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Extron electronic 3000B Switch User Manual

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1. CROSS MANUFACTURE SEMO3 110 pus www exatron com 9 2 Chapter 9 Replacement Parts Exatron 3000B AS USED ON EXATRON HANDLERS NPN SILICON TRANSISTORS SENSORS WHITE PART 0 509 ES MANUFACTURE BLUE mes MA CASE PLASTIC RECTANGLE ford LEAD SPACING 100 Es E 4 Les CROSS PART GIG 0 76 A LENS Omaras CROSS MANUFACTURE SEMO3 140 A rer mem UFACTURE 1125 10 641 934 10 86 Tr sum 03010 78 15536 www exatron com 9 3 Chapter 9 Replacement Parts Exatron 3000B AS USED ON EXATRON HANDLERS EMITTER SENSOR PAIR ASSEMBLIES PART 7 OPB828 C MANUFACTURE CASE PLASTIC LEAD SPACING 2X2 CROSS PART CROSS MANUFACTURE SEMO3 220 SP o WHITE GREEN PART OPB706 A MANUFACTURE OPTEK CASE PLASTIC LEAD SPACING 4 SIP CROSS PART CROSS MANUFACTURE SEMO3 210 www exatron com 9 4 Chapter 9 Replacement Parts Exatron 3000B DIP SIP NEY PINS 2001N 42001 EXATRON EXATRON 15 CONTACTS 15 CONTACTS 2110 463 6000 454 w exatron com 9 5 Chapter 9 Replacement Parts www 30008 Exatron 3 PIN 6 PIN 6 PIN CONT CON LUE LONG DIP 2110 A64 2110 A65 www exatron com 9 6 Chapter 9 Replacement Parts Exatron 3000B PEGG PI PINS GOLD PINS EXATRON 84 PIN PLCC UNIVERSAL SOCKET 6000 289 PI OR 6000 624 COMPLETE GO
2. 7 7 19 Sort8 8 20 2 Start 9 21 Start Test Pulse 10 22 HandlerVcc 5VDC 11 23 Handler Ground 12 24 O REMEMBER 1 Use the 24 pin handler port 3000B Input 9 EOT Not Used Not Used Not Used Output 8 Output 7 Output 6 Output 5 Output 4 Start Test Level HandlerVcc 5VDC Handler Ground NOTE NEVER CONNECT TESTER Vcc TO HANDLER Vcc 2 All signals are TTL CMOS compatible 3 Opto isolation is available as an optional feature except on the 20008 Series Handlers To obtain this feature for your Model 3000B or Model 5000 Handler please specify your request at the time of placing your handler order Additionally all 3000B and 5000 Series Handlers may be upgraded to opto isolation in the field To order this upgrade for an existing handler contact the EXATRON Sales Department and order PCB 5000 D76 Opto Isolation Interface Light Pole Option PCB Our toll free telephone number is 1 800 EXA TRON 4 The 5 volt output on the handler port Pins 11 23 is NOT to be used by or connected to the tester unless it is isolated at the tester 5 Pins 12 and 24 are ground connections 6 Refer to FIGURE 3 2 following for timing diagram For further timing sort details please refer to DRAWING 5000 F 62 www exatron com Chapter 3 Interface Info Exatron 3000B FIGURE 3 2 HANDLER PORT INTERFACE Timing Detail The handler first moves a device into the test site After allowing time for the device to settle
3. Output cover LEDs will blink output Bin locations 00C8 Label Pick up 1000 step setting 3000BL only 1000 00 9 Pick Up Step 100 0 __ 301039 Label Pick up 100 step setting 3000BL only 00 00CB 00 00CD Apply Step 10 30 to 39 Label Apply 10 step setting 3000BL only 00CE Label Apply 1 step setting 3000BL only OOCF Label Que 01 00 to 19 Sets the number of labels printed on power up Setting depends on version of 3000BL In most cases set to 01 prints only 1 label 3000BL onl 0000 Add Label FF 00 AA For 3000BL only FF 00 Test and Label in one operation FF Test only skip the label site AA Label only no test 00D1 Bit Check 00 FF For PROGRAMMER RS 232 Interface only Performs Bit Test at the start of the programming cycle 00 Bit Check ON Data I O FF Bit Check OFF Bytek 0002 Interface Type 26 23 25 Sets default interface to be used by the handler 26 23 PROGRAM RS 232 Interface Data I O Bytek 25 EXATRON RS 232 Interface 26 HANDLER PORT Interface 0003 P V L 02 02 04 For PROGRAMMER RS 232 Interface only 08 Selects Program Verify or Load Master operation 02 Program 04 Verify 08 Load Master ses For Plunge to Board 4 Changeover Kits Sets the Steps1000 1000s digit of the Z motor plunge to contact steps Set as ASCII Number 00D5 Plunge Steps 100 3 30to39 For Plunge to Board Type 4 Changeover Kits Sets the 100s digit of th
4. This error message advises that the operator is using the wrong algorithm diskette for this programming job Replace the current diskette with the correct algorithm diskette and restart operations www exatron com 3 24 Chapter 3 Interface Info Exatron 3000B Chapter 4 Handler Set Up Overview The intelligent front panel microterminal of the Model 3000B handler controller allows jobs to be set up and running in minutes Set Up consists of making handler operation selections regarding Package Type Interface Type Output Tube Full Count Plunge Depth for plunge to board changeover kits and Stop On Fail features for the job you wish to run MICROTERMINAL DISPLAY UD OREA 1 2 n f RUN MANUAL 4 5 6 SET UP PAUSE g 9 E DIAGNOSTICS Soja E Please read and understand this entire User s Manual before attempting to Set Up your EXATRON handler After you have done so use the following procedure to begin regular production 1 First verify the following A Handler is plugged into power outlet with working EARTH ground connection If the type of changeover kit requires it the handler is connected to a dry air pressure supply of 80 PSI 3 PSI The air supply must be free from moisture and oil C The programmer tester is properly docked to the back of the handler Verify that the programmer tester is installed with the correct Pin 1 orientation NOTE D
5. 4 Unscrew the bolts to remove the wooden base from the handler www exatron com 2 2 Chapter 2 Installation Exatron 3000B 5 Save the bolts and their washers with the wooden base and return them to the shipping container 6 Replace the internal carton and the top cushion panel 7 Carefully examine the space between the container and the four side cushion panels for any additional parts since Tube Holder extensions and sample devices are often packed in these spaces 8 Replace all packing material and internal boxes The shipping carton should now be ready for storage DO NOT DISCARD If it becomes necessary to return this handler to Exatron use this shipping container and re pack the handler in the reverse order of the unpacking procedure described above UNPACKING THE POWER SUPPLY The power supply is shipped in a separate 20 x 18 x 18 cardboard box Open the box with the DELICATE INSTRUMENT label side up and remove the top internal box containing handler peripherals such as Octoloader Plate Air Regulator Shuttle User s Manual and Power Cords Set these items aside Open the bottom internal box and remove the power supply using both hands Set the power supply aside and return the packing material to the empty box The shipping carton should now be ready for storage DO NOT DISCARD Proceed with the unpacking assembly instructions If you have not purchased a Free Rolling Exatron Dolly or FRED skip the following ste
6. Handler displays DIAGNOSTICS Press the 1 key Handler displays SENSOR CHECK Press the 2 key Handler displays SHUT 4 6 If the shuttle is empty and centered above the right Home bin output tube 5 1 Shuttle at Output 1 Sensor 2 Shuttle at Output 2 Sensor 3 Shuttle at Output 3 Sensor 4 Shuttle at Output 4 Sensor 5 Shuttle at Output 5 Sensor 6 Shuttle at Output 6 Sensor 7 Shuttle at Output 7 Sensor 8 Shuttle at Output 8 Sensor Pressing the Clear button will flash the terminal s displayed message to confirm the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check If you suspect that you have a bad sensor LED pair use the EXATRON LED checker part 3000 052 small blue plastic box This diagnostic tool is equipped with a transistor blue white wires and an IR LED orange green wires Direct the transistor at any of the handler s IR LEDs The LED on the checker should turn off Direct the checker s LED at any of the handler s transistors The corresponding number should turn OFF on the handler s display www exatron com 5 7 Chapter 5 Diagnostics Exatron 3000B Tube Full Sensors 1 Through 8 Lead In Sensors This diagnostic tests port B3 located on PCB 5000 A89 PAL A69 6 Please refer to drawings 5000 066 and 6000 517 for sensor wiring details TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 1 key Handler displays SENS
7. 7 8 UNPACKING 3000B Locate the two blue pivot plates 3000 035 Locate two 3 8 x 16 x 2 75 long bolts four 3 8 x 16 x 1 75 long bolts six 3 8 lock washers and six 3 8 x 16 hex nuts Place the 3 8 x 16 bolts and pivot plates on the risers push the bolts in just far enough to hold this assembly together and still leave room for the handler frame to be placed inside The bolts can then be pushed quickly into the handler frame while it is held in position Handlers with Hot Rails are shipped pre assembled on their FRED frames THE HOT RAIL HANDLER ASSEMBLY Open the large handler box with the DELICATE INSTRUMENT label side up by carefully removing the two reusable straps on the box There is no need to cut any tape or remove any staples lift the top of the box straight up and remove the inner protective packaging assembly You should now be able to see the handler The handler assembly is very heavy and will require two people to unpack it With one person at each end of the unit pick the handler assembly straight up out of the box 1 www exatron com With two people holding the handler frame assembly by its sides and a third person ready to push the bolts into place position the handler assembly horizontally at the long pivot bolts Push those pivot bolts into the frame on each side of the handler With both people still holding the handler frame assembly by its sides tilt the handler to the desired tilt angle a
8. Mask bin 4 009B Baud Rate 0 5 Table Stores the baud rate of the RS 232 interface between RS 232 in Interface the handler system and the PC Chapter Must be set to OC for EXATRON SUPER Interface 0C 9600 BAUD 009C Data Format 03 See Table Stores the parity stop data bits in Interface Must be set to 03 for EXATRON SUPER Interface Chapter 03 No Parity 8 bits 1 stops 07 No Parity 8 bits 2 stops PA 00 FF To wiggle the shuttle during sorting 00 Wiggle shuttle FF Wiggle turned off 009E Time Out 20 00 to FF A timed delay before the handler aborts the test and turns off all solenoids Counts down in HEX in 1 second steps When this address is set to 00 the system will never time out OO9F Shuttle Thump 00 FF To thump the shuttle during a jam by firing the 00 Thump the shuttle FF Thump turned off tT 00A2 Index Delay Type 5B Kits only Adds delay for DUT to fall into the lu EE EN pick up location just after being indexed Counts down in 10 msec steps uil EMEN Type 5B Kits only Adds delay for DUT to settle down into the pick up location just before being picked up Counts down in 10 msec steps 00A4 T Site Out Delay 05 Type 5B Kits only Adds delay for DUT to fall past the ud du exit sensor after leaving the test contacts Counts down in 10 msec steps 00A5 Opto Input FF 00 FF Enables optional Opto Isolation PCB Option Handler must be equipped with optional 5000 D76 Opto
9. NOTE this settling time is programmable use address 0097 the test head plunger picks up the device and plunges it down toward the contactors Then the handler issues a start pulse Pin 10 to the tester The start pulse width is programmable address 0098 but will be pre set to 20 milliseconds This pulse is normally High 5 and goes Low for the pulse width There is an additional signal available on Pin 22 This testing signal will go Low for the duration of the test It will go Low at the start of the start pulse and will not go High again until the handler receives a sort signal e SORT MUST BE STABLE FOR 1 MSEC MINIMUM PRIOR TO EOT PULSE OR LEVEL __ HANDLER ALLOWS ONLY BN ONE SORT INPUT PER TEST diclus ALL HANDLER INPUTS AND d OUTPUTS STANDARD TTL LOGIC ASS NORMALLY HIGH pis ACTIVE LOW 20 MSEC 1 ADJUSTABLE 1 A TEST TIME lt NDEX SORT TIME To complete the test the tester must send back one of eight sort signals These signals must be normally High and go Low for at least two milliseconds The sorts must appear on Pin 1 through Pin 8 on the handler port connector We recommend that you use Pin 1 for PASS and Pin 2 for FAIL when using the handler in PASS FAIL applications The Input Sort is connected to a PAL device which latches the signal The latch sets the falling edge of the sort signal ON Make certain that your interface does not allow fast glitches which may become
10. venturi to create the vacuum used in the operation of the specific kit Please refer to FIGURE 7 3 following this section for vacuum generator assembly mechanical details Please note that in some cases the venturi assembly will not include the control valves Please refer to the manufacturer s data sheet PISCO Vacuum Switch in Chapter 10 of this manual for additional information To Order from EXATRON PISCO VACUUM GENERATOR ASSEMBLY WITH CONTROL VALVES PART ZVGH10F 1 4 1 4 PISCO VACUUM GENERATOR ASSEMBLY WITHOUT CONTROL VALVES PART VGH10B 1 4 1 4 REPLACEMENT AIR FILTER PART ZVGFE10 1 Inspect the vacuum generator s air filter weekly The filter should be clean and white These filters can be cleaned however EXATRON highly recommends replacing dirty filters with new filters instead How frequently you need to replace the vacuum generator filter is a function of how clean your environment is and how clean the devices being run are REMEMBER A Dirty Filter Poor Handler Operation DIRTY FILTER CLEAN FILTER www exatron com 7 12 Chapter 7 Preventive Maintenance Exatron 3000B 2 Check the vacuum sensor adjustment First be aware that the vacuum sensor adjustment is a 270 total turn potentiometer If you try to turn it more than the 270 allowed it will break The vacuum generator is an expensive component and abuse is not covered by the EXATRON warranty The red indicator LED on the vacuum generator should nor
11. NEVER USE OIL OR LUBRICANT OF ANY KIND ON SOLENOIDS 2 Check for loose and or missing nuts and bolts which may have been caused by vibration to the handler Replace missing parts immediately Re tighten any loose nuts and bolts 3 Check stepper motor set screw tightness 4 Check the voltage of the 5 volts and 24 volts intelligent power supplies built into your handler Calibrate if necessary The acceptable voltage ranges are 5 05 volts to 5 25 volts and 22 volts to 26 volts respectively Please refer to FIGURE 7 1 for power supply mechanical details TO CHECK VOLTAGE A the handler power OFF B Remove the blue side cover plate of the handler control box This will expose the internal card cage Locate the 3000B Front Panel PCB card The Exatron part is 5000 A89 C 3 Locate the three posts on the right side of the card labeled 24V 5V and GROUND C Attach the positive probe of a volt meter to the 24V post Attach the ground probe of the volt meter to the post marked GROUND D Turn the handler power ON If the voltage registers in the acceptable range nothing further is required for the 24 volts supply If the voltage is out of acceptable range calibrate the 24 volts supply TO CALIBRATE CAUTION THIS POWER SUPPLY USES HIGH VOLTAGES ONLY QUALIFIED SERVICE TECHNICIANS SHOULD CALIBRATE THE POWER SUPPLY A Remove the blue sheet metal power supply cover B Locate the blue plastic potentiometer pot
12. RS 232 2 HANDLER OUT CHECK 3 ISSUE NEW START 4 SERVO RS 232 CHECK to return to INTERFACE CHECK return to DIAGNOSTICS Menu 4 key ALL MOTOR CHECK then 1 SORT MOTOR CHECK to return to ALL MOTOR CHECK 1 1 Step Left 2 N A 3 1 Step Right 4 2 Steps Left 5 N A 6 2 Steps Right 7 Jog Left 8 N A 9 Jog Right 0 Motor Off www exatron com 5 4 Chapter 5 Diagnostics Exatron 3000B 2 SERVO MOTOR CHECK lt to return to ALL MOTOR CHECK 1 Move to Pickup Site 2 Move to Test Site 3 Move to Exit Site 4 Set Pickup Location _ 5 Set Test Site Location _____ 6 Set Exit Site Location _ Enter the location in steps starting with the ones position Example entering 1234 Sets the location to 4 231 steps 6 Display Current Exit Site Location _ 8 9 Display Current Pickup Site Location _ Delete key Pickup Vacuum On Off Space key Air Blast On Off to return to ALL MOTOR CHECK To return to DIAGNOSTICS Menu 5 key OCTO INDEX CHK then 1 N A 2 SHUTTLE GATE SOLENOID 3 Input Sensors 1 8 to return to OCTO INDEX CHK To return to DIAGNOSTICS Menu www exatron com 5 5 Chapter 5 Diagnostics Exatron 3000B v1 Test Site Sensors 0 Through 7 This diagnostic tests port 08 located on PCB 5000 398 PAL 398 72 U1 U2 Please refer to the Test Head Wiring Diagram in your Changeover Kit Supplem
13. WAITING FOR R 2 TESTER SENDS R READY 3 HANDLER CLOSES TEST CONTACTS ONTO THE DEVICE UNDER TEST DUT If an R is received the handler will close the contacts or plunge the device onto the contacts If the handler does not receive a response the display will briefly read NO RESPONSE NO RESPONSE will alternate with WAITING FOR R once per second Pressing the Enter button on the front panel will cause the handler to send a new If anything other than an or an is received the handler will pause and display the message BAD RESPONSE The handler will output the HEX equivalent of the actual character received by the handler to the LEDs on the handler s output shuttle cover LED 1 is bit 01 LED 8 is bit 80 Pressing the Enter button on the front panel will cause the handler to send a new H and the handler will try again to receive Pressing the Clear button on the front panel will cause the handler to flush the device from the test site and restart operation The display will read BIN 5 SO FLUSH 4 HANDLER SENDS 5 CR START TEST FIRST TEST CYCLE As stated above once the handler receives an R the test contacts will close onto the DUT The handler will allow time for the test contacts to close Then the handler sends an S CR for Start Test to the tester The display will read START 1 TEST If you wish to abort the test at this point press the Cle
