model 5000 manual

8/6/2019 Model 5000 Manual

1/296

Gravity-Feed Model 5000

User Manual

Version 3.3June 8, 2010

Exatron, Inc.2842 Aiello Drive

San Jose, California 95111(408) 629-7600 Tel(800) exa-tron Tel

(408) 629-2832 Faxwww.exatron.com


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Copyright NoticeCopyright 2010 Exatron

This document contains proprietary information which is protected by copyright.All rights are reserved.

EXATRON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THISMATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

The information contained in this document is subject to change without notice.


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06/2010 Copyright Exatron, 2010 Contents-1

Table of Contents

List of Figures

Chapter 1: Safety and SupportChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Exatron Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Electrical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Laser Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Lock-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Facilities Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Air/Vacuum Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

DUT (Device Under Test) Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Customer In-House Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Offshore Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Exatron Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Warranty and Support Contracts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Service Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Preventive Maintenance Contract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Customer Service Support Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

End-of-Life Handler Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Significance of This Manuals Version Number . . . . . . . . . . . . . . . . . . . . . . 1-23Typographical Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . 1-24

Terms Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Chapter 2: System DescriptionChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Overview of Model 5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Key Movements and Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Key Positions for Handler with Quad Test Site. . . . . . . . . . . . . . . . . . . . . 2-7

Model 5000 Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Devices and Packages Accommodated . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Taper Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

-- continued on next page --


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Contents-2 Copyright Exatron, 2010 06/2010

Chapter 2: System Description continuedMechanical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Tilt Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Safety Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Motors and Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Output Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Changeover Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Electronic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

EMO (Emergency Stop) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Power Supplies and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Pickup Head Motor Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28Index and Stack Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30Test Site Stop Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32Photo Display of Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32Laser Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35Shuttle Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Output Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38Tray Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Octoloader/Input Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41Test Site/Track Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42Laser Mark Site/Track Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43Shuttle Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44Tube Present Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45Tube Full Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Connectors and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Pneumatic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Air Blast Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49


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Chapter 3: Handler Setup and RAM ListingChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Changing Device Sizes or Package Types . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

What the Changeover Kit Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Identification of Ports, Solenoids, and Test Site Sensors . . . . . . . . . . . . . 3-4

Installing the Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Resetting Software Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Aligning the Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Testing Alignment of the Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Loading Tubes into the Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Securing Output Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Curved Aluminum Output Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Straight Plastic Output Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Output Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Power-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Introduction to the Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34Messages from the Laser Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Laser Safety Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Introduction to the Laser Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Edit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Work Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Aligning the Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Setting Temperatures for the Hot Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Understanding the Control Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Changing Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47Selecting Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Selecting Device Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Selecting Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Selecting Manual Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Selecting Stops at Each Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Selecting Number of Input Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Setting Pickup Head Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Selecting Laser Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Selecting Number of Devices per Output Tube . . . . . . . . . . . . . . . . . . . 3-54

Selecting Number of Devices to Be Tested Simultaneously. . . . . . . . . . 3-54

Selecting Tray or Tube Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55Manual Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Resetting Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Beginning a Production Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Homing the Octoloader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Displaying Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59



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Chapter 3: Handler Setup and RAM Listing continuedChanging RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

RAM Address Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Updating Your EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

Setting Sorts in RAM Addresses C0 to C7 . . . . . . . . . . . . . . . . . . . . . . . . . 3-77ExamplePassed Devices to Four Tubes . . . . . . . . . . . . . . . . . . . 3-78ExamplePassed Devices to Taper . . . . . . . . . . . . . . . . . . . . . . . . 3-78

Setting Bin Displays in RAM Addresses B8 to BF. . . . . . . . . . . . . . . . . . . . 3-79

Decimal-Hex-ASCII Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

Chapter 4: Diagnostics and TroubleshootingChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Accessing DIAGNOSTICS Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Diagnostics Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

SENSOR CHECK: Test Site Sensors 0-7 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12SENSOR CHECK: Test Site Sensors 8-Ffor Laser . . . . . . . . . . . . . . . . . 4-13

SENSOR CHECK: Test Site Sensors 8-Ffor Quad Tester . . . . . . . . . . . 4-14

SENSOR CHECK: Shuttle Position Sensors 1-8 . . . . . . . . . . . . . . . . . . . . 4-15

Example of Shuttle Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

SENSOR CHECK: Tube Full Sensors 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Example of Tube Full Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

SENSOR CHECK: Tube Present Sensors 1-8 . . . . . . . . . . . . . . . . . . . . . . 4-20

Example of Tube Present Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

OUTPUT CHECK: Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

OUTPUT CHECK: Solenoid Toggle Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-24OUTPUT CHECK: Light Pole Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

OUTPUT CHECK: CPU Port Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

INTERFACE CHECK: RS-232 Port Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

INTERFACE CHECK: RS-232 Port #2 Checkfor Pickup Heads . . . . . . . 4-28

INTERFACE CHECK: Handler Port Output Check . . . . . . . . . . . . . . . . . . . 4-31

INTERFACE CHECK: Handler Port Input Check . . . . . . . . . . . . . . . . . . . . 4-32

ALL MOTOR CHECK: Shuttle Motor Check . . . . . . . . . . . . . . . . . . . . . . . . 4-33

ALL MOTOR CHECK: Pickup Head Motor Check . . . . . . . . . . . . . . . . . . . 4-34

ALL MOTOR CHECK: Octoloader Motor Check . . . . . . . . . . . . . . . . . . . . . 4-36

