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Preventi ve Mai nten ance ProM aster 25 00 User Manua l 5-7 Optics Optics detect and monitor the lo cation of devices, the movement and position of the beam , labeler movement, orbital m otor positio ns, label position o…

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5-6 ProMaster 2500 User Manual

If the device programs without errors, the PE goes to a verify cycle. Most

semiconductor manufacturers specify setting the device V

to two

different levels during the device verify cycle, one above and the other

below the nominal operating V

. All fuses in the device are verified at

each level. This tests the device to make certain that the correct data is

read when the device’s V

pin is set slightly below and above the

nominal V

level. The PE sets the device’s V

pin to the specified low

level and verifies all the fuses in the device. It then sets V

to the

high level and checks all fuses a second time. If one fuse does not pass

this test when V

is set to the low level, TaskLink displays

VERIFY

FAIL, PASS1

. If the fuse test passes with V

low but fails to verify when

is set to its high level, TaskLink displays

VERIFY FAIL, PASS 2

When the device passes all these tests, the PE sends a “pass” message to

TaskLink, and the device count in the System Log is advanced. TaskLink

in turn sends a “pass” category signal to the handler. The handler uses

this category status to determine whether to apply a label, and which of

the two output tubes to use.

Device Moves to

Labeler

If the device programmed correctly, and labeling has been selected in the

task, the beam moves the device to the labeler. If the device failed

programming, the beam places the device in the failed device output

track.

Device Is Labeled

The labeler prints a label and the labeler motor advances it between the

platen and the press bearings, into position to be applied to the next

device. The beam pulls the device across the application plate and press

bearings, and the liner wraps around the platen at an angle that allows

the label to peel off. The label is applied to the device as the beam moves

the device forward and past the peeled off label. The label drive motor

and the ADC optic move the next label into position for printing.

Device Moves into

Receiving Tube

The beam moves the device to the “passed” output track and releases it.

The default designation for the passed output track is output track 1 (see

Figure 5-1). The device release optic detects the device in the track and

the output orbital motor agitates the output orbital assembly, helping the

devices slide into the tube. Devices are also helped into the tube by air

triggered by output track air solenoid 3.

Output tube optics (12 and 14 in Figure 5-1) detect the devices as they

enter the tube. The 2500 counts the devices as they pass between the

output tube optics. When the device count reaches the number set in the

Parts/Tube

parameter in the task, operation stops and the handler

displays

CATEGORY X BIN NOT AVAILABLE

. Operation continues when a

microswitch on the output tube clamp toggles, indicating to the handler

that the full tube was removed and an empty receiving tube has been

inserted.

The following sections describe major 2500 subsystems in greater detail.

Preventive Maintenance

ProMaster 2500 User Manual 5-7

Optics

Optics detect and monitor the location of devices, the movement and

position of the beam, labeler movement, orbital motor positions, label

position on the liner (the translucent label backing material), and position

of the ribbon and ribbon pinch roller in the thermal printer (25 and 26 in

Figure 5-1). The optics are mounted in pairs at various places on the

handler. Each pair of optics is made up of an infrared light-emitting

device (emitter) in line with a light-sensitive collector.

All emitters are of two standard types and can be exchanged with like

emitters from any location during troubleshooting. Emitters are

identified by red-and-black or blue-and-black wires crimped to a slide-on

connector. Collectors are identified by blue-and-yellow or red-and-

yellow wires.

Track Optics

The track optics monitor the presence and movement of devices in the

tracks.

Positioning Optics

The reference position optic (17 in Figure 5-1) detects when the beam is at

the far right position and sets the encoder to “0,” which establishes the

starting position of the beam.

Optics 3 and 4 detect the vertical position of the beam.

ADC Label Calibration

Optic

The ADC optic on the dot matrix and thermal label printers senses the

position of labels on the liner so they are positioned properly for the print

head and applied correctly to the device. This optic pair detects the

presence of a label by using the liner as a reference. During label

calibration, light from the emitter passing through the liner is sensed by

the optic collector. As a label on the liner travels between the optic pair,

the decreased light level is detected. When the amount of light increases

again, the ADC optic interprets that change as the end of the label.

Label Sensing Optic

The label-sensing optic on the dot matrix label printer monitors the label

liner and detects when the 2500 runs out of labels.

Switches

A mercury switch on the top cover senses when the hood is open and

causes the 2500 to display a warning message. The 2500 will operate with

the hood up only when you are running the motor diagnostic tests.

A mercury switch on the main plate senses when it is in the raised

position.

A microswitch on the input tube clamp detects the presence of an input

tube (19 in Figure 5-1), and each of the output tube clamps have a

microswitch that detects the presence of an output tube (20 and 21 in

Figure 5-1).

Switches on the front and back side of the programming module engage

when it is properly installed. If the switches do not engage, an error will

be displayed.

Motors

Stepper motors are used on the 2500 to control the movement and

labeling of devices.

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5-8 ProMaster 2500 User Manual

The beam has a traverse motor (with an encoder) that moves the beam

along the lead screw in its horizontal (left-to-right) travel. The encoder

counts the number of steps the beam travels from the home position and

sends that information to the main board. The beam assembly also has a

beam rotate motor that controls the rotation of the device on the chuck.

The 2500 has three additional stepper motors. The label drive motor

(used in the dot matrix printer and in the thermal printer) advances labels

at a precise rate past the print head to create even spacing between

characters. This motor also advances the liner so the label contacts the

device according to the position defined by the label placement value

specified in the Task.

The input orbital motor rotates, causing the input orbital assembly to

shake. This shaking helps the devices slide from the input tube to the

input track. The output orbital motor performs a similar function when

devices are sliding from the output track to the output tubes.

Solenoids

The handler uses air solenoids that are activated by signals from

MOSFET circuitry on the controller board. When the correct logic drive

signal for a specific solenoid is active, an LED associated with that circuit

is lit.

Beam and Chucks

The microprocessor-controlled beam, using a pick-and-place head and an

interchangeable vacuum chuck, picks up and places devices at the

programming or labeling station and releases devices into the output

track.

The beam traverse stepper motor drives the beam on the horizontal (left-

to-right) axis along the lead screw. You must keep this lead screw clean

and lightly lubricated to ensure correct beam operation. If you do not

keep the lead screw clean, the beam may eventually develop alignment

problems and fail to locate the center of a device.

Beam stalling is a term used to describe the failure of the beam to travel

freely on the lead screw, resulting in lost steps and the inability to travel

the full distance of the lead screw. The chance of this occurring is very

low, because the beam traverse motor has an encoder that keeps track of

the beam’s movement.

A device rotate motor, which is mounted on the beam assembly, is

connected to the beam head by a timing belt. The device rotate motor

controls the rotation of devices on the chuck so that the device orientation

can be adjusted for programming or labeling.