14. and telephone number Please refer to the Preventive Maintenance Chapter in your user s manual for further details regarding the Particle Interconnect process BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 16 Chapter 1 Introduction Exatron 3000B 5000 494 Please use this part number when ordering this label DO NOT REMOVE OR DETACH THIS CYLINDER OPERATOR INJURY IS POSSIBLE WITH THE CYLINDER REMOVED Label shown actual size Dimensions 13 16 x 3 1 2 Colors Red DANGER black text on white backround This cautionary label will be affixed to your EXATRON handler if it is equipped with a Hot Chamber In such cases this label will appear each of the two hydraulic cylinders which support the hot chamber door and enable the operator to open the hot chamber with ease These cylinders must not be removed or detached at any point The double insulated doors of the high temperature hot chamber are heavy and hot when in use If either of the hydraulic door cylinders is altered the operator may be susceptible to injury from impact or burns Please refer to your Model 5080 Hot Chamber User s Manual for complete hot chamber operating details BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 17 Chapter 1 Introduction Exatron 3000B 5000 958
15. www exatron com 2 14 Chapter 2 Installation Exatron 3000B The Exatron Octoloader EXATRON S eight tube capacity automatic tube loading mechanism called the Octoloader will automatically load any device supplied in tubes into your EXATRON handling system The Octoloader assembly snaps onto the handler for easy conversion from one device size type to another The Octoloader is a moving plate that holds tubes of devices and is controlled by the handler s CPU via a stepper motor During production the plate automatically moves from side to side positioning each tube above the handler input track When the input track becomes empty the Octoloader automatically searches for tubes with devices A sensor mounted at the junction of the input track allows the Octoloader to see a device jam if one occurs The Octoloader will then stop moving to prevent damage to the jammed device In addition the Octoloader has an automatic wiggle cycle that will attempt to clear the jam automatically without operator assistance TO INSTALL FULL TUBES INTO THE OCTOLOADER 1 Tubes are installed upside down into the Octoloader 2 Raise the blue anodized tube gates if present on the Octoloader so that they are in the open or up position 3 Remove the stopper from the top of a full tube of devices Hold the lower half of the tube in your right hand and place the index finger of the left hand over the top of the tube to prevent the devices f
16. 5 ALL MOTOR CHECK Test Site Plunger Motor Check for further details Ifthe Clear button is pressed the handler will abort this error loop If the 0 button is pressed the handler will turn off the Z motor only The display will read MOTOR OFF To turn the Z motor back on press the Enter button Ifthe 1 or 7 button is pressed the Z motor will jog up one step If the 3 or 9 button is pressed the Z motor will jog down one step 4 button is pressed the Z motor will jog up 80 steps fthe 6 button is pressed the 2 motor will jog down 80 steps When the plunger does arrive at the upper limit stop switch the displayed message will change to Z MOTOR IS UP To verify that the stop switch is actually working correctly and not causing Z MOTOR NOT UP messages in error toggle the stop switch by moving the plunger away from and then back to the stop switch EXATRON recommends the following method 1 Push the Z plunger down manually or press the 6 button to jog the Z motor down 80 steps 2 Press the Enter button to automatically locate the Z limit stop switch and restart the handler ZERO COUNT ERR The operator has set the output tube full quantity to 0000 Set the count for more than 0000 Please refer to FULL TUBE message earlier in this section www exatron com 6 24 Chapter 6 Display Dictionary Exatron 3000B Chapter 7 Preventive Maintenance Overview This chapter d
17. A 3000B POWER SUPPLY WIRING 3000 A58 A 3000B CARD CAGE PCB POWER WIRING 5000 397 3 B 1 QUAD STEPPER DRIVER PCB ASSEMBLY 5000 397 2 1 QUAD STEPPER DRIVER PCB SCHEMATIC 5000 398 3 C TEST SITE DRIVER PCB ASSEMBLY 5000 398 2 TEST SITE DRIVER PCB SCHEMATIC 5000 A89 C 3 3000B FRONT PANEL PCB ASSEMBLY 5000 A89 C2 3000B FRONT PANEL PCB SCHEMATIC 5000 A89 3 A 3000B INPUT WIRING FOR OLDER 3000 CO KITS SCHEMATIC 5000 A89 4 B 3000B INPUT WIRING FOR NEW 30008 CO KITS SCHEMATIC 5000 066 3 OUTPUT DOOR PCB ASSEMBLY 5000 066 1 OUTPUT DOOR PCB SCHEMATIC www exatron com 8 2 Chapter 8 Drawings Exatron 3000B ELECTRICAL Continued 5000 JO2 47 37 B1 SHUTTLE AIR BLAST VALVE WIRING 5000 69 1 1 OUTPUT DOOR TUBE SWITCH CABLE 6000 517 C 3 TYPE 2 SWITCH BOARD ASSEMBLY 6000 517 1 2 SWITCH BOARD SCHEMATIC www exatron com 8 3 Chapter 8 Drawings Exatron 3000B www exatron com 8 4 Chapter 8 Drawings Exatron 3000B Chapter 9 Replacement Parts Overview Illustrations and Information for replacement sensors LEDs contactors output tubes and edge connectors are provided in this chapter beginning on the following page These parts may be ordered as needed from the EXATRON Sales Department between 8 00 AM and 5 00 PM Monday through Friday Please call for quote Our toll free telephone number is 1 800 EXA TRON For a complete listing of your handler s components includin
18. Exatron 3000B Exatron Super The Exatron Super interface allows for computer control of the handler tester programmer and label laser marker as a complete system This interface uses the handler s RS 232 Control Port to communicate with the controlling computer running Exatron E5000 laser software or Exatron Label Maker software The actual connection to the computer is usually COM1 COM3 or the first port on the Digiboard I O box This may vary depending upon your handler s configuration All aspects of production are controlled by the computer carrying out instructions as they are defined in a file called a Job Job files may be created edited and saved as desired by the operator All serial connections are 25 pin to 25 pin straight through If a special cable is needed for your programmer tester please provide Exatron with the pin out configuration or the cable itself so that we may furnish compatible interface hardware The communications settings are fixed in the firmware at 9600 Baud No Parity 8 Data Bits 1 Stop All serial devices connected to the Exatron controlling computer should be so configured The connector on the handler is a 25 pin RS 232 type connector with female pins The mating connector on the interface cable must use male pins The RS 232 side panel port uses the following pins Pin 1 GROUND Pin 2 RECEIVE input to handler Pin 3 SEND output from handler Pin 7 GROUND Typically this cab
19. Handlers with Hot Rails require 7 Amps at 110 VAC Electricity supplied to the handler must be within the specified operating ranges If the line voltage drops too low the handler may not function properly or may be seriously damaged Verify that correct operating line voltage is present If it is not contact Exatron for assistance SERVICE CALLS MADE TO THE CUSTOMER FACILITY TO CORRECT PROBLEMS CAUSED BY IMPROPER ELECTRICAL SUPPLY ARE NOT COVERED BY THE EXATRON WARRANTY Air Requirements Depending upon the type of Changeover Kit used the Model 3000B may require a filtered air pressure supply of 80 psi 5 cfm 3 PSI This air supply must be Clean containing no particulate matter greater than 5 microns in size Dry having a dew point of 36 F to 38 F and free of any oil To maintain these levels of pressurized air quality replace the coalescing 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 coat these air lines and the insides of the handler s cylinders causing them to stick or to stop functioning altogether The best defense against this kind of contaminate is to prevent it from occurring in the first place by maintaining the clean air supply described above If the ai
20. PASS and FAIL Sort Once a Sort Bin setting has been determined and saved in the handler s RAM we highly recommend saving the settings in the handler s EPROM as default settings Please contact the EXATRON factory for instruction on how to save RAM changes in the handler s EPROM 6 HANDLER OPENS TEST CONTACTS 7 DUT CYCLES TO AN OUTPUT TUBE A NEW CYCLE STARTS The following address in the handler s battery backed up RAM may be edited to fine tune the handler for your specific programmer tester and sorting requirements This address is not part of the standard power up selections and may be modified only by Changing The RAM as described in the Handler Set Up Chapter of this manual D TEST ASCII OUT ADDRESS 00AD This address stores the ASCII letter which the EXATRON RS 232 interface will use as an output on a double test The factory setting is an 53 in The user may wish to distinguish between START 1 TEST and a START 2 TEST The user may set this address to D 44 in HEX in which case the handler will issue an S on a First Test Cycle and a D on any Double Test Cycles www exatron com 3 21 Chapter 3 Interface Info Exatron 3000B HP RS 232 The HP RS 232 interface was originally added to the Model 5000 handler at the request of one of Exatron s customers at Hewlett Packard The customer wanted to use the basic Exatron RS 232 Interface with some additional information sent from the handler to t
21. Please refer to Diagnostics Chapter 5 for complete details FULL 12345678 One or more of the numbers shown above is displayed following the word FULL Please refer to the Diagnostics Tube Full Sensor Check section in Chapter 5 of this manual for details FULL TUBE There will be four digits displayed following the word _ _ _ _ This refers to the number of devices the handler will place into each of the handler s output tubes The number is adjustable up to 45 devices which would be displayed as 0045 Make certain to not set the count for more devices than will fit into the handler s output tubes Use the keypad to make your selection The handler accepts changes to each digit from lowest to highest in order First enter Ones then Tens then Hundreds then Thousands The minus key will set the count to 0000 Enter Sets your selection Clear Resets to the top of the handler s FULL TUBE 0045 loop This will also reload the handler s EPROM default values www exatron com 6 7 Chapter 6 Display Dictionary Exatron 3000B HANDLER OUT CHK Please refer to the Diagnostics INTERFACE CHECK Output Port Check Output Cover LED Check section in Chapter 5 of this manual for details HANDLER PAUSED You have pressed the PAUSE button The handler is now in a wait loop Nothing will occur until you press one or more of the handler controller s buttons WHILE THE HANDLER IS IN PAUSE MODE YOU MAY MAKE THE FOLLOWING FU
22. Please use this number when ordering this label CAUTION HIGH PRESURE AIR SOURCE Label shown actual size Dimensions 1 1 16 x 1 1 2 Colors Polished silver border and text on yellow background Your EXATRON handler may require pressurized air to operate various sub systems In such cases this cautionary sign made of aluminum will be affixed to the handler main plate next to the high pressure air source s Working with air under high pressure may be hazardous NEVER operate any EXATRON equipment which requires compressed air without an approved air regulator and shutoff valve lt is the responsibility of the customer to properly train all handler operators in every aspect of the safety practices associated with the use of compressed air BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 18 Chapter 1 Introduction Exatron 3000B 5000 967 Please use this part number when ordering this label CAUTION CONTAINS HOT SURFACES Label shown actual size Dimensions 1 1 16 x 1 1 2 Colors Polished silver border and text on yellow background This hot surfaces caution sign made of aluminum will be affixed to your EXATRON handler if it is equipped with a Hot Chamber The hot chamber is a completely enclosed double insulated compartment for pre heating devices prior to testing The interior heated tracks of some hot chamb
23. Valve 4 Solenoid Z4 Pickup Head Valve 5 Solenoid 5 N A 6 Solenoid 6 N A 7 Solenoid 7 Stack Solenoid 8 Solenoid 8 Index Solenoid 9 All Solenoids ON 0 All Solenoids OFF return to DIAGNOSTICS Menu www exatron com 5 3 YELLOW BUTTON WHITE BUTTON ORANGE BUTTON BLACK BUTTON GREEN BUTTON GREY BUTTON RED BUTTON BLUE BUTTON Chapter 5 Diagnostics Exatron 3000B 3 LIGHT POLE Optional Function Only installed on 3000B at customer request This routine is used to check the functionality of the light pole for those systems so equipped The buttons act as toggle switches for the lights As in the solenoid check the 0 key will turn all the lights off and the 9 key will turn them all on DEFINITION OF LIGHT UNDER NORMAL OPERATION 1 Green light Handler running parts normally 2 Amber light Handler is operating normally but requires operator intervention to continue For example a new tray of parts needs to be loaded 3 Red light Error in handler operation Handler will pause and error message will flash on the microterminal display Needs immediate operator intervention to resolve problem 9 All lights on For diagnostic purposes only 0 All off For diagnostic purposes only e to return to OUTPUT CHECK To return to DIAGNOSTICS Menu 4 CPU PORT CHECK N A to return to OUTPUT CHECK To return to DIAGNOSTICS Menu 3 key INTERFACE CHECK then 1
24. asking you to select one of the following seven package type cycles while in the MOD SET UP YS Mode 1 RUN PLCC PLUNGE 2 RUN DIPS PLUNGE 3 RUN SOIC PLUNGE 5 PLCC SWING HEAD 6 RUN DIPS 2800 7 RUN TYPE3 SOIC 8 RUN SOT Enter Sets your selection Clear Resets to the top of the handler s PICK PACKAGE 2 loop PICK UP ERROR 1 The handler has failed to pick up the device at the start of the pick up test cycle This message refers to Type 2 Swing Head PLCC Changeover Kits only PICK UP ERROR 2 The handler has completed a test It has failed to pick up the tested device and place it back into the handler s track This message refers to Type 2 Swing Head PLCC Changeover Kits only PLCC SWING HEAD This message is displayed during MOD SET UP YS Mode It is one of the package type settings which may be selected if your handler has a PLCC Swing Head Changeover Kit These kits may be referred to as Type 2 PLCC Kits PLEASE WAIT This message is displayed while the handler is powering up No action is required www exatron com 6 16 Chapter 6 Display Dictionary Exatron 3000B PLUNGE A four digit number will be displayed following PLUNGE _ _ _ _ This refers to the number of steps the plunger will move when placing the DUT into the handler s Pl contacts Each step of the motor is approximately 003 0640 is the factory default setting although the number of steps is adjustable Be careful not to
25. backed up RAM to store your desired binning data A chart with all relevant memory addresses is shown at the end of this document and on the Test Signal Bin Sort Data Worksheet To edit the Handler memory from the front panel display follow this procedure 1 0 Make sure you have a copy of the EXATRON supplied RAM address listing for your system While most handlers store the binning information as described in the chart on the worksheet some custom handlers have variations in addresses A copy of this address listing is in the supplemental chapter at the end of this manual 2 0 Verify that the handler is in Manual Mode Display will read MANUAL MODE 3 0 Press the SET UP key Display will read CHANGE RAM NO 4 0 Press the SET UP key Display will read CHANGE RAM YES 5 0 Press the Enter key Display will read LOAD DEFAULT NO 6 0 Press the Enter key Display will read 0090 DATA 01 The handler is now in the edit mode of the handler s battery backed up RAM 7 0 Press the SET UP key to increment the address The TOTALS key will decrement the address 8 0 Press the SET UP key until address 00 0 is displayed Display will read 0 0 DATA xx where xx is the hexadecimal data at that address Address 00 0 is the address where data for Sort Signal 1 is stored on standard handlers Note that LEDs on the output door are now flashing The flashing lights indicate which tubes are currently selected for Sort 1 If you change the da