OCTO/INDEX CHECK: Shuttle Solenoid Check . . . . . . . . . . . . . . . . . . . . . 4-37

OCTO/INDEX CHECK: Input Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . 4-38

Example of Octoloader Home and Input Sensors . . . . . . . . . . . . . . . . . 4-39

LASER CHECK: Laser Firing Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

LASER CHECK: Laser Input Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41



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Chapter 4: Diagnostics and Troubleshooting continuedLASER CHECK: Laser Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

SERVO TEACH MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Cycling the Handler in Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Cycling the Handler in Loop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Chapter 5: Dictionary of Displayed MessagesChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

#### OLDNEW #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

00## DATA ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

- PILOT /. FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

1 LEFT STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

1 RIGHT STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

2 LASER DUT ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

2 LEFT STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

2 RIGHT STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8ALIGN MOTORS ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

ALL MODES OFF ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

ALL MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

ALL MOTORS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

ALL OUTPUTS FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

BAD RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

BAD TEST RESULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

BIN # S# C#### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

BIN 5 S0 FLUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

CHANGE RAM ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

CHANGE RAM ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10CHECK BEAM TUBE? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

CHECK CONTACTS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

CHECK SUM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

CHECKING LASER ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

CHK OUTPUT DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

CHK SMOKE TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

CHK VAC ADJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

COUNTS RESET 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

CPU ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

DISPLAY TOTALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12DOUBLE PART ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

DUT IN LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

DUT/SHUT LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

EMPTY ALL TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

EMPTY FLUSH TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14



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Chapter 5: Dictionary of Displayed Messages continuedEMPTY/LOAD PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

END LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

END TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

EXATRON SUPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

FAIL CHECK ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15FAIL LOAD ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

FAIL PROGRAM ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

FAIL VERIFY ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

FIRE LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

FLUSH ALL ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

FLUSH TEST SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

FULL 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

FULL TUBE= #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

HALT!! RESTART ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

HANDLER OUT CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

HANDLER PAUSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16HOME OUTPUT? NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

HOME OUTPUT? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

INDEX EMPTY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

INPUT 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

INSERTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

INTERFACE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

INTO LASER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

INTO SHUT(TLE) JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

INTO STAGE JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

INTO T SITE JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

IS LV PC READY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18IS THE AIR ON ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

ISSUE NEW START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

JOG DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

JOG LEFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

JOG RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

JOG UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

LASER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

LASER GATE ERR?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

LASER GATE OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

LASER MARK ? / LASER MARK ? NO / YES . . . . . . . . . . . . . . . . . . . . 5-19

LASER OUT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20LASER SIMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

LASER SITE JAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

LIGHT POLE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

LOAD DEFAULT NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

LOAD DEFAULT YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21



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Chapter 5: Dictionary of Displayed Messages continuedLOAD DEVICE ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

LOAD EMPTY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

LOAD EPROM>RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

LOAD REMOTE RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

LOADER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21LOADING MASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

LOOP MODE ON ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

LV SET UP ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

MANUAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

MARK & CYCLE ON?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

MARK SITE EMPTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

MEMORY ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

MOD SET UP ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

MOD SET UP ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

MODEL 5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

MOTOR BUSY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23MOTOR ERROR ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

MOTOR OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

MOVE MOTOR DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

MOVE MOTOR UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

MULTI SORT ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

NO OUTPUT TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

NO RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

NO SORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

NO TUBES OR FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

OCTO MOTOR CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

OCTO/INDEX CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26OCTOLOADER OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

O.K. TO RUN ? # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

OUTPUT CLEAR ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

OUTPUT GO LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

OUTPUT GO RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

OUTPUT TO BIN 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

OUTPUT TUBE JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

PART IN SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

PART IN T SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

PASS PROG/PASS VERIFY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

PASSWORD ABC? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27PICK CHANGE KIT? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

PICK INTERFACE? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

PICK PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

PICK UP = ##### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

PLUNGE = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28



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Chapter 5: Dictionary of Displayed Messages continuedPROGRAM DEVICE? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

PROGRAM RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

RAM AUTO RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

READY TO MARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29READY TO RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

RESET TOTALS NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

RESET TOTALS YES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

RS-232 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

RUN 1-2-3-4 PART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

SEN0-7 01234567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

SEN8-F 89ABCDEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

SERVO IS AT ZERO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

SERVO MOVING ? 1 / 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

SET # INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31SET P/V/L MODE? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

SHUT 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

SHUTTLE EMPTY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

SHUTTLE IS LOST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

SHUTTLE OUT JAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

SOAK = #.# SECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

SOAK DELAY ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

SOLENOID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

SORT INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

SORT MOTOR CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

SORT RESET ERR? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32START 1 TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

START 2 TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

START LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

STOP MODE ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

STOP MODE ON ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

STOP ON FAIL ? / STOP ON FAIL NO / YES . . . . . . . . . . . . . . . . . . . . 5-34

STOP ON FAIL YES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

SUM CHECK = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

SUM CHECK ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

T0[1-8] #### ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

T SITE NOT FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36T SITE OUT JAM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

T SITE OUT JAM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

T SITE OVERFILL? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

TEST ABORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

TEST SITE EMPTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37



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Chapter 5: Dictionary of Displayed Messages continuedTHANK YOU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

TO EXIT = ##### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

TO SITE = ##### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

TOP OF TUBE JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

TOTALS SET TO 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38TRANSFER ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

