1 - 5 291685.slddrw Base Pages 1 - 7 291681.slddrw Pick & Place Assembly Pages 1 - 10 291822.slddrw Pick & Place Head Pages 1 - 2 292752.slddrw...
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  • Page 303 751 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 304 TM-403 Document List Section Pages File Name Cover Sheet Pages 1 - 2 D292106.1g.fm EC Declaration of Conformity Page 1 of 1 TM-400 DOC.pdf Introduction Pages i - xii D292106.2a.fm Table of Contents Pages 1 - 4 D292106.3c.fm Chapter 1: Installation & Assembly Pages 1-1 to 1-12 D292106.4b.fm...
  • Page 305 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 306 751 Summit Avenue Mankato, MN 56001 (507) 387-2039 FAX: (507) 387-2257 www.vtekusa.com Email: info@vtekusa.com...

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