26. calling the programmer company using the following information e The operator has likely used DATA l O firmware to improperly select the package type PLCC SOIC DIP etc 1 The file data sent to the programmer has test vectors that were written for a different package type This causes a problem for example when loading a file compiled for DIPs but the parts to be programmed are PLCCs 2 Refer to the DATA I O user s manual for instructions This subject is covered in the Communications Parameters section of the Commands chapter Follow the instructions entitled JEDEC I O Translate DIP LCC Vectors Y N to eliminate this programmer problem e The operator has possibly selected a device type not supported by the Data I O socket adapter 1 Use the correct Data I O socket adapter with the correct Data I O firmware and the correct translation format code for the Data I O programmer For Binary translation format send code 10 For JEDEC translation format send code 91 For Intel HEX translation format send code 88 2 Verify that you have entered the correct translation format code in the EXATRON control firmware and this problem should be eliminated 2 When click the RunALL icon at the start of a new job the monitor displays BD ERROR This error occurs when using a DATA I O programmer only The error message has been sent by the DATA I O programmer and is being displayed on your EXATRON equipment
27. drawn around a part you are trying to identify The dimensions of this cube can be checked against this size dimension and may be of assistance in determining a required part number When the parts list indicates another part number in the size column then the part was made by modifying an existing EXATRON part The modification is required for this handler only When ordering replacement parts be sure to use the part number and not the size the size column indicates see print then the part is made from sheet metal a PC board or is something which is not made from a solid cube of material 7 MATERIAL This designates the material from which the part was made The Material column may also indicate the manufacturer of the part 6061 6061 aluminum machined part 5052 5052 aluminum sheet metal WHT DEL White delrin plastic BLK DEL Black delrin plastic DEL AF Brown delrin High temperature plastic PEEK Very high temperature plastic beige in color TORLON Very high temperature plastic dark green in color G 7 High temperature fiberglass white in color G 10 FR 4 Standard fiberglass Either green or blue used in printed circuit boards SS Stainless steel See print for exact type BRASS Brass material PYREX Pyrex glass high temperature transparent LEXAN Lexan plastic high temperature transparent LEDEX Ledex solenoid modification ULTEMP Amber colored plastic high temp transparen
28. drive the DUT too far into the handler s contacts The device s leads probably will not be bent but you will cause handler contact device jams to occur In addition the life of the handler s contacts will be decreased if too much plunge is used Use the keypad to make your selection The handler accepts changes to each digit from lowest to highest in order First enter Ones then Tens then Hundreds then Thousands The minus key will set the count to 0000 Enter Sets your selection Clear Resets to the top of the handler s PLUNGE 0640 loop This will also reload the handler s EPROM default values PLUNGER NOT UP The test site plunger has failed to return to the top of the Z motor assembly when it should Press the 0 key to turn the motors off Check for mechanical jams and verify that the plunger moves freely up and down through its full cycle It is possible that the Z plunger is going up but the Z limit top position switch is not being depressed Verify proper operation of the switch by running Diagnostics ALL MOTOR CHECK Test Site Plunger Motor Z Motor Check as described in Chapter 5 Replace the felt pad used on certain changeover kit versions to close the Z assembly top position switch Press the Enter button to resume operation PROGRAM DEVICE This message applies when the handler is using the Program RS 232 control interface only Please refer to SET P V L MODE message below PROGRAM RS 232 Ple
29. edited to fine tune the handler for your specific programmer tester and sorting requirements These addresses are not part of the standard power up selections and may be modified only by Changing The RAM as described in the Handler Set Up Chapter of this manual BAUD RATE 009A This address stores the baud rate setting for the RS 232 serial port The RS 232 port uses the 25 pin RS 232 connector on the side of the handler 9600 Baud Default setting This address stores the data format setting for the RS 232 port 009A 06 19200 Baud 009A OC 009A 18 4800 Baud 009A 30 2400 Baud 009A 60 1200 Baud 009A 600 Baud 009A 80 300 Baud DATA FORMAT 0098 __ 0098 02 No parity 009B 2A Stick one 0098 Stick zero 0098 1A Even parity 009B 0 Odd parity 009B 06 No parity 0098 2E Stick one 0098 Stick zero 0098 1E Even parity 0098 OE Odd parity 009B 03 No parity 009B 2B Stick one 009B 3B Stick zero 009B 1B Even parity 0098 0098 07 parity 009B 2 Stick one 0098 Stick zero 0098 Even parity 009B OF Odd parity www exatron com 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 8 Data 8 Data 8 Data 8 Data 8 Data 8 Data 8 Data 8 Data 8 Data 8 Data 1 Stop 1 Stop 1 Stop 1 Stop 1 Stop 2 Stop 2 Stop 2 Stop 2 Stop 2 Stop 1 Stop Default setting 1 Stop 1 Stop 1 Stop 1 Stop 2 Stop 2 Stop 2 Stop 2 Stop 2 Stop Chapter 3 Interface Info
30. installed on the handler s Front Panel Card 5000 A89 The EOT signal when used will cause the handler to ignore all tester sort input signals until the EOT normally High active Low is received by the handler PAL 101 12 JED Sum check 7680 No signal required PAL 101 12EOT JED Sum check 75B0 EOT signal required by the handler CORRECT PALS MAY ALWAYS BE OBTAINED FROM EXATRON AT NO CHARGE Listed below are addresses in the handler s battery backed up RAM which may be edited to fine tune the handler for your specific programmer tester and sorting requirements These addresses are not part of the standard power up selections and may be modified only by Changing The as described in the Handler Set Up Chapter of this manual START PULSE WIDTH ADDRESS 0098 This delay controls the Start of Test pulse width The delay counts down in HEX in 1 millisecond steps The standard default is 14 This sets the start test pulse width to 20 milliseconds On interfaces using a PC to control the handler a longer start pulse width may be required to guarantee that the PC sees the start test pulse from the handler CHECK SORT RESET ADDRESS 00A6 00 On FF Off The Check Sort Reset feature should always be used on handlers which are employing the Handler Port interface This check verifies that all Sort signals to the handler are turned off at the end of the Start pulse all Sorts are at Logic High Occasions may arise dur
31. is using the PROGRAM RS 232 interface The handler is attempting to communicate with the programmer and cannot obtain a correct answer Verify the following 1 The programmer is turned on 2 The RS 232 cable is connected from the handler s RS 232 port directly to the programmer s RS 232 port labeled Handler on Autosites 3 The programmer is in Computer Remote Control CRC 4 The programmer s baud rate is set for 9600 The programmer s port set up is 1 stop 8 bits no parity www exatron com 6 22 Chapter 6 Display Dictionary Exatron 3000B UART OUT ERROR The handler s UART has detected an error Turn the handler OFF then ON and try again If the problem continues replace the handler s 8085 CPU PCB EXATRON part 3000 055 UP STEPS XX The handler is in the Automatic Z Plunger Top Position Adjustment routine At this point the plunger has jogged upward until it reached its top position The words UP STEPS will be followed by a number between 10 and 50 where the XX is shown above This number indicates the amount of steps necessary to close the top position micro switch Please refer to Automatic Z Adjust Feature in Diagnostics Chapter 5 for complete details VERIFY DEVICE Please refer to SET P V L MODE message earlier in this section VERIFYING The handler is using the PROGRAM RS 232 interface The handler 1 currently verifying a device with the programmer You may press the Clear button to abort the tes
32. latched causing the handler to mis sort If desired the PAL may be modified to one that requires an End of Test edge as well Further details are provided in the Handler Port Options section later in this chapter www exatron com 3 11 Chapter 3 Interface Info Exatron 3000B To abort the test press the Clear button on the handler controller This will sort the DUT to the Home bin output tube 5 Once the handler receives a sort pulse it checks that 1 The sort has a corresponding output If not you will see NO SORT ERROR displayed advising that there are no outputs available 2 Only one sort has been received Only one sort signal is allowed If multiple sorts were received you will see MULTI SORT ERR displayed The output shuttle cover LEDs will blink the pattern of the actual sorts latched by the handler Two or more LEDs will blink indicating the multiple sort error If the received sort pulse is acceptable the contacts will open and the device will be sorted to an output tube Or in the case of plunge to board changeover kits the test site plunger will pick up the device and rise to its highest point From there the device will be sorted to an output tube Handler Port Options EOT END OF TEST The handler port is controlled by two PAL devices These PALs control the polarity of the handler s input output signals and whether EOT is to be used or not The EOT input pin 13 is not active unless the correct PAL is
33. meet your specific application requirements www exatron com 3 1 Chapter 3 Interface Info Exatron 3000B General Interface Options and Set Up Accessing a Handler Control Interface When the handler powers up you will be given the opportunity to PICK INTERFACE If you press the Enter button the previously selected interface or default interface if RAM was cleared will be selected Listed below are the standard interfaces currently supplied with the handler NOTE New interfaces are added to the handler from time to time Please contact EXATRON for updates as required Our toll free telephone number is 1 800 EXA TRON From PICK INTERFACE displayed on the front panel 1 Key Sets the handler to use HANDLER PORT 2 Key Sets the handler to use EXATRON SUPER 3 Key Sets the handler to use RS 232 NOTE FOR LABEL TEST LABEL ONLY AND TEST ONLY OPTIONS PLEASE REFER TO THE MODEL 3000B L USER S MANUAL 4 Key Sets the handler to use PROGRAM RS 232 5 Key Sets the handler to use RS 232 Enter Key Sets your choice into the handler Clear Key Rejects selection and returns to PICK INTERFACE General Interface RAM Selections Listed below are addresses in the handler s battery backed up RAM which may be edited to fine tune the handler for your specific programmer tester and sorting requirements when using either the Handler Port parallel or the RS 232 serial port
34. motor control cable is plugged in and is not broken 4 Replace the Motor Driver Module and or the Motor Control PCB 5 Contact EXATRON for assistance and replacement parts MOTOR OFF The stepper motor being checked is now off MOVE MOTOR DOWN The plunger motor has moved downward MOVE MOTOR UP The plunger motor has moved upward www exatron com 6 13 Chapter 6 Display Dictionary Exatron 3000B MULTI SORT ERR The handler is at end of the test cycle More than one sort command from the tester has been received The output cover LEDs will flash the sorts which were received by the handler Check whether your tester is working correctly Check your interface cables for short circuited connections Press the Enter button to ISSUE NEW START and to clear the handler s input latch If you are using an EXATRON LED Checker as a simulator make sure that only DIP switch 1 is turned ON NO BIN TIME OUT The handler has a timer which runs during testing This timer can be set to desired length in the handler s RAM If no bin signal is received from the tester before the timer times out the handler will turn off all solenoids and display this message Press the Enter button to Restart the test or Press the Clear button to Abort the test and flush the device in the test site NO OUTPUT TUBES The handler 1 trying to sort a device to an output tube but no tubes are available Check the handler s output cover an
35. page for timing diagrams of several 2ND START set up examples If you are having interface problems please call the EXATRON factory for free customer service advice Our toll free telephone number is 1 800 EXA TRON EXATRON cannot be held responsible for mis sorted devices when the tester s sort signal timing is not correctly set up and fully understood by the customer www exatron com 3 13 Chapter 3 Interface Info 7 30008 FIGURE 3 3 20 _ START PULSE PIN TO au C 0098 DATA 14 20 MSEC ioe 2ND START 0008 DATA 00 HANDLER INPUT y 2ND START DELAY SORTS NOW READY 0009 DATA START 20 MSEC 0098 DATA 14 20 5 5 MSEC ENS RM 2ND START 0008 DATA 14 2ND START DELAY 4 20 h 0009 05 _ 5 MSEC 20 MSE START UG START PULSE 0098 14 20 MSEC 10 MSEC START 2ND START TS 10 MSEC 0008 28 20 2ND START DELAY 00 40 MSEC j 09 DATAN a 0 START 20 MSEC e ee eign Re NAO 0098 DATA 14 20 MSEC 10 MSEC END STAG 2ND START ane 0008 1 36 2ND START DELAY 0009 DATA 00 30 MSEC www exatron com 3 14 Chapter 3 Interface Info Exatron RS 232 Interfaces 3000B EXATRON SUPER EXATRON RS 232 RS 232 PROGRAMMER RS 232 RS 232 Port Options Listed below are addresses in the handler s battery backed up RAM which may be
36. port LED CHECKER To enter Diagnostics Mode press the DIAGNOSTICS button on the handler s controller The display will read DIAGNOSTICS You may enter Diagnostics Mode whenever the handler powers up is in the READY TO RUN Mode or is in the MANUAL Mode MICROTERMINAL DISPLAY gt a 5 6 _ stue _ muse 7 9 J rows S08 a www exatron com 5 1 Chapter 5 Diagnostics Exatron 3000B You may also enter Diagnostics Mode during most automatic device jam clearing cycles when the output tube cover LEDs are flashing Diagnostics Mode is accessed during a jam the handler will exit its automatic jam clearing cycle and enter Diagnostics When Diagnostics procedures are complete the handler will return to its previous place in the program upon exiting Diagnostics In most cases if the jam is cleared during Diagnostics the handler will also automatically restart after returning from Diagnostics NOTE On some custom machines there are more options available inside DIAGNOSTICS See the supplement at the end of this manual for all the functions available on your particular handler Diagnostics Quick Reference pal This symbol means Press the Enter button DIAGNOSTICS Enters DIAGNOSTICS Menu 1 key SENSOR CHECK then 1 key SENSORS 0 7 then 1 PICKUP HEAD VACUUM to return to SENSOR CHECK 2 INDEX SENSOR to return to SENSOR CHECK 3 PART PRESENT AT PICKUP to return
37. reset check OFF You may press the Enter button so that the handler will ISSUE NEW START This may reset the input signals and allow the handler to continue operation NOTE Turning off the sort check will allow the handler to be cycled with an EXATRON LED Checker but it may also cause the handler to missort by using previous cycle sort information from testers with poor interface controls We recommend leaving this check ON www exatron com 6 19 Chapter 6 Display Dictionary Exatron 3000B START 1 TEST The handler has issued a Start Test command to the tester PC START 2 TEST The handler has detected a failure on the first test and is attempting to double test the device A second Start Test command possibly more has been sent to the tester PC STOP ON FAIL STOP ON FAIL STOP ON FAIL NO STOP ON FAIL YS 1 The handler is in the STOP ON FAIL YS mode that is stopped with plunger down contacts closed and a device in the test site 2 The handler stopped because it received a fail at the end of the test 3 You may press the Enter button to proceed past the stop 4 You may press the Clear button to flush the device out of the test site 5 You may press the 1 key to pick up the device reseat it and test it again If the device passes this time operation will continue If the device fails then the handler will again STOP ON FAIL 6 You may press the 2 key to test the device again without removing it from th
38. right hand stop 1 Not used 2 Not used 3 Not used 4 Not used 5 OPTIONAL Fiber optic test site 6 Top of rail sensor 7 Octo rail gap sensor 8 Octoloader right hand stop limit switch If this feature which detects device in test site is not functional 1 The on off ROM address listing may be required Please contact the EXATRON factory for assistance 2 Verify that the switch on the sensor controller part number E3X A11 is set with L ON and D ON 3 The front panel PCB part number 5000 A89 may require a PAL update Please contact the EXATRON factory for assistance Pressing the Clear button will flash the terminal s displayed message to confirm the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check www exatron com 5 18 Chapter 5 Diagnostics Exatron 3000B Modified Automatic Z Adjust Feature All EXATRON 3000B Series Plunge to Board handlers come equipped with a modified version of our automatic Z plunger top position adjustment After the operator performs certain initializing functions manually the handler automatically positions the plunger s pick up block to correctly intercept and secure the DUT before plunging it to the contacts Proper plunger positioning is important for the smooth operation of the Model 3000B The following plunger self adjustment operation should be implemented whenever the device size is changed so that the h