TRAY/TUBE OUT ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

TUBE 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

TUBE CLEAR WORKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

TURN ON REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

UART OUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

VERIFY DEVICE ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

VERIFYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

WAITING FOR PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

WAITING FOR R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Z MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40Z MOTOR CRASH ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Z MOTOR IS UP / Z MOTOR NOT UP. . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

ZERO COUNT ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Chapter 6: Servicing and TroubleshootingChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Cleaning the Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Checking Motor Serial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Air Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Checking Incoming Air from the House Supply . . . . . . . . . . . . . . . . . . . . 6-3Checking the Moisture/Dirt Trap in the Air Regulator . . . . . . . . . . . . . . . . 6-3

Checking the Air Regulator Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Adjusting Air Pressure on the Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Adjusting Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Solenoid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Fiberoptic Photoelectric Sensor Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 6-11


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Chapter 7: Parts ListChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Guide to the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Exatron (Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Part Quantity Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

List of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Chapter 8: Prints

Chapter 9: Test InterfacesOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

General Interface Options and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Accessing a Handler Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

General Interface RAM Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3INTERFACE TYPE: ADDRESS 00B7 . . . . . . . . . . . . . . . . . . . . . . . . 9-3TEST SOL DELAY: ADDRESS 0096 . . . . . . . . . . . . . . . . . . . . . . . . 9-3STOP ON FAIL Y/N: ADDRESS 00A5 . . . . . . . . . . . . . . . . . . . . . . . 9-3DOUBLE TEST SORT: ADDRESS 00AC . . . . . . . . . . . . . . . . . . . . . 9-3TESTER SORT SET UP: ADDRESSES 00AF TO 00B6. . . . . . . . . . 9-4

Handler Port Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

TTL Handler Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Handler Port Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8EOT (END OF TEST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8START PULSE WIDTH: ADDRESS 0098 . . . . . . . . . . . . . . . . . . . . . 9-9CHECK SORT RESET: ADDRESS 00A2 . . . . . . . . . . . . . . . . . . . . . 9-9

EXATRON RS-232 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

RS-232 Port Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10BAUD RATE: ADDRESS 009B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11DATA FORMAT: ADDRESS 009C . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

EXATRON RS-232 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Handler/Tester Test Cycle Handshake Summary . . . . . . . . . . . . . . . . . 9-12

Explanation of Test Cycle Handshake . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12DOUBLE TEST ASCII OUT: ADDRESS 00A7 . . . . . . . . . . . . . . . . 9-14

Index


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06/2010 Copyright Exatron, 2010 Figures-1

List of FiguresFigure 1-1: Pause Button on Control Panel (Left); Emergency Stop Button (Right) . . . . . . . . . . 1-2

Figure 1-2: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF

Position with Lock (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Figure 1-3: Air Line Attached to Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Figure 2-1: Model 5000 OverviewWith Octoloader Motor and Shuttle Motor Only . . . . . . . 2-3

Figure 2-2: Model 5000 OverviewWith Pickup Head and Third Motor. . . . . . . . . . . . . . . . . . 2-4

Figure 2-3: Flow of Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 2-4: Key Device Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 2-5: Key Positions for Handler with Quad Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-6: Tilt MechanismLeft Side (Left); Right Side (Right) . . . . . . . . . . . . . . . . . . . . . . 2-10

Figure 2-7: Safety Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Figure 2-8: Motor with Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Figure 2-9: Drive Chain Tension Adjuster for Octoloader (Left), for Shuttle (Right) . . . . . . . . 2-12Figure 2-10: Octoloader at Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Figure 2-11: Octoloader Back with Snap-On Pins (Left); Octo Car Block with Holes for

Snap-On Pins (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Figure 2-12: Octoloader Front with Two Tubes Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Figure 2-13: Octoloader Gate Depressed by Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Figure 2-14: Devices Stopped by Octoloader Gate (Left); Devices Released by Octoloader

Gate (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Figure 2-15: Octoloader Gate Pin Blocking Exit (Left); Device Exiting Octoloader Chute

(Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Figure 2-16: Octoloader Gate Closed (Left); Octoloader Gate Opened (Right) . . . . . . . . . . . . . 2-17

Figure 2-17: Pickup Head Motor and Lead Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Figure 2-18: Device Attached to Plunger on Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Figure 2-19: Pickup Head (Left); Device at Pickup Site (Right) . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Figure 2-20: Pickup Head at Pickup Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Figure 2-21: Pickup Head at Test Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Figure 2-22: Pickup Head at Drop-off Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Figure 2-23: Output Tray with Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Figure 2-24: Output Gates and Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Figure 2-25: Releasing Devices From Output Tray to Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Figure 2-26: Example Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Figure 2-27: Example Changeover Kit for Hot-Rail Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Figure 2-28: EMO (Emergency Stop) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Figure 2-29: Power Wiring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25


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Figures-2 Copyright Exatron, 2010 06/2010

Figure 2-30: Motor Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Figure 2-31: Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Figure 2-32: Fuses Near Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Figure 2-33: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Figure 2-34: Cable for Sensors 0-7 Above Test Site; Cable for Sensors 8-F Below Test Site . . 2-28

Figure 2-35: Override Buttons and Corresponding Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Figure 2-36: Index/Stack Pin Override Button (Left); Shuttle Pin Override Button (Right) . . . 2-30

Figure 2-37: Index and Stack Pins at Default Position (Left); at Reverse Position (Right) . . . . 2-31