39. step This new setting will be used in the next cycle also www exatron com 6 20 Chapter 6 Display Dictionary Exatron 3000B 10 You may press the 7 key This key only operates when the PROGRAM RS 232 interface has been chosen The handler will display SET P V L MODE Select one of the following operations 1 PROGRAM DEVICE Sets the handler to bit check and Program the device in the handler 2 VERIFY DEVICE Sets the handler to Verify the device in the handler 3 LOAD DEVICE Sets the handler to Load data from the device to the programmer RAM Enter Sets your selection Clear Resets to the top of the handler s SET P V L MODE 11 You may press the 8 key The handler will now display STOP ON FAIL Choose to make the handler either stop on fail or continue operation If STOP ON FAIL YS is chosen then the handler will stop operation at every DUT test failure the handler receives The handler provides many helpful troubleshooting operations while the DUT is in the contacts and STOP ON FAIL is displayed by the handler 1 STOP ON FAIL YS Stop on fail is now ON 2 STOP ON FAIL NO Stop on fail is now OFF Enter Sets your selection Clear Resets to the top of the handler s STOP ON FAIL loop SUM ____ Four alphanumeric characters will be displayed following the message shown above The handler is using the PROGRAM RS 232 interface The handler has just completed a successful data lo
40. the 2000B Series handlers are equipped with a broad range of features found in all EXATRON handlers including e Wide Variety of Device Handling Capability e Quick Changeovers Using Modified Snap On Change Kits e Variety of Interfaces Positive Binning e Plunge to Board Test Contact Mechanism e ESD Safeguards The Model 5000 Series of Production Handling Systems The 5000 Series of production handlers integrate any combination of customer specified ambient temperature programming test sites hot chamber s elevated temperature test site s and a smart laser marking system In addition automatic tube loader reloader components from various manufacturers may be integrated into EXATRON s Model 5000 when the laser marking system option is specified When equipped with a laser marker the entire system is controlled by a single 80486 33 computer One or more test sites are available on all of the various Model 5000 configurations The EXATRON Model 5000 Series of Heavy Duty Handling Systems are ideal for automating high volume program test and mark applications www exatron com 1 5 Chapter 1 Introduction Exatron 3000B FIGURE 1 1 A OCTOLAODER MOTOR B TILT MECHANISM C AIR REGULATOR D SERIES 3000B REMOTE POWER SUPPLY BASE PLATE Please refer to drawing 3000 215 for base plate bolt down hole pattern ALL BENCHTOP HANDLERS MUST BE SECURELY BOLTED TO THE TOP OF THE WORKBENCH F TEST HEAD DOCKING BLOCK G SHU
41. the contacts Immediately check the handler contacts and remove any dropped device If the message 2 MOTOR CRASH only is displayed the device has been picked up but the Z plunger and the device are too high up You may press the Clear button to flush all devices from the handler and start over You may also run the Self Adjust Z Procedure as described at the end of Chapter 5 Diagnostics CHECK EXIT SEN A device may have become jammed when exiting the test site en route to the output shuttle or the Exit Sensor 5 may not be working properly First visually inspect the exit track and free any jammed devices If this does not resolve the situation run the Test Site Sensors 1 Through 8 Diagnostic as described in Chapter 5 CHECK PICK UP The handler has indexed a device but the pick up sensor has not located this device in order to pick it up for testing programming The device may be jammed or the Test Site Pick up Sensor may not be working properly First visually inspect the test site and free any jammed devices If this does not resolve the situation run the Test Site Sensors 1 Through 8 Diagnostic as described in Chapter 5 CHECK SUM ERROR The programmer tester PC has sent new RAM data to the handler The handler has calculated the check sum for the file and it does not match the check sum sent by the programmer tester PC Press the Enter button to skip past this error From the programmer tester PC stop the
42. there Manually clear the jammed device and the handler will automatically restart Or press the Clear button to thump the test rail clears many jams common to this area Or press Enter to try the load cycle again NOTE This may cause DOUBLE PART ERR messages to appear ISSUE NEW START The handler has been instructed by the operator to send a new start test pulse to the tester PC JOG DOWN The plunger has moved down one step about 003 JOG LEFT The shuttle octoloader has moved one step left about 006 JOG OCTOLOADER This message is displayed during power up while the handler is self aligning the octoloader No action required JOG RIGHT The shuttle octoloader has moved one step right about 006 JOG SHUTTLE This message is displayed during power up while the handler 1 self aligning the shuttle No action required JOG UP The plunger has moved up one step about 003 LOAD DEFAULT NO Exits routine without reloading the EPROM default settings into the handler s RAM Enter will exit with no changes SET UP will toggle back to LOAD DEFAULTS YS LOAD DEFAULT YS Allows the operator to reload the handler s RAM with settings stored in the handler s EPROM Enter will load defaults from EPROM to RAM SET UP will toggle back to LOAD DEFAULTS NO www exatron com 6 10 Chapter 6 Display Dictionary Exatron 3000B LOAD DEVICE Please refer to SET P V L MODE message later in this sec
43. tube or the handler can be set to stop If set to STOP ON FAIL YES then the handler will stop on a failure and allow the operator to retest the device again and again as often as desired This is very useful when calibrating test fixtures and programs Gate Delay Address 00 This delay allows additional time for the test site gate to first open and then secondly allows additional time after the handler closes the gate at the end of the test cycle The delay counts down in HEX in 10 millisecond steps This feature applies to Plunge to Board changeover kits only Double Test Sort Address 00BC This address tells the handler which test sorts to double test if desired A setting of 00 will turn off the double test for all sorts A setting of FF will set the tester to double test all devices Assuming Sort 1 is Pass and all other sorts are to be double tested set this address to FE Each bit represents a tester sort Tester Sort Set Up Addresses 00CO to 00C7 1 RAM ADDRESS CO RAM ADDRESS C2 RAMADDRESSC Remote Flush i USED BY EXATRON RS 232 a Te AN AND RS 232 ONLY 0 i i Remote Retest i USED BY EXATRON RS 232 1 i 9 232 ONLY The handler uses the specifications shown in the table above to assign Output Bins to tester Sorts The Current Setting column is provided for the customer s reference purposes Please enter your settings in this column If the handl
44. using the keypad keys as described below 1 Jog the octoloader left display will read JOG LEFT 3 Jog the octoloader right display will read JOG RIGHT After alignment is complete press the Enter button again to resume operation This entire octoloader alignment procedure may be repeated as necessary If you have any trouble with this procedure call the EXATRON factory for assistance Our toll free telephone number is 1 800 EXA TRON www exatron com 7 2 Chapter 7 Preventive Maintenance Exatron 3000B Monthly Maintenance arrer 160 HOURS OR MORE OFTEN AS NEEDED 1 8 Check the shuttle chain for signs of wear Broken or worn links will cause the handler to jam and may cause damage to your devices Replace chain as necessary Check all exposed flat ribbon cables for worn insulation Replace as necessary Check all solenoid plunger tips and their dowel pins for wear Replace as necessary Run the full HANDLER DIAGNOSTICS sequence detailed in Chapter 5 of this manual to detect any malfunction in all switches sensors solenoids motors displays and ports Check the shuttle chain tension When approximately five pounds of pressure is applied by hand to the center of the shuttle chain it should deflect not more than 1 4 inch Tighten the tension as needed by adjusting the red metal return block part 5000 370 which holds the right hand sprocket of the shuttle chain To do so loosen the two Allen screws holding the re
45. x 20 x1 50 long bolts and two lock washers mount the plate hanger blocks onto the frame threaded end up These holes are marked G on FRED detail Figure C Do not tighten the bolts yet 5 Remove the handler main plate 3000 301 from the base plate 3000 216 Remove the hinges and the tilt blocks 6 Using two 1 4 x 20 x 62 long bolts and two lock washers bolt the handler to the plate hanger blocks on the frame through the holes marked G on FRED detail Figure C 7 Using four 1 4 x 20 x 1 37 long bolts and four lock washers bolt the handler main plate to the frame through the four tapped holes on the main plate also used by the base plate hinges These holes are marked E on FRED detail Figure C 8 Verify that the slide angle and handler height are correct for your application then tighten all bolts on the frame risers rigid support bars and uprights 9 TRAY OPTION Using three 1 4 x 20 x 2 50 long bolts three lock washers and three 1 4 x 20 hex nuts bolt the tray extension frame to the bottom edge of the FRED frame Tighten all three bolts DETAIL C 1 37 O 10 DIA 02 F a 7 15 OOO OZ21 F LRE HINGE TAPS IN MAIN PLATE _ 4 ALCS 20 1 57 5 E 1 4 20 x 1 50 2 7025 G 4 20 x 62 7 705 www exatron com 2 6 Chapter 2 Installation Exatron 3000B UNPACKING HOT RAIL HANDLERS MODEL 3010B Tools required One standard flat blade
46. 0 003 4 key The plunger will move up five steps or as far as the Z upper limit switch whichever comes first 5 key The plunger will move up until it finds the Z upper limit switch 6 key The plunger will move down five steps 7 key The plunger will move up the current up steps setting 8 key N A 9 key The plunger will move down the current up steps setting www exatron com 5 19 Chapter 5 Diagnostics Exatron 3000B 5 BEGIN MOVING THE PLUNGER DOWN USING THE 6 KEY FIRST then the other keys as needed Stop when you can see the pick up head just start to compress against the gate as viewed from above the plunger 6 PRESS THE Enter BUTTON to start the self adjust operation 7 THE HANDLER WILL DISPLAY JOG DOWN QUICKLY FOLLOWED BY JOG UP The plunger will jog down until the pick up head trips the test site sensor The index section will singulate a device which will come to rest against the pick up head The plunger will jog up enough to allow the DUT to fall into position in the test site 8 THE HANDLER WILL DISPLAY Z DOWN PART TOP The plunger will then jog an additional three steps up to allow enough clearance for the DUT to rest against the pick up block s stop The vacuum will then turn on and hold the device against the pick up block 9 THE HANDLER WILL BRIEFLY DISPLAY FOUND PICK UP The plunger will begin to jog up in the Z plunger assembly 10 AS IT DOES THE HANDLER WILL DISPLAY UP STEP
47. AC heaters are located within the Hot Exceptional temperature control is maintained by constantly monitoring four points in the Rail and four points in the Test Site The guaranteed accuracy is 3 C everywhere in the Soak Rail and 2 in the Test Site All four zones in the hot rail are controlled by an EXATRON designed computerized temperature controller The input of the Hot Rail has a manually operated two input tube holder assembly All Model 3010B Handlers are supplied with a Free Rolling EXATRON Dolly FRED For operation the handler is to be mounted onto this floor stand which has four large tires for easy positioning and four floor jacks to lock it into place Also Available From Exatron The Model 2000B with Two Tube Manual Input The Model 20008 is an ambient handler with a manually operated two input tube holder assembly for low to mid volume handling applications The tube holder must be manually shifted when one tube of devices empties in order to present another tube of devices to the input track The Model 2000B uses Snap On Change Over Kits to accommodate various size packages The tube holders are custom machined to a specific tube size and are included as standard equipment with Model 2000B Snap On Change Over Kits All Model 2000B Handlers are supplied with bench top base plates which must be bolted directly to a bench or table top to secure the handler Although smaller and less expensive than our Model 3000B
48. AM YES will appear Press Enter The message LOAD DEFAULT NO will appear If you choose LOAD DEFAULT NO the handler will leave all RAM addresses as they were From LOAD DEFAULT NO you may proceed in either of two directions A If you wish to make specific changes to the RAM and do not wish to load the default values press Enter again The display will read 0090 DATA 01 Proceed directly to step 4 of this procedure B If you do wish to set the RAM with ROM values press SET UP to toggle the YES NO option of the LOAD DEFAULT message to YES Press Enter BLASTING THE RAM When you choose LOAD DEFAULT YES the handler loads all default addresses from the EPROM to the RAM After loading the EPROM into the RAM you may still make specific RAM changes as described below if you wish Or you may proceed directly to step 5 Press SET UP or TOTALS to scroll through the addresses The SET UP button will scroll the address up The TOTALS button will scroll the address down Press the Space button to increment the upper data nibble in any individual address as desired Press the Delete button to increment the lower data nibble in any individual address as desired Press the minus button to set a specific address to FF Press the zero key 0 to set a specific address to 00 Press the Clear button to load the default value from the EPROM into the RAM for a specific address only To exit the CHANGE RAM mode press Ente
49. ANGE BUTTON 4 Solenoid 4 4 BLACK BUTTON 5 Solenoid 5 5 GREEN BUTTON 6 Solenoid 6 6 GREY BUTTON 7 Solenoid 7 7 RED BUTTON 8 Solenoid 8 8 BLUE BUTTON 9 Solenoids ON ALL On 0 All Solenoids OFF ALL Off Pressing the Clear button will flash the terminal s displayed message to confirm the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check and return to the DIAGNOSTICS message www exatron com 5 10 Chapter 5 Diagnostics Exatron 3000B v INTERFACE CHECK RS 232 Check Control Panel Check For external Handler RS 232 port this diagnostic tests port 28 29 2A 2B 2C 2D 2E located on PCB 3000 055 PAL ROB 1 U11 U15 For internal Front Panel RS 232 port this diagnostic tests port F8 F9 FA FB FC FD FE located on PCB 5000 89 U1 UART Connect a remote terminal to the Handler s RS 232 port NOTE The handler may be set up to use any number of baud rates and stop parity bits The standard factory settings are RAM ADDRESS 009A OC 9600 BAUD RAM ADDRESS 0098 03 1 STOP 8 BITS NO PARITY TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 3 key Handler displays INTERFACE CHECK Press the 1 key Handler displays RS 232 CHECK Press each of the handler terminal s keys buttons save Enter for last As you do the correct ASCII character 0 should appear on the dumb terminal Send any ASCII character to the han
50. CE STOP ON FAIL PICK PACKAGE PLUNGE Plunge to board changeover kits FULL TUBE MODEL 3000 B Power up message no action required www exatron com 6 12 Chapter 6 Display Dictionary Exatron 3000B MOTOR A BUSY shuttle MOTOR B BUSY Z Motor Test Site Plunger MOTOR BUSY Octoloader MOTOR D BUSY optional May Not Be Used The handler is checking to see if the stepper motor is moving as needed for each of the above handler components If this message does not go away within a few seconds the handler will not operate To resolve this condition 1 Turn the handler power OFF then ON and try again 2 Check whether the motor setting address in RAM is correct RAM ADDRESS 0091 3 Verify that the motor control cable is plugged in and is not broken 4 Replace the Motor Driver Module and or the Motor Control PCB 5 Contact EXATRON for assistance and replacement parts MOTOR A ERROR shuttle MOTOR B ERROR Z Motor Test Site Plunger MOTOR C ERROR Octoloader MOTOR D ERROR Optional May Not Be Used The handler is checking to see if the stepper motor is powering up properly as required for each of the above handler components If this message does not go away within a few seconds the handler will not operate To resolve this condition 1 Turn the handler power OFF then ON and try again 2 Check whether the motor setting address in RAM is correct RAM ADDRESS 0091 3 Verify that the
51. Call us for details www exatron com 7 6 Chapter 7 Preventive Maintenance 30008 Exatron FIGURE 7 1 EXATRON POWER SUPPLY 3dAL 3215 19VX3 391438 3933 3dAL 12 53513 30vid3M ev 353H5 ANO 32435 ISN WN8I31NI SVH 5 H9IH NOILQVO DIA S L 90A Z 99LEdNS LINMAS 2300 4 13502 AIddNS SQA S AlddNS 2 1fidNI TYSU3AIND OGAS 9 7 Nid 1 D a nct li MEAT i 19131580 3 1ON OQ 3574 INPOOD 90A vZ 140 LNO NO NI 5 H3MOd NIVN 43MOd ONINOON OL Q3193NNOO NO LHOM 3504 OV Alddns HOlv nod ANS 43MOd JO MOVE M3MOd JO INOJ Chapter 7 Preventive Maintenance 7 7 www exatron com Exatron 3000B General Solenoid Maintenance Guidelines 12 13 Keep the solenoids as clean as possible If the handler is used with devices which have excessive mold flash the solenoids will require cleaning regularly The frequency is dependent upon how much mold flash gets into the solenoids NEVER use oil or lubricant of any kind on solenoids When cleaning solenoids take care not to put excessive stress on solenoid wiring Check all wiring for signs of wear exposed conditions or broken connections Replace as needed
52. DS 6000 290 SOCKET HANDLE 6000 272 THRU 278 SOCKET 6000 537 REPLACE Pl FINGERS PCB 6000 250 REPLACEMENT FOAM PAD 6000 612 REPLACEMENT HOLD DOWN SPRING 6000 624 ONLY REPLACEMENT GOLD FINGERS PCB www exatron com 9 12 Chapter 9 Replacement Parts Exatron 3000B PLCC MCT PI G PINS EXATRON 5000 528 UNIVERSAL PLCC CONTACT LIVE BUG MCT FOOT PRINT 20 28 32 44 52 68 84 PIN PLCC LCCS 6000 540 BOTTOM SIDE OF CONTACT www exatron com 9 13 Chapter 9 Replacement Parts Exatron 3000B PI G I PINS EXATRON 6000 354 20 28 32 PIN PLCC LIVE BUG CONTACT MCT FOOT PRINT BOTTOM SIDE PCB TOP SIDE OF PCB O O O 9 m i i O O 024 DIA PINS STANDARD BYPASS CAP DETAIL eae AXIAL DEVICE GUIDES 6000 272 20 PIN PLCC OUTSIDE ROW V 6000 273 28 PIN PLCC ee 6000 274 32 PIN PLCC NOT SHOWN ON TOP VIEW www exatron com 9 14 Chapter 9 Replacement Parts 30008 SOIC 050 Exatron NEY PINS 05 EXATRON 2700 059 2700 058 gt 05 12700 055 2700 054 05 42700 057 EXATRON 42700 056 HEADER PCB 43044 386 1 Chapter 9 Replacement Parts 9 15 www exatron com Exatron 3000B SOIC NEY PI
53. EXATRON LED Checker into the handler s control port The checker has four LEDs which may be used to check the first four outputs from the handler port As output 1 flashes so should the corresponding LED on the checker etc Press the Enter button to EXIT this diagnostic check www exatron com 5 12 Chapter 5 Diagnostics Exatron 3000B v1 INTERFACE CHECK Input Sort Check This diagnostic tests port 14 located on PCB 5000 A89 PAL A89 2 TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 3 key Handler displays INTERFACE CHECK Press the 3 key again Handler displays SORT INPUT CHK Plug the EXATRON LED Checker into the handler s control port Slide each of the LED checker s eight position DIP switch micro switches As you do the corresponding red output cover LED will turn on These input signals should be latched and saved by the handler Anytime you wish to reset the interface latch turn off all of the DIP switches and then press the handler controller s 1 key Output Cover Handler Interface 24 pin D Connector LED Input Pin 1 Sort 1 2 Sort 2 3 Sort 3 4 Sort 4 5 Sort 5 6 Sort 6 7 Sort 7 8 Sort 8 13 Special order only Pressing the Clear button will flash the controller s displayed message to confirm that the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check www exatron c
54. Interface PCB 00 Turn option on FF turn option off 00 Check Sort Reset FF 00 FF Allows the handler to check whether all sort signals are OFF at the start of the test To enable this option set this address to 00 To disable this option set this address to FF Set this to FF when using LED checker boxes for simulation purposes www exatron com 4 7 Chapter 4 Handler Setup Exatron 3000B ADRS DESCRIPTION ROM RAM COMMENTS OPTIONS 00 7 Wiggle Octoload 00 FF To wiggle the octoloader as it moves from track to track or during a jam 00 Wiggle Octoloader FF Wiggle turned off 00A8 Octo 0 4 8 Tubes 00 04 00 setting is for no octoloader hand input 08 04 sets octoloader for 4 tube input 08 sets octoloader for 8 tube input 00A9 Pick up Delay 00 to FF Time delay to allow the DUT to settle before turning on the vacuum to pick up the DUT prior to plunging The delay counts down in HEX in 10 millisecond steps Stop on Fail Y N Set to 30 The handler will not stop on fail and the Stop on Fail set up question is enabled allowing Stop on Fail to be turned on off at any time Display Set to FF The handler will stop when a fail sort is Diction received from the tester The Stop on Fail set up ae further question is turned off details See Address 0088 for Stop on Fail Sort s setting Gate Open Delay 10 00 to FF Time for Gate to open on PLCC Type 4 CO Kits Counts down in HEX in 10
55. KET 05 PITCH 3000 311 5 015 THICK 20 PINS PER GROUP 05 PITCH Chapter 9 Replacement Parts Exatron 3000B BUILD YOUR OWN PI G I PINS 6000 540 32 PIN 6000 540 28 BeCu Pl 1 PINS 05 PTICH 21 PINS PER STRIP www exatron com 9 29 Chapter 9 Replacement Parts Exatron 3000B BUILD YOUR OWN PI GI PINS 8 O 2214 6000 561 10 6000 581 SHORT PIN SPECIFY OF PINS SPECIFY OF PINS 100 PITCH 100 PITCH 6000 645 LOGUE 6000 349 LOGUE GOLD GI PINS COATED PINS 2 GROUPS PER ASSEMBLY 2 GROUPS PER ASSEMBLY 05 PITCH FOR 20 28 32 DEVICES 05 PITCH FOR 20 28 32 DEVICES 6000 293 44 2 GROUPS ASSEMBLY 05 PITCH FOR 20 28 32 44 DEVICES www exatron com 9 30 Chapter 9 Replacement Parts Exatron 3000B oU PICH G I PINS 6000 642 20 PINS PER GROUP 6000 643 p 20PINS PER GROUP 475 www exatron com 9 31 Chapter 9 Replacement Parts Exatron 3000B o 5 q q 52 3044 537 3044 538 20 PIN PLCC 28 PIN PLCC LIVE DEAD BUG LIVE DEAD BUG 5 52 72 3044 539 3044 540 32 PIN PLCC 44 PIN PLCC LIVE DEAD BUG LIVE DEAD BUG 5 q q 82 1 02 3044 578 3044 564 52 PIN PLCC 68 PIN PLCC LIVE DEAD BUG LIVE DEAD BUG STANDARD EXATRON EXTRUDED TUBES STANDARD LENGTH 21 SCALE 2 1 JUNE 1996 www exatron com 9 32 Chapter 9 Replacement Parts Exat
56. LD lt 7 E ili af SOCKET HOOD 6000 287 DOES NOT INCLUDE HOLD DOWN HANDLE REPLACEMENT SPRING CLIP 5000 288 HOLD DOWN HANDLE 6000 290 HOLD DOWN SPRING 6000 612 6000 540 PIN 6000 615 GOLD REPLACEMENT PINS PCB ASSEMBLY 6000 537 PI OR 6000 624 ONLY GOLD www exatron com 9 7 Chapter 9 Replacement Parts Exatron SOOO PECG 6000 616 6000 5617 6000 614 6000 619 6000 620 6000 621 6000 622 www exatron com 9 8 Chapter 9 Replacement Parts Exatron 3000B O 6000 271 NO CUT OUT REPLACEMENT PAD 6000 250 www exatron com 9 9 Chapter 9 Replacement Parts Exatron 3000B PLCC 24 PIN PINS EXATRON 6000 607 24 PIN PLCC LCC CONTACT 6000 540 PIN NOTE USE WITH 6000 289 HOOD HANDLE ASSEMBLY www exatron com 9 10 Chapter 9 Replacement Parts Exatron 3000B PECE G I PINS SQUARE END UNIVERSAL SOCKET Lm PINS 6000 615 CUSTOM 32 PLCC LCC CONTACT ASSEMBLY 5000 J47 B www exatron com 9 11 Chapter 9 Replacement Parts Exatron 3000B PLCC DIO PINS GOLD PINS E 6000 540 P 6000 615 GOLD SE BO EA 1 AS A A Zhu o e J EXATRON 3900 AUTOSITE PLCC SOCKET 6000 551 WITH HANDLE AND ALL HOODS 6000 551 ONLY NO CLAMP NO HOO
57. MOVE WITH HANDLER POWER ON IN HOUSE ONLY THIS ORDER CONTAINS PARTICLE INTERCONNECT 5000 494 DANGER DO NOT REMOVE OR DETACH 5000 958 CAUTION HIGH PRESSURE AIR SOURCE 5000 967 CAUTION CONTAINS HOT SURFACES Availability of Warning Labels Current laws pertaining to the cautionary labels required to be installed on electronic equipment vary from state to state EXATRON makes every attempt to comply with all known labeling laws and safety considerations as they relate to our component handling systems In effect virtually every surface of the handler could be covered with warning signs and labels For aesthetic reasons we choose to produce a machine with a less cluttered appearance while still providing adequate visual caution indicators Individual customers may wish to obtain additional labels to facilitate safe operation and service for this or other electronic equipment in use at their locations The labels listed above are shown in detail on the following pages and may be purchased from the EXATRON factory as desired Our toll free telephone number is 1 800 EXA TRON www exatron com 1 8 Chapter 1 Introduction 30008 F LABO3 001 Please use this part number when ordering this label DANGER INVISIBLE LASER RADIATION WHEN OPEN AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION Label shown actual size Dimensions 3 x 1 Colors Red and black on white background This laser caution
58. Model 30008 Gravity Feed Automatic Component Handling System User s Manual IIBIBINIDINIBIDII 16 84 s N UCI ROO Mg I Qi IQ 3 FOX Version 3 0 3 June 5 2001 e Exatron Inc 2842 Aiello Drive San Jose California 95111 408 629 7600 Tel 800 exa tron Tel 408 629 2832 Fax www exatron com Exatron 3000B www exatron com ii TOC Exatron 3000B TABLE OF CONTENTS www exatron com i TOC Exatron 3000B www exatron com ii TOC Exatron 3000B www exatron com iii TOC Exatron 3000B www exatron com iv TOC Exatron 3000B Chapter 1 Introduction This user s guide provides installation operation and maintenance information for all 3000B Series Handlers The EXATRON Model 3000B Handler 1 a tube to tube gravity feed eight sort handler designed for a wide variety of package types both surface mount and through hole technologies using Snap On Changeover Kits to convert from one device size to another Model 3000B Overview EXATRON S Model 30008 Series of automatic component handlers integrates customer specified ambient temperature programming test sites elevated temperature soak tracks and up to eight automatic device inputs and outputs The EXATRON Model 3000B retains the best features of the original Model 3000 including compatibility with most older 3000 Series Changeover Kits and incorporates many technologi
59. NCTION CHANGES IN ANY ORDER PLUNGE DEPTH Plunge to board change kits Press the 2 key Display will read PLUNGE The current plunge depth setting will be shown Enter desired plunge depth changes using the controller keypad number keys The handler allows changes to each digit from lowest to highest in order First enter Ones then Tens then Hundreds then Thousands For example to enter a plunge depth of 625 press 5 then 2 then 6 then 0 The display will read 0625 Press the Enter button to return to HANDLER PAUSED message STOP ON FAIL Press the 3 key Display will read STOP ON FAIL 2 Answer Yes by pressing the 1 key Answer No by pressing the 2 key Press the Enter button to return to HANDLER PAUSED message PICK INTERFACE Press the 4 key Display will read PICK INTERFACE Select HANDLER PORT by pressing the 1 key Select EXATRON SUPER by pressing the 2 key Select PROGRAM RS 232 by pressing the 4 key Select EXATRON RS 232 by pressing the 5 key Press the Enter button to return to HANDLER PAUSED message PICK PACKAGE Press the 5 key Display will read PACKAGE Select RUN PLCC PLUNGE by pressing the 1 key Select RUN DIPS PLUNGE by pressing the 2 key Select RUN SOIC PLUNGE by pressing the 3 key Select RUN AIR PLUNGER by pressing the 4 key Select PLCC SWING HEAD by pressing the 5 key Select RUN DIPS 2800 by pressin
60. NS 2710 001 C TYPE 1 CONTACT ASSEMBLY www exatron com 9 16 Chapter 9 Replacement Parts Exatron 3000B SOIC DEAD BUG NEY PINS EXATRON 2710 520 DEAD BUG SOIC CONTACTS PALINEY PINS SOOO SOIC BUG NEY PINS EXATRON 2710 5397 LIVE BUG SOIC CONTACTS PALINEY PINS lt 2 4 Pd Exatron 3000B SOIC PI PINS PET 314 40 BLANK PET 314 40 EDGE PET 314 40 PIN 6000 242 PINS EXATRON 050 PITCH SOIC BeCu PIN 514 48 314 48 www exatron com 9 19 Chapter 9 Replacement Parts Exatron 3000B SOIC G I PINS 314 GOLD SOIC SOCKET PINS 6000 642 CUSTOM 28 PIN SOIC CONTACT 5000 53 www exatron com 9 20 Chapter 9 Replacement Parts Exatron 3000B SOIC PLUNGE TO BOARD 8 SSOIC PARTICLE INTERCONNECT 1 0 MM PITCH BY 40 PINS 8 PET 259 SOIC PARTICLE INTERCONNECT RIGID PCB CONTACT 050 1 27MM PITCH BY 40 PINS www exatron com 9 21 Chapter 9 Replacement Parts Exatron 90008 SSOIC PLUNGE TO BOARD 578 SSOIC PARTICLE INTERCONNECT RIGID PCB CONTACT 065 MM PITCH BY 40 PINS www exatron com 9 22 Chapter 9 Replacement Parts Exatron 3000B SOIC PLUNGE TO BOARD PET 417 SSOIC PARTICLE INTERCONNECT PCB CONTACT TRUE 025 PITCH BY 40 PINS www exatron com 9 23 Chapter 9 Repla
61. OR CHECK Press the 3 key Handler displays FULL 2 are displayed they indicate if all output tubes lead in sensors are clear of devices If numbers 1 Tube 1 Full Sensor 2 Tube 2 Full Sensor 3 Tube 3 Full Sensor 4 Tube 4 Full Sensor 5 Tube 5 Full Sensor 6 Tube 6 Full Sensor 7 Tube 7 Full Sensor 8 Tube 8 Full Sensor Pressing the Clear button will flash the terminal s displayed message to confirm the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check If you suspect that you have a bad sensor LED pair use the EXATRON LED checker part 3000 052 small blue plastic box This diagnostic tool is equipped with a transistor blue white wires and an IR LED orange green wires Direct the transistor at any of the handler s IR LEDs The LED on the checker should turn OFF Direct the checker s LED at any of the handler s transistors The corresponding number should turn OFF on the handler s display www exatron com 5 8 Chapter 5 Diagnostics Exatron 3000B Tube Switch 1 Through 8 This diagnostic tests port B6 located on PCB 5000 89 PAL A89 8 Please refer to drawing 6000 517 for sensor wiring details TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 1 key Handler displays SENSOR CHECK Press the 4 key Handler displays TUBE displayed they indicate if all output tubes are removed from the handler If numbers are 1 T
62. PART NUMBER FEMALE SOLDER EDGE CONNECTOR 20 PIN EZC1ODRSH 34 PIN EZC17DRSH 40 PIN EZC20DRSH 50 PIN EZC25DRSH 60 EZCSODRSH FOR WIRE WRAP LENGHT PINS ADD WIRE WRAP TO PART NUMBER 2 34 17 2852 5 i 40 20 2852 5 60 0 2852 5 FEMALE CRIMP EDGE CONNECTOR 20 PIN RF10 2852 5 34 RF17 2852 5 40 RF20 2852 5 50 RF25 2852 5 www exatron com 9 36 Chapter 9 Replacement Parts Exatron 3000B Chapter 10 Supplement PARTS LISTS Overview Following the descriptive guide below is a Component Parts List for the Model 3000B Handler This Guide shows how to use the parts list to determine the exact part number of any custom part in your machine in order to replace it if necessary The Parts List contains those items which EXATRON has custom manufactured They include machined parts sheet metal printed circuit boards cables and standard vendor parts which have been modified by EXATRON A limited number of standard vendor parts are also listed here The title shown at the top of the list indicates the type of parts list This should match your system s hardware The parts list may change as EXATRON improves each model with each new generation If you have different generations of the same model the parts list will vary Whenever possible EXATRON makes design improvements capable of being retrofi
63. R INTO THE POWER SUPPLY YET First plug the power supply only into a grounded wall outlet Turn the power supply on by pressing the red power button and verify that the 5 volts and 24 volts are operational If you wish to check calibrate the power supply output please refer to Chapter 7 Preventive Maintenance 5 Turn the power supply off again Now connect the handler power cord to the power supply via the white Molex connector If your application requires it turn the compressed air supply on Turn the orange switch on the air regulator to the on position 7 Move the octoloader plate so that it is flush against the octoloader home switch Hold the plate in this position until the power is on 8 Turn the handler power on by pressing the Red power button on the power supply and observe closely the display on the handler controller microterminal NOTE Power to the Model 3000B may be turned off and then on again at virtually any time during handler operation The only time it is not advisable to turn the power off is within the first 10 seconds of turning the handler on First you will see VO1 01 Test Ok displayed quickly followed by your handler model number and firmware revision date If you have a plunge type test assembly the next message to be displayed will be JOG UP which tells you that the Z plunger is moving up to locate its top position switch The next message displayed is MOD SET UP NO 9 Press the DIAGNOSTICS
64. RIGHT STEPS The Octoloader will move two tubes to the right Press the 7 key JOG LEFT The Octoloader will move one step to the left about 006 Press the 9 key JOG RIGHT The Octoloader will move one step to the right about 006 Press the 0 key MOTOR OFF The Octoloader Motor is now off Pressing the Clear button will flash the terminal s displayed message to confirm the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check www exatron com 5 16 Chapter 5 Diagnostics Exatron 3000B M OCTO INDEX CHECK Shuttle Solenoid Check This diagnostic tests port B1 located on PCB 5000 89 PAL A89 10 TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 5 key Handler displays OCTO INDEX CHK Press the 2 key The handler will cycle the shuttle solenoid one time The solenoid should turn on for 1 4 second and then turn off Pressing the Clear button will clear the terminal s display Press the Enter button to EXIT this diagnostic check and return to the DIAGNOSTICS message www exatron com 5 17 Chapter 5 Diagnostics Exatron 3000B OCTO INDEX CHECK Input Sensor Check This diagnostic tests port B2 located on PCB 5000 89 PAL A89 10 TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 5 button Handler displays OCTO INDEX CHK Press the 3 button Handler displays INPUT 8 if the handler is empty and the octoloader is at the