Figure 2-38: Cover Foot Retracted and Stack Pin Extended (Left);

Cover Foot Extended and Stack Pin Retracted (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Figure 2-39: Stack Pin Extended to Restrain Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Figure 2-40: Test Contacts Closed on Device (Left), Opened (Right) . . . . . . . . . . . . . . . . . . . . 2-33

Figure 2-41: Test Contacts on Custom Quad TesterClosed (Left), Opened (Right). . . . . . . . 2-34

Figure 2-42: Air Valve for Test Site Contact Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . 2-34

Figure 2-43: Test Site Stop Pin Extended (Left), Retracted (Right) . . . . . . . . . . . . . . . . . . . . . . 2-35

Figure 2-44: Laser Gate Extended (Default, Left), Retracted (Right). . . . . . . . . . . . . . . . . . . . . 2-36

Figure 2-45: Shuttle Pin Extended to Hold Device (Left), Retracted (Right). . . . . . . . . . . . . . . 2-36

Figure 2-46: Shuttle and Override Button in Closed Position (Left), in Open Position (Right). 2-37

Figure 2-47: Shuttle at Home Position Between Test Track and Fifth Tube . . . . . . . . . . . . . . . 2-37

Figure 2-48: Output DisplaysLED On/Off (Left), Digits (Right) . . . . . . . . . . . . . . . . . . . . . . 2-38

Figure 2-49: PPPP-030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Figure 2-50: PP-PF030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Figure 2-51: Tray Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Figure 2-52: Octoloader at Home Sensor (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Figure 2-53: Device at Octoloader Gap Sensor (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Figure 2-54: Device at Top of Track Sensor (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Figure 2-55: Sensors 0-2 (Left); Sensors 4-7 (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Figure 2-56: Device at Stack Pin Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Figure 2-57: Device at Mark Site Sensors 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Figure 2-58: Shuttle SensorsWithout Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Figure 2-59: Shuttle SensorsWith Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Figure 2-60: Tube Present Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Figure 2-61: Tube Full Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Figure 2-62: Ports, ClockwiseServo Motor, Sensor Port, Solenoid Port . . . . . . . . . . . . . . . . 2-47

Figure 2-63: Solenoid Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Figure 2-64: Hot-Rail Connectors and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Figure 2-65: Air Regulator Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Figure 2-66: Air Blast Switch in OFF Position (Left), in ON Position (Right) . . . . . . . . . . . . . 2-49

Figure 3-1: Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2


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List of Figures


Figure 3-2: Three-Piece Hot Rail Assembly (Only for Hot-Rail Handlers) . . . . . . . . . . . . . . . . . 3-3

Figure 3-3: Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Figure 3-4: Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure 3-5: Output Tube Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure 3-6: Ports and Override Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Figure 3-7: Ports, ClockwiseServo Motor, Sensor Port, Solenoid Port . . . . . . . . . . . . . . . . . . 3-5

Figure 3-8: Solenoid Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Figure 3-9: Snap-On Output Tube Holder Screwed Onto Handler Base . . . . . . . . . . . . . . . . . . . 3-8

Figure 3-10: Output Tube Holder with Cutouts at Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Figure 3-11: Screws for Cutouts on Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Figure 3-12: Output Tube Holder On Handler BaseIn Unlocked Position (Left); in

Locked Position (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Figure 3-13: Back of Shuttle with Snap-On Pins (Left); Insertion Holes on Shuttle

Assembly (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Figure 3-14: Shuttle with Black Air Hose Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Figure 3-15: Inserting Test Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Figure 3-16: Screwing in Bolts at Each End of Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Figure 3-17: Two-Pin Molex Connector Plugged In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Figure 3-18: Pickup Head Cylinder Block Without Plunger (Left);

Inserting Plunger into Pickup Head (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Figure 3-19: Plunger Inserted into Pickup Head (Left); Tightening Pickup Head Screw

(Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Figure 3-20: Track Opening in Octoloader Ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Figure 3-21: Test Site Screwed Onto Handler Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Figure 3-22: Sliding in Index Rail, Bottom First (Left); Index Rail in Place (Right) . . . . . . . . . 3-14Figure 3-23: Index Rail Pins in Grooves of Rail Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Figure 3-24: Index Rail Screws to Tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Figure 3-25: Connection for Index Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Figure 3-26: Six Screws to Be Tightened on Each Hot Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Figure 3-27: Clear Cover with Cutout at Bottom of Hot Rail (Left); Snapping Cover

Latches Closed (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Figure 3-28: Air Connected to Handler Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Figure 3-29: Connectors and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Figure 3-30: Connectors Plugged Into Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Figure 3-31: Octoloader Back with Snap-On Pins (Left); Octo Car Block with Holesfor Snap-On Pins (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Figure 3-32: Red Thumb Screws to Be Unscrewed Before Removing Cover . . . . . . . . . . . . . . 3-21

Figure 3-33: Octoloader Aligned to Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Figure 3-34: Track Aligned to Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Figure 3-35: Perimeter Screws for Horizontal Alignment of Output Tube Holder. . . . . . . . . . . 3-22

Figure 3-36: Perimeter Screws on Output Tube HolderLeft and Right. . . . . . . . . . . . . . . . . . 3-23
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Figure 3-37: Shuttle Aligned to Output Tube Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Figure 3-38: Shoulder Screws for Vertical Alignment of Output Tube Holder . . . . . . . . . . . . . 3-24

Figure 3-39: Device at Stop Pin as Seen Through Changeover Kit . . . . . . . . . . . . . . . . . . . . . . 3-25

Figure 3-40: Device at Shuttle With Override Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Figure 3-41: Octoloader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Figure 3-42: Loading a Tube Perpendicular to Octoloader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Figure 3-43: Securing Tube at Bottom of Input Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Figure 3-44: Dowel Pin on Holder Fits Dowel Hole on Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Figure 3-45: Tube Held Out Away from Dowel Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Figure 3-46: Tube Snapped Into Place on Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Figure 3-47: Tube Top in Place on Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Figure 3-48: Releasing Devices From Output Tray to Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32


Figure 3-50: Control Panel Message "READY TO RUN" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34


Figure 3-52: Laser Supply Unit Powered OFF (Left), ON (Right) . . . . . . . . . . . . . . . . . . . . . . . 3-37

Figure 3-53: Laser MessagesWAIT FOR START (Left), LASER READY (Right) . . . . . . . 3-37

Figure 3-54: Smartist Laser Software in Edit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Figure 3-55: Smartist Laser Software in Work Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Figure 3-56: Laser ReadyYellow (Left); Laser FiringRed (Right) . . . . . . . . . . . . . . . . . . . 3-41

Figure 3-57: Octo Stop Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Figure 3-58: Four Hot Rail Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Figure 3-59: Heater Controller Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Figure 3-60: Modifying SetupReference Flowchart for Handler with Pickup Head. . . . . . . . 3-48Figure 3-61: Modifying SetupReference Flowchart for Handler with Quad Tester . . . . . . . . 3-49

Figure 3-62: Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Figure 4-1: Eight-Bit LED Checker #3000-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Figure 4-2: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Figure 4-3: Diagnostics Reference Flowchartfor Handler with Pickup Head and Laser . . . . . 4-4

Figure 4-4: Diagnostics Reference Flowchartfor Handler with Quad Tester . . . . . . . . . . . . . . 4-5

Figure 4-5: Shuttle Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Figure 4-6: LED Pattern for Each Shuttle Position When Shuttle Is Empty. . . . . . . . . . . . . . . . 4-16

Figure 4-7: Shuttle Position Sensors 4 and 6 Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Figure 4-8: Shuttle Position Sensors 4-6 Blocked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Figure 4-9: Tube Full Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Figure 4-10: Tube Full Sensor Blocked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Figure 4-11: Tube Present Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Figure 4-12: Tube Present Sensors Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Figure 4-13: Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22


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List of Figures


Figure 4-14: CPU Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Figure 4-15: Pickup Head at Pickup Site (Key 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Figure 4-16: Pickup Head at Test Site (Key 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Figure 4-17: Pickup Head at Top of Track (Key 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Figure 4-18: Shuttle Solenoid Light with Override Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Figure 4-19: Shuttle in Extended/Closed Position with Device (Left), in Retracted/Open

Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Figure 4-20: Octoloader at Home Sensor (Display 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Figure 4-21: Device at Octoloader Gap Sensor (Display 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Figure 4-22: Device at Top of Track Sensor (Display 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Figure 4-23: Octoloader Home and Input Sensors Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Figure 4-24: Changing Distances on Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Figure 5-1: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Figure 6-1: Serial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Figure 6-2: SMC Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Figure 6-3: Small Black Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Figure 6-4: Metal Casing Unscrewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Figure 6-5: Clear Glass Casing Snapped Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Figure 6-6: Large Black Inner Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Figure 6-7: SMC Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Figure 6-8: SMC Air Regulator Turned OnAnother Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Figure 6-9: SMC Air Regulator Turned Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Figure 6-10: Air Valves with Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Figure 6-11: Sensor Controller Set to L-ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Figure 6-12: Green and Red Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Figure 6-13: Conditions of Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Figure 7-1: Dimensions Listed From Smallest to Largest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Figure 9-1: Eight-Bit LED Checker #3000-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Figure 9-2: Handler Port (Parallel Port) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Figure 9-3: 24-Pin D Connector on Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Figure 9-4: Standard TTLHandler Port Interface Timing Detail for One Tester . . . . . . . . . . . 9-7

Figure 9-5: Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Figure 9-6: Typical RS-232 Interface Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10


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Model 5000 Manual



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06/2010 Copyright Exatron, 2010 1-1

Chapter 1:

Safety and Support

Chapter OverviewThis chapter discusses the following main topics:

Please read and understand this entire User Manualbefore installing or using your Exatronhandler.

A short glossary of terms used in this manual and other keys to understanding is found at theend of this chapter.

Exatron Safety WarningsTypically, the handler is simply one part of a complete test system. It is the responsibility of thecompany purchasing the handler to properly train all handler operators in all of the safetypractices required for every component of the test system.

The following safety procedures must be followed at all times.

Topic Page

Exatron Safety Warnings 1-1

Lock-Out Procedures 1-3

Facilities Requirements 1-4

Installation Overview 1-7

Standard Warranty 1-8Exatron Support Services 1-10

Warranty and Support Contracts 1-10

End-of-Life Handler Disposal 1-23

Significance of This Manuals Version Number 1-23

Typographical Conventions Used in This Manual 1-24

Terms Used in This Manual 1-24

WARNING! Hi-Pot testers contain high voltage. Do not defeat the interlocks.

WARNING! Keep fingers, hair, and clothing away from any moving parts on the handler.Its motors are very powerfuland can cause severe injury.