65. RON in California Replacement parts are furnished for a period of one year from 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 local EXATRON Representative or an extended warranty agreement must be purchased directly from your local EXATRON Representative Please supply the following information when requesting offshore service or replacement parts 1 The part number s required If the part number is not known photocopy 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 Handler s 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 freight forwarder GN In most cases faxed requests and shipment of replacement parts orders are processed within twenty four hours of receipt by EXATRON The Model 3000B with Eight Automatic Inputs EXATRON S eight tube Octoloader is an ambient automatic eight tube loader The standard Model 3000B comes equipped with this octoloader which is a moving metal plate holding up to eight tubes of devices controlled by the handler s CPU by means of a ste
66. S 000 This number 000 will scroll up in value as the plunger moves up The plunger will continue to jog up until the top position micro switch is closed 11 ONCE THE MICRO SWITCH IS CLOSED The handler will display the UP STEPS message with the actual number of steps required to close the switch Note that there is a limited range of steps within which the plunger must close the top position micro switch The minimum number of steps is 10 The maximum number of steps is 50 12 IF THE NUMBER OF STEPS THE PLUNGER MOVES IS NOT WITHIN RANGE The handler will display ADJ Z SWITCH The switch itself must be moved so that the plunger will stop within the defined range 13 THE Z PLUNGER ADJUSTMENT OPERATION IS NOW COMPLETE To exit the self adjust routine and return to Manual Mode press the Clear button on the handler controller keypad REMEMBER closer the number of steps is to 10 the shorter the distance the plunger will have to move in order to intercept the DUT This slightly speeds up the whole production cycle by minimizing the pick up cycle and plunge to board depth www exatron com 5 20 Chapter 5 Diagnostics Exatron 3000B Automatic Z Adjust Quick Reference With at least one device in the index section Press MANUAL 2 Press 5 3 Press RUN to begin the self adjustment operation Press Clear to exit Self Adjust 2 and return to Manual Mode www exatron com 5 21 Chapter 5 Diagnostic
67. TTLE STEPPER MOTOR H HANDLER PORT INTERFACE OCTOLOADER SIDE BEARING BLOCK J RS 232 INTERFACE PORT K FRONT PANEL CONTROL L LEFT HAND OCTOLOADER STOP ADJUST BLOCK OCTOLOADER CHAIN TENSION ADJUST BLOCK OPTIONAL AIR QUICK DISCONNECT OCTOLOADER GUIDE BAR SHUTTLE CHAIN TENSION ADJUST BLOCK TEST HEAD MOUNTING BOLT DOWN HOLE PATTERN RIGHT HAND OCTOLOADER STOP ADJUST BLOCK CHANGEOVER KIT INPUT OUTPUT PORTS a O voz SHUTTLE ASSEMBLY Standard PLCC shuttle assembly shown www exatron com 1 6 Chapter 1 Introduction 30008 Exatron 1 FIGURE 1 MODEL 3000B HANDLER OCTOLOADER INPUT PLATE UP TO 8 TUBES 9 NOTE OUTPUT DOOR SHUTTLE COVER NOT SHOWN 25 000 ALL DIMENSIONS IN INCHES 3000 431 A 1 7 Chapter 1 Introduction www exatron com Exatron 3000B Warning Caution Labels YOUR NEW EXATRON HANDLER WILL ARRIVE WITH SOME OR ALL OF THE FOLLOWING WARNING LABELS ATTACHED EXATRON PART NUMBER LABEL TEXT LABO03 001 DANGER INVISIBLE LASER RADIATION WHEN OPEN LAB03 004 DANGER ELECTRICAL HAZARD LAB03 006 CAUTION DO NOT OPERATE WITHOUT GUARDS LAB03 007 DANGER WATCH YOUR HANDS AND FINGERS LAB03 008 CAUTION BEFORE CLEANING OR SERVICING LABO6 001 CAUTION HIGH TEMPERATURE LABO09 001 THIS UNIT SOLD AND SERVICED BY LABO09 002 WARNING DON T RE
68. These addresses are not part of the standard power up selections and may be modified only by Changing The RAM as described in the Handler Set Up Chapter of this manual Interface Type Address 00D2 This address allows the user to set the default interface to be used by the handler The following table lists available settings EXATRON SUPER PROGRAM RS 232 LASER ONLY KIT MODEL 5000 ONLY EXATRON RS 232 data setting 21 data setting 23 data setting 24 data setting 25 data setting 26 HANDLER PORT data setting 27 LOW GOING PULSE USES SPECIAL PAL A89 2LP data setting 28 H P RF RS 232 Start Test Delay Address 0097 For DIP devices only this delay adds settling time to the DUT The delay allows the DUT more time to come to rest in the test site before the contacts close The delay counts down in HEX in 1 millisecond steps www exatron com 3 2 Chapter 3 Interface Info Exatron 3000B Pick Up Delay Address 00A9 This delay allows additional time after the handler has detected the device under the plunger before turning on the vacuum to pick up the DUT at the start of the test cycle The delay counts down in HEX in 10 millisecond steps This feature applies to Plunge to Board and Swing Head changeover kits only Stop On Fail Y N Address 00AA 30 Stop on Fail FF Run Failed Devices No Stop This option allows the handler to Stop on Fail or not The handler can either automatically cycle a failed device into an output
69. WIRED VALVE DEAD VALVE www exatron com 7 14 Chapter 7 Preventive Maintenance Exatron 3000B FIGURE 7 3 A VACUUM FILTER B AIR INPUT Typically 80 PSI 3 PSI C VACUUM PORT Connects to Pick Up Apply Head D VACUUM SENSOR ADJUSTMENT POTENTIOMETER E VACUUM ON VALVE AIRON VALVE Blow off G VENTURI GENERATOR H VACUUM SWITCH ASSEMBLY www exatron com 7 15 Chapter 7 Preventive Maintenance Exatron 3000B PARTICLE INTERCONNECT CONTACT MAINTENANCE WHY CLEAN P I CONTACTS EXATRON S patented Particle Interconnect P contacts can best be visualized as a microscopic bed of nails The nails themselves are nickel plated diamond particles which are coated with a nickel or gold finish These particles are evenly distributed on a beryllium copper or copper clad PCB substrate resulting in a contact surface with a rough nail file appearance Typical PI coating on flexible BeCu Pin One of the outstanding features of P contacts is their ability to penetrate the build up of oxidation on component leads P CLEANING PREVENTIVE MAINTENANCE PROCEDURE PREPARATION DISMANTLING THE P I CONTACT ASSEMBLY To clean and or recondition your P contacts it is necessary to disengage the contacts from their operating environment so that you may work with unobstructed P surfaces EXATRON manufactures two types of P contact assemblies Handler Contactors part 6000 242 H compatible with Autos
70. YOUR HANDS AND FINGERS 3053 EMED Co Inc 1 800 442 3633 Label shown actual size Dimensions 21 2 x 17 Colors Black white red Your EXATRON handler is an automated electronic system with a variety of moving parts and subsystems which require care and alertness by its operators at all times Keep hands and fingers hair clothing jewlery etc away from the handler s moving parts and other hazardous areas The warning label shown above is a good example of the type of label which could theoretically blanket the entire handler As stated previously EXATRON prefers for cosmetic reasons not to do so PLEASE NOTE THAT EVEN BODY PARTS NOT SHOWN ON LABELS MUST BE KEPT OUT OF HARM S WAY WHEN OPERATING YOUR HANDLER BE SURETO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 11 Chapter 1 Introduction Exatron 3000B LABO3S 008 Please use this part number when ordering this label BEFORE CLEANING OR SERVICING DISCONNECT POWER SUPPLIES 50611 EMED inc 1 800 440 0009 Label shown actual size Dimensions 1 x 217 Colors Black on yellow background This cautionary label will be affixed to EXATRON handlers with external power supplies Always disconnect the power supply before moving your handler as well The warning label shown above is a good example of the type of label which could theoretically blanket t
71. about 006 Press the 0 key MOTOR OFF The Output Sort Motor is now off Pressing the Clear button will flash the terminal s displayed message to confirm the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check www exatron com 5 14 Chapter 5 Diagnostics Exatron 3000B v1 ALL MOTOR CHECK Test Site Plunger Motor Z Motor Check This diagnostic tests input port C5 output port C5 C9 located on PCB 5000 397 PAL 397 4 U8 TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 4 key Handler displays ALL MOTOR CHECK Press the 2 key Handler displays Z MOTOR CHECK Press the 1 key MOTOR UP The handler will move the plunger up by the number of PLUNGE steps The motor will not move if it recognizes that it is already at the Z limit switch Press the 2 key the handler will display the current motor settings in RAM This display is helpful when trying to increase the motor s speed Press the 3 key MOVE MOTOR DOWN The handler will move the plunger down by the number of PLUNGE steps Press the 4 key MOTOR UP The plunger will move up exactly 30 steps The motor will not move if it recognizes that it is already at the Z limit switch Only if the plunger is down with a device in the contacts press the 5 key START 2 TEST This will cause the handler to pick up the device and re seat it into the test contacts This is part of the handler s norm
72. ad of a master device into the programmer s RAM The handler is displaying the sum check reported back from the programmer SUM CHECK ERROR The handler is using the PROGRAM RS 232 interface The handler has asked the programmer for the current sum check and an error was detected Check the programmer set up You may press Enter to skip past this error and try again Or you may press Clear to flush the handler of all devices T SITE OUT JAM The handler is attempting to move a device out of the test site and into the shuttle The device has failed to arrive 1 Inspect the output of the plunger for a jammed device If you manually clear the jam the handler will automatically restart 2 Press the Clear button to flush the handler 3 Press the MANUAL button to stop the operation and enter Manual Mode Verify the plunger upper stop setting by running the Self Adjust Z procedure as described in Chapter 5 of this manual www exatron com 6 21 Chapter 6 Display Dictionary Exatron 3000B TEST ABORTED The handler has been instructed by the operator to abort a test before the end of the test program cycle The device in the test head will be sorted to a fail tube TEST SITE EMPTY The handler control program was directed to test a device but none is present at the test site This message indicates that the handler has either gone through an incorrect mechanical cycle has been recently flushed or is experiencing mechanical
73. al Retest On Fail cycle Press the 6 key MOVE MOTOR DOWN The plunger will move down exactly 30 steps Press the 7 key JOG UP The plunger will jog up one step about 003 Press the 8 key the handler will automatically move up and stop at the Z Limit Switch and flush any devices into output tube 5 Press the 9 key JOG DOWN The plunger will jog down one step about 003 Pressing the Clear button will flash the terminal s displayed message to confirm the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check www exatron com 5 15 Chapter 5 Diagnostics Exatron 3000B v ALL MOTOR CHECK Octoloader Motor Check This diagnostic tests input port output port C9 located on PCB 5000 397 PAL 397 5 U9 TO ENTER THIS CHECK WARNING VERIFY THAT THE OCTOLOADER IS EMPTY OF ALL DEVICES BEFORE USING THIS DIAGNOSTIC Handler displays DIAGNOSTICS Press the 4 key Handler displays ALL MOTOR CHECK Press the 3 key Handler displays OCTO MOTOR Press the 1 key 1 LEFT STEP The Octoloader will move one tube to the left Press the 2 key the handler will display the current motor settings in RAM This display is helpful when trying to increase the motor s speed Press the 3 key 1 RIGHT STEP The Octoloader will move one tube to the right Press the 4 key 2 LEFT STEPS The Octoloader will move two tubes to the left Press the 6 key 2
74. andler may conform to specific device height The SELF ADJUST Z function may be activated from either of two points during handler operation A When the handler has just powered up and is in Handler Set Up follow the procedure described below B Press the MANUAL button to place the handler into MANUAL MODE then press the 5 key to display SELF ADJ Z PLCC Proceed to Step 3 below Please refer to Figure 5 2 later in this chapter for mechanical details 1 BEFORE POWERING UP THE HANDLER Allow the handler to confirm its current plunger top position by manually moving the plunger down if necessary so that it is not touching the top position micro switch 2 POWER UP THE HANDLER Answer all set up questions appearing on the handler controller display 3 WHEN THE HANDLER DISPLAYS SELF ADJ Z PLCC Install an output tube into the bin 5 position Load a tube of devices into the octoloader so that the devices will fall into the index section or manually load a single device into the index section 4 PRESS THE RUN BUTTON to display the current UP STEPS message followed immediately by SET PICK UP The following functions are now available 1 key The plunger will jog up one step approx 0 003 2 key STEPS ____ The current setting will be displayed again followed immediately by SET PICK UP NOTE To exit without making any changes press Enter now 3 key The plunger will move down one step approx
75. apter 5 LOADING MASTER The handler is using the PROGRAM RS 232 interface The handler is currently loading a master device into the programmer You may press the Clear button to abort the test and sort the device to a fail tube LOW GOING PULSE This is a communications interface for older applications only and is not normally used Please refer to Interface Information Chapter 3 for details www exatron com 6 11 Chapter 6 Display Dictionary Exatron 3000B MANUAL MODE You have pressed the MANUAL button You may now make mechanical adjustments to the handler make changes to the Set UP or run Diagnostics sequences as needed You may resume automatic handler operation by pressing the RUN button MEMORY ERROR The handler s internal memory has failed self test Replace the 8085A CPU PCB EXATRON part 3000 055 MOD SET UP NO Press the Enter button if no changes to the handler s set up are required Press the SET UP button to make changes in the handler s set up MOD SET UP 2 YS If you do not wish to make any changes to the handler s set up press the SET UP button If you wish to make any changes to the handler s set up press the Enter button The handler will now scroll through all of the set up routines listed below and wait for changes to be entered using the handler controller keypad keys Please review the Set Up Procedure in Chapter 4 of this manual for details regarding each set up PICK INTERFA
76. ar button This will sort the DUT to the Home bin output tube 5 www exatron com 3 20 Chapter 3 Interface Info Exatron 3000B NOTE If the handler receives an incorrect bin sort the message BAD TEST RESULT will be displayed The handler display will also flash the HEX equivalent of the result received on the handler s output door LED s You may press the Enter button to reissue a Start Test command and the handler will try a second test You may press the Clear button to abort the test and restart operation or send the handler an ASCII 2 in HEX This will automatically flush the DUT and begin a new test cycle 5 TESTER SENDS TEST SORT RESULT 1 THROUGH 8 OR 0 FOR REMOTE RETEST To complete a test the handler must receive a test result Please refer to the TESTER SORT SET UP ADDRESSES CO TO C7 table of correct test Sorts and the bins to which the handler will sort the DUTs The handler uses the specifications shown in this table to assign Output Bins to tester Sorts The Current Setting column is provided for the customer s reference purposes Please enter your settings in this column Memory addresses in handler memory for output binning data Sort Address 00 0 00 1 00C2 00C3 00C4 00C5 00C6 00 7 1 2 3 4 5 6 7 8 The customer may re assign any combination of bins to any Sort by setting the selection in the handler s RAM Be very careful not to assign the same bin s to a
77. ar sign and end with a cr carriage return The handler does not require any input back from the tester s computer The handler sends these messages to the computer as FYI information only After the dollar sign there will be an upper case ASCII letter This letter may indicate the status of the handler s light pole The light pole is optional equipment obtained by special order Other letters are used for specific error conditions Except the case of a the handler will then follow the ASCII letter with a space and then with up to 16 character upper case ASCII error message string The final character in the communication from the handler will always be a cr carriage return Message String Details G for GREEN handler is running normally No operator action is required R for RED the handler is stopped with a serious jam condition and requires operator assistance If your handler is sending excessive RED error messages check that the handler is properly set up and is in good working order Y for YELLOW the handler is stopped but not jammed The operator should check the handler and restart its operation Yellow errors include the handler being in PAUSE MANUAL SETUP DIAGNOSTIC and ALL MOTORS OFF modes B for BLUE the handler is stopped and reporting the following bin information bin number sort current tube count www exatron com 3 22 Chapter 3 Interface Info Exatron 3000B L for a spe