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Model 5000 Manual Chapter 1: Safety and Support

1-2 Copyright Exatron, 2010 06/2010

Figure 1-1: Pause Button on Control Panel (Left); Emergency Stop Button (Right)

Exatron specifically disclaims responsibility and/or liability for any injury which occursas a result of any interlock being defeated and/or bypassed, or for any injury whichoccurs as a result of any fixed cover being removed during operation.

Using compressed air can be hazardous. It is the responsibility of the company purchasing thehandler to properly train all handler operators in every aspect of the safety practices associ-ated with the use of compressed air.

Electrical HazardsHigh Voltage Testing Applications: It is the policy of Exatron to determine the precise applica-tion for every handler we make prior to shipment. In some cases, the handler will be used totest devices at high voltages. If your handler will be used to test devices with voltages inexcess of 80-volt DC or 80-volt AC, the handler should be equipped with safety covers. Notify

WARNING! Always reset all motors before running the machine. Do not run it withouthoming the motors.

WARNING! Never try to stop an action of the handler with your hands or any other device.To stop the handler, press the EMO (emergency stop) button or press the Pause key on

the control panel.

WARNING! If your Exatron handler is equipped with safety covers, never operate thehandler without them. Never remove the safety covers. Never defeat any electrical inter-lock switch supplied with the handler.

WARNING! Never operate any Exatron system which requires compressed air without anapproved air regulator and shutoff valve, such as that originally supplied with your system.

WARNING! Never unplug a pressurized air hose while the air regulator is turned on.


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Lock-Out Procedures Laser Hazards


Exatron immediately and place an order for safety covers, if this has not already been done.Added safety covers will be provided at additional cost to the user.

If Exatron is notified of high voltage requirements as described above on the written purchaseorder at the time of order placement, we will equip your handler with safety covers havingelectrical interlock switches. These switches are intended to be utilized by the operator by

connecting them to the customer-supplied tester. When the interlock switch is open, the testerwill be shut down with no possibility of high voltage at the handler's contacts. All safety hard-ware should be verified for proper operation by the customer's own in-house safety officer.

In most cases, there are no high voltages used inside the Model 5000 handler electronicswith the exception of those using a Hi-Pot tester or the Model 5080 Hot Chamber.

High voltage from the facility's electrical line current is present in the Model 5000 power sup-ply. Only qualified service technicians should do any repair work on the power supply. Makesure to use qualified service technicians when attempting to repair any portion of the handlerthat uses high electrical voltages.

Laser HazardsIf your handler is equipped with a laser, follow all the federal and state safety regulations forsafely operating the laser. Follow the safety warnings in the laser manufacturers manual.

Lock-Out ProceduresLock-out/tag-out procedures should be followed when servicing or repairing the handler. This

prevents an operator from turning on the handler when it may be partially disassembled andthus prevents damage or injury.

Before servicing or repairing your handler, turn off the air regulator and lock it in the OFF posi-tion as shown in Figure 1-2. Then, if you have to leave the handler in an inoperable or unsafecondition, no one can turn it on by mistake.

WARNING! Only a qualified in-house laser safety officer (LSO) should service the laser, ifthe handler is equipped with a laser.

NOTE: Locking devices such as padlocks are provided by you, the customer.

WARNING! Turn off the air regulator and lock it in the OFF position before servicing.


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Figure 1-2: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right)

Facilities Requirements

Environmental RequirementsThe Model 5000 handler should be installed in a temperature-controlled, dust-free environ-

ment to preclude dust and dirt particles from contaminating its moving parts, especially thoseparts which come into contact with the devices being tested. The life of your handler is greatlyenhanced by keeping it as clean as possible. See Chapter 6 for instructions.

Airborne dust and moisture, if present, will naturally settle on all surfaces of your handler. Ifallowed to build up, dust can eventually block sensors, clog solenoids, fill up the filters of cool-ing fans and generally inhibit the smooth movement of devices through the handler. The bestdefense against this kind of contaminant is to dust the handler off with blasts of compressedair at least every 8 hours.

There are no special ventilation requirements.

As specified in the table shown below, Exatron handlers are designed to withstand the impactof any physical environment that they may be used in. Periodic maintenance as described inChapter 6 will ensure that emergency "down time" is kept to a minimum.

Handler/Hot Rail Handler with Printer

Temperature 40 to 115 F, 5 to 45 C 40 to 105 F, 5 to 40 C

Relative Humidity 20% to 85%, noncondensing 20% to 80%, noncondensing


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Facilities Requirements Electrical Requirements


Electrical RequirementsIf the handler is to be used in an electrically noisy environment or near large electromechani-cal equipment, Exatron recommends the use of a reliable power conditioner to filter line noise,surges, and spikes which can cause the handler to operate improperly or become damaged.

All Model 5000 series handler chassis are directly connected through the power supply toearth ground. All guide rails, shuttles, tube holders, hot chamber trays and output trays areconnected to earth ground. The handler's power supply ground is directly connected to earthground.

Handlers shipped within the United States are factory pre-wired for 110V AC, 60 Hz, unlessotherwise specified.

Handlers shipped off-shore have built-in electrical supply capability for 100-volt AC to 240-voltAC, 50-Hz to 60-Hz, except in the case of the Model 3010B Hot Rail. The Hot Rail thermocou-ple card contains either a 50-Hz crystal or 60-Hz crystal, which must be specified by the cus-tomer.