78. are full Insert an empty tube into any of the handler outputs which have flashing output cover LEDs www exatron com 6 2 Chapter 6 Display Dictionary Exatron 3000B BAD RESPONSE The handler is using the EXATRON RS 232 Interface While the handler is establishing initial communication it is seeking a Ready response R from the tester If anything other than an or is received the handler will pause and display the message BAD RESPONSE BAD TEST RESULT The handler is using the EXATRON RS 232 Interface After testing a device the handler has received an incorrect bin sort You may press the Enter button to reissue a Start Test command and the handler will try a second test You may press the Clear button to abort the test and restart operation or send the handler an ASCII or 2A in HEX This will automatically flush the DUT and begin a new test cycle If further details are required please see Chapter 3 Interface Information Bl N S The shuttle is returning after properly placing a device in the output tube whose number is represented above by an asterisk BIN The handler had received a sort command represented above by an asterisk S from the tester PC The current device count in that output tube is represented above by four asterisks Actual numbers will be displayed in place of the asterisks on your computer readout For example The message BIN 1 1 0001 indicates that the shuttle is re
79. are working on under Sort Signal Write a 1 under each tube you wish to use for that signal Write a 0 under each tube you are not using Compare the pattern with the chart on the left of the page Enter the Data result under each pattern Put that data result in the handler memory at the address shown for that sort number Note Tube 5 are written in DESCENDING order below they appear in ascending order on the face of the handler output door This example shows how to derive binning data Using bins 1 3 7 amp 8 the binning data is C5 Consult handler chart bottom for proper address Memory addresses in handler memory for sort hinnins data Sort Addr 1 00CO 2 00C1 3 00 2 Patterns 4 00C3 5 00 4 Chapter 3 Interface Info 6 00C5 7 00C6 8 00C7 Exatron 3000B www exatron com 3 8 Chapter 3 Interface Info Exatron Handler Port Interface 3000B THE HANDLER PORT INTERFACE USES SIMPLE TTL COMPATIBLE SIGNALS TO CONTROL THE HANDLER This parallel port interface utilizes the 24 connector on the side of the handler It has been designed to be compatible with MCT type tester control interfaces The HANDLER PORT interface uses the addresses 00CO through 00C7 for tester sort to output bin and address 00 for double test on off selection Please refer to the General Interface RAM Selections secti
80. arth ground All guide rails shuttles tube holders hot rails and output trays are connected to earth ground The handler s power supply ground is directly connected to earth ground The handler power supply MUST be connected to a properly grounded power outlet NEVER operate the handler with the power line ground removed or defeated All handler main plates covers and non trackwork handler parts are plated with conductive finishes Exatron uses a very limited quantity of anodizing finishes on handler surfaces www exatron com 2 10 Chapter 2 Installation Exatron 3000B DUT Materials Device Under Test Component packages vary in the materials from which they re made The composition and size of packages can cause wear on the parts of the handler with which they come into contact Heavy rough surfaced DUTs will cause handler wear faster than lighter smoother materials The best defense against the effects of the DUT material on a handler is to ensure that the handler is properly adjusted for the package it is running The height of the handler door over the DUT should be as close as possible The test site contacts should close on the DUT with enough pressure to provide good electrical contact but not press hard enough to force the DUT to the left or the right of the test site rail If you have any questions regarding handler adjustment issues please contact the Exatron Customer Service Department If your handler does experience high
81. ary to carry a failed device across the good bin 5 to some other location This is not recommended If your test results provide for grades then the best grades should be in the outside bins with lower grades toward the inside If a highest rated device is accidentally dropped in a lower grade bin that is not as bad a problem as if a lower grade device is dropped in a higher grade bin C Unused Sort Signals It is wise to always assign the retest tube as the output for unused sort signals This acts as a defense against ghost signals which may occur as a result of tester interface noise or power fluctuations III Finding Bin Assignment Data To figure out the correct binning data for your desired tube outputs please consult the Test Signal Bin Sort Data Worksheet which accompanies this document www exatron com 3 4 Chapter 3 Interface Info Exatron 3000B IV Storing Bin Assignments in Handler Memory The handler uses a look up table to assign handler output bins tubes to tester sort signals The output tube parameters are stored as a two digit hexadecimal number in the handler s memory e g 5 The first digit describes what happens with tubes numbered five through eight and the second digit describes what happens with tubes numbered one to four The first digit is called the Most Significant Bit and the second the Least Significant Bit You will need to edit the memory addresses in the handler s battery
82. ase refer to PICK INTERFACE message above PROGRAMMING The handler is using the PROGRAM RS 232 interface The handler is currently programming a device with the programmer You may press the Clear button to abort the program test and sort the device to a fail tube RAM AUTO RESET The handler has detected errors in its RAM and automatically reloaded its RAM with defaults stored in EPROM This should occur very rarely or after unexpected power line interruptions Replace the 8085 CPU PCB EXATRON part 3000 055 if this message appears frequently www exatron com 6 17 Chapter 6 Display Dictionary Exatron 3000B READY TO RUN The handler is ready to run press the Enter button to operate RS 232 CHECK Please refer to the Diagnostics INTERFACE CHECK RS 232 Check Control Panel Check section in Chapter 5 of this manual RUN DIPS 2800 RUN DIPS PLUNGE RUN PLUNGE RUN SOIC PLUNGE RUN SOT RUN TYPE3 SOIC These are package type handler cycle choices Any of the above selections may be entered from the MOD SET UP YS PICK PACKAGE Mode Please review the Handler Set Up procedure in Chapter 4 of this manual for details regarding each set up SELF ADJUST Z The handler is preparing to run the Automatic Z Plunger Adjustment Procedure At this point you may press the RUN button to start the self adjust operation or press the Clear button to exit this routine and return to Manual Mode Please refer to Diagnostics C
83. ation for further details As specified in the table shown below Exatron handlers are designed to withstand the impact of virtually any climate and or environment that they may be used in Periodic maintenance as prescribed in Chapter 7 of this manual will ensure that emergency down time is kept to a minimum 2 Handler Hot Rail Handler with Printer Temperature 40 to 115 F 40 to 105 F 5 to 45 C 5 to 40 C Relative Humidity 20 to 85 Noncondensing 20 to 80 Noncondensing Airborne dust and moisture if present will naturally settle on surfaces of your handler If allowed to build up dust can eventually block sensors clog solenoids fill up the filters of cooling fans vacuum generators air filters and generally inhibit the smooth movement of devices through the handler The best defense against this kind of contaminate is to install and use your handler in a dust free environment to preclude dust and dirt particles from contaminating its moving parts especially those parts which come into contact with the devices being tested If dust is a factor in your operating environment dust the handler off with blasts of compressed air at least every 8 hours Make sure that the compressed airis clean dry and free of any oil ESD Grounding All Model 3000B Handlers meet or exceed all known device manufacturers ESD specifications All 3000B Series Handler chassis are directly connected through the power supply to e
84. be removed while the handler power is on For fhose cables displaying the above warning label it is crucial to turn the handler power off before disconnecting the cable s Locations for this critical type of electrical cable include the flat ribbon cable connecting the EXATRON Hot Chamber door to the handler Remember that this warning applies to either end of the cable connector assembly BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 15 Chapter 1 Introduction Exatron 3000B This label FYI only not available for purchase THIS ORDER CONTAINS ITEMS MADE WITH PARTICLE INTERCONNECT UNDER U S PATENTS 4 804 132 5 083 697 exatron automatic test equipment 2842 AIELLO DRIVE SAN JOSE CA 95111 UNITED STATES 408 629 7600 Label shown actual size Dimensions 3 4 x 214 Colors Gold metallic on purple metallic background Your EXATRON handler may contain Particle Interconnect 1 Technology ultra high performance test contactors EXATRON holds the exclusive distribution rights to this patented technology in the manufacture of automated test handling equipment If your handler is equipped with P contactors replacement contactors may only be obtained directly from the EXATRON factory The label shown above will be affixed to your P contactor shipping box to advise patent protection information as well as our address
85. button on the handler microterminal and perform the complete set of Diagnostic Tests on your handler and included options These Diagnostics procedures are detailed for you in Chapter 5 of this manual This is your opportunity to become familiar with the handler s controller and mechanical functions as you observe its self testing cycles www exatron com 2 13 Chapter 2 Installation Exatron 3000B Practice session Cycling sample devices 1 Upon completion of all Handler Diagnostics sequences turn the handler power off then on again When the handler controller displays MOD SET UP NO press the SET UP button to toggle this message to MOD SET UP YS 2 Make all necessary Set Up Modifications as detailed in Chapter 4 Handler Set Up 3 Locate a sample set of devices and tubes to use for practice 4 An Exatron LED Checker part 3000 052 may be used as a simulator to run sample devices through the handler In this case select the Handler Port Interface during Set Up Modification and switch the Sort Select Pin 1 to the ON position This will simulate the tester programmer A sort select of 1 will force all parts cycled to binned to a PASS tube LED CHECKER 5 Run the sample devices until you are comfortable with the operation of the Model 3000B handler You are now ready to interface the handler to your tester or PROM programmer Please refer to Chapter 3 Interface Information for details on communications interface selection
86. cal advances developed from the Series 5000 Production Handling Systems The improved performance reduced size and classic flat back bench top style of the Model 3000B provide the ideal solution for medium to high volume automated test and programming applications Blank untested devices are loaded in tubes at the top of the handler then indexed to a test contact mechanism Among the standard choices the customer may select special SMD Surface Mount Device test sites which plunge the Device Under Test DUT up to 1 5 inches past the back of the handler to a load board Programming and testing take place here using any of several types of programmers and testers The devices are sorted by Pass and Fail categories after each test After testing failed devices are sorted into reject tubes Devices which pass the test stage are sorted to the output tubes for retrieval by the operator Many options are available for the Model 3000B Handler most of which may be added in the field Available options are described in detail at the time of equipment price quote and include e 1 Track Hot Rail e Upgrade to Automatic Print and Apply Labeler e High Frequency Particle Interconnect Contact Sets e Extruded Aluminum Output Tubes e Output Tube Guard e Live Bug or Dead Bug Operation Available in most cases Bowl feed Input e Output Tape and Reel e Free Rolling EXATRON Dolly FRED e Opto Isolation Interface e Status Light Pole e Exte
87. cement Parts Exatron 3000B CUSTOM NEY PINS EXATRON CUSTOM HUGHES CONTACT 265 www exatron com 9 24 Chapter 9 Replacement Parts Exatron 3000B CUSTOM CONTACTS ra 260 lt gt 260 ME RN LT IE n BMC END CONTACT BMC MIDDLE CONTACT 5000 J30 END 5000 J30 MIDDLE NOTE CONTACTS MACHINED FROM COPPER THEN GOLD PLATED CONTACTS SH OWN AT 2 TO 1 SCALE www exatron com 9 25 Chapter 9 Replacement Parts Exatron 3000B Pl CONTACT CLOSE UP DETAIL S gt lt Q a E SUBSTRATE FR 4 KAPTON CERAMIC POLYIMIDE TMM3 10 DUROID GETEK OTHERS _ PET 256 9 4 S a E PARTICLE INTERCONNECT COATING DUT 9 LOAD BOARD 9 LOAD BOARD www exatron com 9 26 Chapter 9 Replacement Parts Exatron 3000B EXPERT PI COATED INTERPOSERS PI PADS FRONT SIDE PI PADS BACK SIDE O 00000006000000000000000 DODOOOOGODOUgCOOOOOOODODOO EXP 007 44 PIN INTERPOSER a ooo PI PADS FRONT SIDE PI PADS BACK SIDE 000000000000000000000 DODDOODODOUDOOUDOOOOLODODCOLCEJUOO na na 00000000009000000000000 009 84 PIN INTERPOSER www exatron com 9 27 Chapter 9 Replacement Parts 30005 BUILD YOUR OWN O PINS IEVIIIIIII IIIII 6000 615 PINS 2 GROUPS PER ASSEMBLY SPECIFY 015 THICK OR 007 THICK FOR 84 PIN UNIVERSAL PLCC LCC SOC
88. cial case error In the case of PART DROPPED message the handler has failed to pick up the device with the test site plunger The operator may press the handler s Enter button to have the handler try again to pick up the device at the plunger Or the operator may press the Clear button to abort the test cycle and flush any device at the test site plunger to an output tube E for the special case error that the handler is empty EMPTY LOAD PART message instructs the operator to load new devices into the handler Programmer RS 232 This interface uses the handler s RS 232 Port The control characters have been selected to drive various types of prom programmers equipped with CRCs Computer Remote Control The exact controls used herein are not to be changed by the user If you try to use this interface and encounter problems please contact Exatron for assistance Please refer to RS 232 Port Options at the beginning of this section for Baud Rate and Data Format settings The Programmer RS 232 interface is compatible with the following programmers BP Microsystems Models 1200 and 1400 with Advanced Feature Software Also use Exatron RS 232 Interface Handler Port Interface Data Autosite E Model 2900 Model 3900 Unisite Exatron Peregrine System General TurPro TurPro FX The following addresses in the handler s battery backed up RAM may be edited to fine tune the handler for your specific programmer tester and sorting re
89. clean cloth or cotton swab or by using commercial contact cleaner on a cotton swab DO NOT SPRAY CONTACT CLEANER DIRECTLY ONTO THE CONTACTS DO NOT SPRAY OR POUR ALCOHOL DIRECTLY ONTO THE CONTACTS 4 For Particle Interconnect P 1 contact cleaning and maintenance procedure please refer to P Section later in this chapter Weekly Maintenance arrer 40 HOURS OR MORE OFTEN AS NEEDED 1 Wipe all metal trackwork with a clean soft cloth or tissue Or clean the metal trackwork with cotton swabs dipped in isopropyl alcohol DO NOT USE STAINLESS STEEL CLEANER OR ANY OTHER CLEANER WHICH MAY LEAVE A RESIDUE ON METAL TRACKWORK 2 Clean the shuttle wiper bar part 6000 520 with cotton swabs dipped in isopropyl alcohol 3 Verify that the shuttle is tight on the shuttle chain Please refer to item 5 of the Monthly Maintenance Section for further details 4 Verify that all air hoses are tight on their fittings with no air leaks www exatron com 7 1 Chapter 7 Preventive Maintenance Exatron 3000B 5 Wipe down all stainless steel surfaces non trackwork with CHAMPION brand Stainless Steel 75 Cleaner part TLS09 125 sprayed onto clean cloth DO NOT SPRAY STAINLESS STEEL CLEANER DIRECTLY ONTO THE HANDLER DO NOT USE STAINLESS STEEL CLEANER ON HANDLER TRACKWORK Clean the filter on the vacuum generator part VGH10F 1 4 1 4 This filter part VGFE10 is white when clean and is easily visible through the clear plastic cover over th
90. cles Please refer to Diagnostics Chapter 5 for complete details Z MOTOR CHECK Please refer to the Diagnostics ALL MOTOR CHECK Test Site Plunger Motor Check section in Chapter 5 of this manual www exatron com 6 23 Chapter 6 Display Dictionary Exatron 3000B Z MOTOR CRASH This message indicates that the Z plunger has somehow become out of step and has moved too far up in the Z motor assembly At this point the display may read 2 MOTOR CRASH only or it may first read Z MOTOR CRASH and then blink CHECK CONTACTS If the message CHECK CONTACTS is displayed the handler may have inadvertently dropped the device under test onto the contacts Immediately check the handler contacts and remove any dropped device If the message Z MOTOR CRASH only is displayed the device has been picked up but the Z plunger and the device are too high up You may press the Clear button to flush all devices from the handler and start over You may also run the Self Adjust Z Procedure as described at the end of Chapter 5 Diagnostics Z MOTOR IS UP Z MOTOR NOT UP If the message Z MOTOR NOT UP is displayed the Z plunger has not arrived at its upper limit stop switch as required The operator may use the following options to correct this situation If the Enter button is pressed the handler will try again to locate the upper limit switch Ifthe Diagnostics button is pressed the handler will enter Diagnostics Mode Please refer to Chapter