Handlers shipped to the following destinations are pre-wired for the following voltages unlessotherwise specified:

Japan - 100 VAC, 50 Hz

Continental Europe - 240 VAC, 50 Hz

United Kingdom - 220 VAC, 50 Hz Hong Kong - 220 VAC, 50 Hz

Handlers with special features have specific requirements:

Ambient handlers require 3 amps at 110-volt AC.

Hot-rail handlers require 7 amps at 110-volt AC.

Handlers with lasers require 5-10 amps at 110-volt AC.

Handlers with hot chambers have the line frequency fixed at either 50 Hz or 60 Hz, as speci-fied by the customer, but not at both frequencies.

The power supply is "smart," sensing the voltage in the power line, and matching its poweraccordingly.

Electricity supplied to the handler must be within the recommended operating range. If the linevoltage drops too low, the handler may not function properly and may be seriously damaged.Verify that correct operating line voltage is present. If it is not, contact Exatron for assistance.

NOTE: 110V AC at 20 amps is preferred when available.

CAUTION: Connect the power cord to earth-grounded power outlets only.


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Service calls made to the customer facility to correct problems caused by improperelectrical supply are not covered by the Exatron warranty.

Air/Vacuum RequirementsThe Model 5000 system requires a supply of pressurized air at a minimum of 80 PSI/3 CFM

(+/- 3 PSI), filtered for proper operation. The air supply must be clean (containing no particu-late matter greater than 5 microns in size), oil-free, and dry (having a dew point of 36 degreesF to 38 degrees F) to operate correctly. Dirty, oily or wet air will cause the vacuum generator tomalfunction and will make your system unreliable.

If the handler is equipped with a taper, add 0.5 CFM of shop air to the CFM required for thehandler itself.

The external air source should be attached to the air regulator mounted on the handler base.Before turning on the air regulator and using the handler, make certain the compressed air lineis attached to the air regulator fitting. Check to make sure the air regulator gauge on the exter-nal regulator measures the air pressure at 80 PSI, and adjust if necessary.

To maintain these levels of pressurized air quality, replace the air filter (Exatron part #GPA-97-075) in the air regulator of your handler after every 6000 hours or 12 months of operation,whichever comes first; or if your air regulator registers a pressure drop of 15 PSI.

Moisture of any kind will travel through external and internal air lines. This moisture will coatthese air lines and the insides of the handler's electrical solenoids, causing them to stick or tostop functioning altogether. The best defense against this kind of contaminant is to prevent itfrom occurring in the first place by maintaining the clean air supply described above.

If the air lines are allowed to become discolored or the moisture traps become overfilled, dam-age to the system will occur. The only corrective action to take at that point is to replace all of

the air lines and to completely clean all of the solenoids supplied by those air lines. Handlerdamage due to improper air supply is not covered by the Exatron warranty.

A house/shop vacuum is not required. Changeover kit vacuum requirements are supplied bybuilt-in venturi vacuum generators.

The external air source should be attached to the air regulator mounted on the handler base.Before turning on the air regulator and using the handler, make certain the compressed air lineis attached to the air regulator fitting. Check to make sure the air regulator gauge on the exter-nal regulator measures the air pressure at 80 PSI, and adjust if necessary.

Air ConnectionsLocated on the lower right side of the main frame supporting the Model 5000 is an air regula-tor with a pressure gauge and a filter. Before using the Model 5000, make certain that a com-pressed air line of 80 PSI is attached to the fitting of this air regulator.

The Model 5000 has one 1/4" diameter flexible plastic air line on the outside of the handler'schangeover kit.To supply the changeover test site with air, plug this into one of two availablecompressed air outlets mounted on the right side of the main plate of the Model 5000.


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Installation Overview DUT (Device Under Test) Materials


Figure 1-3: Air Line Attached to Outlet

DUT (Device Under Test) MaterialsComponent packages vary as to the materials from which they're made. The composition andsize of packages can cause wear on the parts of the handler with which they come into con-

tact. Heavy, rough-surfaced DUTs will cause handler wear faster than lighter, smoother mate-rials.

The best defense against the effects of the DUT material on a handler is to ensure that thehandler is properly adjusted for the package it is running. The height of the handler door overthe DUT should be as close as possible. The test site contacts should close on the DUT withenough pressure to provide good electrical contact, but not press hard enough to force theDUT to the left or the right of the test site rail. If you have any questions regarding handleradjustment issues, please contact the Exatron Customer Service Department.

Installation OverviewBasic installation of your new Exatron handler will consist of the following major steps:

Unpacking the handling equipment and assembling its peripheral parts

Powering up the handler ("Power-Up Procedure" on page 3-31) and running Diag-nostics sequences (Chapter 4)


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Cycling sample tubes of devices

Interfacing the handler to your tester/programmer (Chapter 9)

The Model 5000 series handler will usually come in a wooden crate which will require somedisassembly to remove the handler. Please inspect the system when it is removed from the

crate for any obvious damage which may be the result of shipping. Contact Exatron and theshipping company immediately if you see any damage.

Standard WarrantyAll Exatron products are under warranty for one year from the date of purchase. Exatronagrees to repair any mechanical or electrical assembly, subassembly, or entire unit which failsduring normal use within its first year. The customer agrees to follow the recommended main-tenance procedure as defined in this User Manual.

Exatron does not warrant test contactors. Handler test contactors are fragile and may be eas-

ily ruined by operator abuse. Exatron uses the finest materials available in our contactordesigns.

Exatron does not warrant the following:

Damage caused by improper packaging of equipment returned to Exatron forrepair

Damage caused by the shipping company

Damage caused by natural catastrophes: flood, fire, earthquake, etc.

Damage caused by equipment connected to improper power line voltages

Damage caused by equipment connected to improper air supply: contaminatedwith oil, water, dirt, etc.

Damage caused by operator abuse or improper practices cautioned against in thismanual

Damage caused by interface hardware not manufactured by Exatron

Damage or malfunction caused by customer modifications

Test contactors


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Standard Warranty Customer In-House Service


Customer In-House ServiceExcept in the case of laser marking systems, Exatron encourages customer in-house equip-ment service and tries to make in-house service as easy as possible to perform. There are no"Void Warranty" warning stickers on Exatron handlers. By using the built-in diagnostic soft-ware and diagnostic tools, it is usually possible for the operator to isolate a problem quickly

and effect a repair.

The customer is responsible for all cost of in-bound shipping expenses. Standard out-boundshipping expenses will be paid by Exatron. In such cases where the customer requests spe-cific out-bound shipping methods to be used, the customer is responsible for all shipping costsand any additional related charges.

Offshore Warranty ServiceAn Exatron handler purchased in the United States and then shipped offshore will be war-ranted through Exatron in California. Replacement parts are furnished for a period of one yearfrom date of purchase with the exception of replacement contactors. In most cases, it will not

be necessary to return the worn part from the offshore user location.

To receive offshore service support, the handler must be purchased through your localExatron representative or an extended warranty agreement must be purchased directly fromyour local Exatron representative.

Please supply the following information when requesting offshore service or replacementparts:

The part number(s) required. If the part number is not known, photocopy or take aphoto of the part and fax it to Exatron.

The model number of the handler

The type of device being run by the handler, such as: DIP, SOIC, SOJ, PLCC,LCC, SIP, PGA, PCB, ZIP, etc.

The handlers serial number

The full shipping address

Any special shipping or customs instructions

Method of shipment, such as: Federal Express, UPS, DHL, U.S. Mail, or the name

of your chosen shipping company

In most cases, faxed requests and shipment of replacement parts orders are processed withintwenty-four hours of receipt by Exatron.


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Exatron Support ServicesFor factory technical support, you can contact us in several ways.

Call 1-800-EXA-TRON or 1-408-629-7600, between 8:00 A.M. and 5:00 P.M.Pacific time, Monday through Friday.

E-mail us anytime at [email protected].

Fax us at 1-408-629-2832.

When contacting us, please have your Exatron equipment close at hand, along with the fol-lowing information:

The model number of your handler with all its options (taper, tubes, etc.)

The exact wording of any messages that appeared on your handler display.

A description of what happened and what you were doing when the problemoccurred.

A description of how you tried to solve the problem.

Warranty and Support ContractsThe following three sample contracts show details of what is covered. They may be changedwithout notice.


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Warranty and Support Contracts Service Contract


Service Contract

2842 Aiello Drive, San Jose, CA 95111 www.exatron.com 408-629-7600

SERVICE CONTRACT Rev Hfor

Customer TBDStreet AddressCity, State, Zip

Please see our Customer Service Support document for detailed warranty details

This contract shall commence on Starting Date for a period of twelve (12) months and shall berenewed only upon receipt of new purchase order for a new 12 month period.

Exatron shall provide service by way of prompt, reliable technical consultation and servicecoordination with respect to Customers Exatron built products located at their TBD facility, fulladdress. Please see section Product Movements, below, for more information regarding thelocation of the Exatron products covered by this contract..

This Service Contract"includes:

Perform Preventive Maintenance procedures as defined in the Exatron Manual. Clean, align and inspect handler for worn and/or damaged parts. Examine handler for signs of wear and notify the Customer. A list of required

replacement parts will be supplied to the customer during each visit. Purchased partsmay be installed during the next visit. 1 year factory labor Installation of any update and diagnostic software as might be available Best effort response time, 1 to 3 business days typical Typical same day shipment of spare parts Toll free 800-EXA-TRON support service phone line

What is NOT covered by this Service Contract: All actual travel costs, see below The cost of all spare parts The cost of consumables and test contacts Any OEM equipment warranty/service costs (non-Exatron products)

Operator and/or service training of customer personnel Shipping damage of any kind Acts of God


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Acts of war Power line problems and damage Air supply problems and damage Ongoing camera & laser application support Any other Exatron products not specifically listed on this contract

Service performed on Exatron-built products only: Service is strictly limited to the Exatron portions of a given system Service work on any OEM subsystem is to be purchased directly from the OEM This includes, and not limited to, bowl feeders, chillers, camera/vision systems, customer supplied equip-

ment, label printers, laser markers, smoke extractors, and any large OEM subsystem used in the overallExatron system

Please note: All laser markers require professional service. Improper service will void the OEM warranty and couldresult in personal injury and/or serious damage to the laser.

This contract does NOT extend the Exatron product warranty.

This contract does NOT provide for any additional service work beyond the limits of thiscontract.

Service Contract ScheduleExatron will make every effort to have a service engineer at the customers facility with in 1 to 3 business days of thecall for service. There are no serv

model 5000 manual

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