91. contact the EXATRON Sales Department kkkk OLD N EW kkkk The handler is using the PROGRAM RS 232 interface The handler has asked the programmer for a sum check which is displayed following the word NEW and compared it to the sum check stored in the handler s RAM which is displayed in front of the word OLD These two sum checks do not match If this is the start of a new job it is normal for the two sum checks to not match In this case if you are sure the new sum check displayed following the word NEW 1 correct press the Enter button If the handler is in the middle of a job and this message appears check your programmer very thoroughly Also check whether the handler is making good electrical contact with the programmer If the above suggestions do not apply the programmer s RAM may be corrupted Stop the job Reload all information and begin again DATA This is the Change RAM routine Current RAM address data will be displayed where each X is shown above Review the following for options allowed Enter Exits routine saves settings into RAM SET UP Scrolls address 0090 to OOFF TOTALS Scrolls address OOFF to 0090 Clear Reloads default settings from EPROM to RAM 0 Sets data to 00 Sets data to FF Space Incrementally changes upper nibble 0 to F Delete Incrementally changes lower nibble 20 to F www exatron com 6 1 Chapter 6 Display Dictionary Exatron 3000B 1 LEFT STEP The mo
92. control commands are used by the EXATRON 5000 Series Handlers The handler must be set to use the EXATRON Super interface only These commands do not apply to the handler s Programmer RS 232 interface or EXATRON RS 232 interface or to any other RS 232 interface For firmware 5000FAST TEST CR The handler has loaded a device into the test site The top test site in dual site handlers The tester should now start testing the DUT for the first time No answer is required Do not send the End Of Test EOT sort until the handler specifically asks for END TEST CR END TEST CR Requests the End Of Test EOT sort for the DUT in the test site The handler must receive an answer before continuing operation Send back a single ASCII character The only legal answers are the numbers 1 through 8 Example for Sort 1 PASS send a 1 for Sort 2 FAIL send a 2 RETEST CR The handler has unloaded a device from the contacts and has reinserted it for a double test operation The top test site in dual site handlers The tester should now begin testing the same DUT for the second or multiple time No answer is required Do not send the EOT sort until the handler specifically asks for END RETEST CR END RETEST CR Requests the End Of Test EOT sort for the DUT s in the test site The handler must receive an answer before continuing operation Send back a single ASCII character The only legal answers are the numbers 1 throug
93. d insert an empty tube at any output with a flashing output cover LED NO RESPONSE The handler is using the EXATRON RS 232 Interface and 1 waiting to receive a control code over the RS 232 port from the tester NO SELECTION Indicates that the handler controller button you have pushed is not used option NO SORT ERROR The handler is trying to bin a device but no End Of Test sort has been received Check the tester PC s set up data to verify whether the handler sorts and handler bins are correctly set up Press the Enter button to skip past this error and try again NO TUBES OR FULL The handler is waiting to sort a device to an output tube but the tube is full or missing Check the output cover LEDs and insert an empty tube at any outputs with a flashing output cover LED TO RUN A number from 1 to 8 will be displayed in place of the asterisk shown above The handler has just exited a jam clearing cycle The operator must press the RUN button or the Enter button to continue The number displayed with O K TO RUN indicates where the stop occurred in the handler s operation OCTO MOTOR CHK Please refer to the Diagnostics All Motor Check section in Chapter 5 of this manual www exatron com 6 14 Chapter 6 Display Dictionary Exatron 3000B OCTO INDEX CHECK Please refer to the Diagnostics OCTO INDEX CHECK section in Chapter 5 of this manual OUTPUT CLEAR There has been a device jam at the han
94. d screwdriver One Phillips head screwdriver The Model 3010B Hot Rail is shipped in at least three boxes The largest box 46 x 23 x 32 contains the handler hot rail as an assembled unit The FRED box is 5 x 33 x 24 and contains the Free Rolling Exatron Dolly frame The third box 20 x 18 x 18 contains two power supplies A fourth box may be included in your shipment containing spare parts or additional handler options Open these boxes in the order listed below so that loose parts do not become mixed or misplaced UNPACKING THE POWER SUPPLY The power supply is shipped in a separate 20 x 18 x 18 cardboard box Open the box with the DELICATE INSTRUMENT label side up and remove the top internal box containing handler peripherals such as Octoloader Plate Air Regulator Shuttle User s Manual and Power Cords Set these items aside Open the bottom internal box and remove the power supply using both hands Set the power supply aside and return the packing material to the empty box The shipping carton should now be ready for storage DO NOT DISCARD Proceed with the unpacking assembly instructions UNPACKING THE FRED ENVI RONMENTAL ASSEMBLY Tools required One standard flat bladed screwdriver One Phillips head screwdriver Size 6 Allen wrench Open the fred shipping box and remove all parts of the metal fred Inside the box you will find one additional set of FRED assembly instructions Detail Figures A B and C and one FRED parts l
95. difficulties The handler should self clear and continue to operate If this message repeats from cycle to cycle you may need service Contact EXATRON for assistance THANK YOU One or more numbers will be displayed following the words THANK YOU where the asterisk is shown above The handler is exiting a jam clearing routine correctly The handler will resume operation at the end of the two second THANK YOU delay If your handler is displaying excessive THANK YOU messages contact EXATRON and report the number displayed with the thank you message This number indicates what part of the program the handler was in just prior to displaying THANK YOU TOP OF TUBE JAM The handler has detected an overfilled output tube Check the output cover LEDs Remove the output tube where the LED is flashing and replace it with an empty tube If the problem continues enter Diagnostics Mode and verify that all of the output sensors are working correctly TRANSFER ERROR The PC is attempting to send remote RAM data to the handler but there has been a data transfer error Turn the handler OFF then ON and try again TUBE 12345678 One or more of the numbers shown above is displayed following the word TUBE Please refer to the Diagnostics Tube Switch 1 Through 8 Check section in Chapter 5 of this manual TUBE CLEAR WORKS Please refer to the Diagnostics Tube Switch 1 Through 8 Check section in Chapter 5 of this manual TURN ON REMOTE The handler
96. dler The character should appear on the handler s 16 digit controller display Verify that communications to from the handler s terminal and the PC are clear NOTE Characters will be added to the existing display readout which will then scroll as more characters are received Press the Enter button to EXIT this diagnostic check www exatron com 5 11 Chapter 5 Diagnostics Exatron 3000B INTERFACE CHECK Output Port Output Cover LED Check For Output Port this diagnostic tests port 12 located on PCB 5000 89 PAL A89 3 For LEDs this diagnostic tests port B5 located on PCB 5000 89 PAL A89 5 Please refer to drawing 5000 066 for LED wiring TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 3 key Handler displays INTERFACE CHECK Press the 2 key Handler displays HANDLER OUT CHK Please refer to the following table Press each of the handler terminal s keypad keys 1 through 9 then 0 last Each key will turn on off the handler s output cover LEDs and will set the corresponding handler interface output low Normally all handler outputs are at Logic High 5 Terminal Output Handler Interface 24 pin D Connector Key Cover LED Output Pin 1 1 10 Start test output 2 2 22 Testing 3 3 9 Optional 4 4 21 Optional 5 5 20 Optional 6 6 19 Optional 7 7 18 Optional 8 8 17 Optional 9 ALL 8 ALL Outputs low GND 0 NONE ALL Outputs high 5 Alternatively you may plug the
97. dler s output The handler now senses that the shuttle and the top of the output tubes are clear of devices Open the handler s output door and verify that there are no jammed devices undetected by the handler s sensors If all is clear close the output door and press the Enter button to resume operation OUTPUT TUBE JAM The handler has sorted a device to an output tube whose LED is now flashing The device is jammed at the top of the tube Either clear the jam manually pressing the red solenoid override button to the right of the output tube holder should do so or remove the output tube and insert an empty tube PART DROPPED The plunger vacuum may need to be strengthened since the plunger has dropped the device under test in route to the test site Press the Clear button to flush the device into output tube 5 Using a small screwdriver slightly turn clockwise the yellow pot on the right side of the plunger vacuum generator When the handler resumes operation the small red light next to the yellow pot will light up if the plunger vacuum is strong enough to properly hold onto the device under test PART IN PI SITE This message applies to Type 2 and Type 3 Changeover Kits only The fiber optic sensor in the P contact assembly has detected that a device has been left behind in the contacts by the pick up head Manually remove the device You may wish to undock the programmer from the handler to do so Then check the tes
98. e Exatron 3000B 9 Check the operation of the air regulator s orange shutoff valve Main Air Flow On Off Switch On Position Shown A Turn the valve OFF and verify that the air is indeed off B Turn the valve back ON 10 If your 30008 Series Handler pick up head uses a rubber suction cup inspect and clean the rubber suction cup inside the plunger assembly A Remove the pick up head end piece from the fiber optic plunger B Remove the suction cup with tweezers Clean with isopropyl alcohol Replace if rubber is torn or shows other signs of wear BLUE SUCTION CUP EXATRON PART PART VC B6 USE FOR AMBIENT TEMPERATURE APPLICATIONS GRAY SUCTION CUP EXATRON PART PART VC B6 60 SIL USE FOR HIGH TEMPERATURE APPLICATIONS C On occasion it is possible that a device under test DUT may become hot enough to melt the blue suction cup and seal it shut If this occurs verify that your tester is operating correctly You may wish to switch to the gray silicon rubber suction cups for high temperature applications www exatron com 7 4 Chapter 7 Preventive Maintenance Exatron 3000B Biannual Maintenance arrer 1000 HOURS OR MORE OFTEN AS NEEDED Schedule your handler to be taken out of service for one day The entire handler should be inspected by a qualified technician The following procedures should be implemented 1 Clean the output solenoid of the shuttle assembly inside and out with isopropyl alcohol on cotton swabs
99. e Z motor plunge to contact steps Set as ASCII Number www exatron com 4 10 Chapter 4 Handler Setup Exatron 3000B Ee pee LL m sss s Steps 10 039 For to Board 4 Changeover Kits Sets the 10s digit of the Z motor plunge to contact steps Set as ASCII Number Plunge Steps 1 to 39 For Plunge to Board Type 4 Changeover Kits Sets the 1s digit of the Z motor plunge to contact steps Set as ASCII Number 0008 2 Start Width 00 to FF Sets the width of an available second start pulse to be used in the event that the tester has a problem with the handler s standard start pulse timing Use this 2 Start feature only to solve interface problems flagged by the error messages SORT NOT RESET and or MULTI SORT ERROR SEE INTERFACE CHAPTER FOR FURTHER DETAILS n 06 20 0 15 19 KM error messages SORT NOT RESET and or MULTI SORT ERROR SEE INTERFACE CHAPTER FOR FURTHER DETAILS pm to 39 Sets a per test cycle Soak Delay for Model 3010 Hot Rails Sets 1 0 second digit EE Time 1 0 S VER to 39 Sets a per test cycle Soak Delay for Model 3010 Hot 0 1 5 Rails Sets 0 1 second digit d Label Size 00 to 06 Sets default label size 01 300 DIP 02 600 DIP 03 20 PLCC 04 28 32 PLCC 05 44 PLCC 06 5 7 LCC Sets label print to vacuum on delay for 3000BL Sets label print to vacuum on delay for 3000BL Sets
100. e contacts Ifthe device passes this time operation will continue If the device fails then the handler will again STOP ON FAIL 7 You may press the 3 key The handler display will read PLUNGE 0640 This refers to the number of steps the plunger will move when placing the DUT into the handler s Pl contacts Each step of the motor is approximately 003 0640 is the factory default setting although the number of steps is adjustable Be careful not to drive the DUT too far into the handler s contacts The device s leads probably will not be bent but you will cause handler contact device jams to occur In addition the life of the handler s contacts will be decreased if too much plunge is used Use the keypad to make your selection The handler accepts changes to each digit from lowest to highest in order First enter Ones then Tens then Hundreds then Thousands The minus key will set the count to 0000 Enter Sets your selection Clear Resets to the top of the handler s PLUNGE 0640 loop This will also reload the handler s EPROM default values 8 You may press the 4 key This will cause the handler to move the plunger up one step about 003 This will also change the handler s plunge setting by one step This new setting will be used in the next cycle also 9 You may press the 6 key This will cause the handler to move the plunger down one step about 003 This will also change the handler s plunge setting by one
101. e vacuum generator VACUUM GENERATOR MAINTENANCE IS DISCUSSED IN GREATER DETAIL AND A CALL OUT ILLUSTRATION IS PROVIDED IN THE VACUUM GENERATOR MAINTENANCE GUIDELINES SECTION LATER IN THIS CHAPTER DIRTY FILTER CLEAN FILTER A Disconnect the flexible plastic air tube from the swivel elbow where it attaches to the plunger assembly by pulling the air tube straight out B Loosen the vacuum generator s gray thumb screw which holds the filter chamber in place Remove the filter and clean it with water or better yet replace the filter element with a new one Replace reinstall filter and tighten the gray thumb screw finger tight only Upon Power Up or As Needed Check octoloader alignment To do so press the 0 key on the handler controller to turn OFF all motors The handler display will read ALL MOTORS OFF Manually move the octoloader plate all the way to the right until it stops At this point the left octoloader track should be centered above the test site area If all is well press the Enter button on the handler controller The handler display will read ALIGN MOTORS Press the Enter button again to resume operation If the left octoloader track is not centered above the test site area press the Enter button on the handler controller once This will turn the motors back on and the handler display will read ALIGN MOTORS The operator may now jog the octoloader by one 003 step at a time until it is properly aligned
102. ent for sensor wiring details TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 1 key Handler displays SENSOR CHECK Press the 1 key again Handler displays SENSOR 0 67 for example if the handler is empty and all sensors are working Please refer to your Change over Kit Supplement for specific sensor information and fill in the blanks provided below The numbers shown in the display indicate 0 Sensor 0 1 Sensor 1 2 Sensor 2 3 Sensor 3 4 Sensor 4 5 Sensor 5 6 Sensor 6 7 Sensor 7 Pressing the Clear button will flash the terminal s displayed message to confirm the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check If you suspect that you have a bad sensor LED pair use the EXATRON LED checker part 3000 052 small blue plastic box This diagnostic tool is equipped with a transistor blue white wires and an IR LED orange green wires Direct the transistor at any of the handler s IR LEDs The LED on the checker should turn off Direct the checker s LED at any of the handler s transistors The corresponding number should turn OFF on the handler s display www exatron com 5 6 Chapter 5 Diagnostics Exatron 3000B v1 Shuttle Position Sensors 1 Through 8 This diagnostic tests port B4 located on PCB 5000 A89 PAL A89 7 Please refer to drawing 5000 D66 and 6000 517 for sensor wiring details TO ENTER THIS CHECK
103. er does not receive one of the above test Sorts the handler will pause and display the message BAD TEST RESULT The handler will output the HEX equivalent of the actual character received by the handler to the LEDs on the handler s output shuttle cover LED 1 is bit 01 LED 8 is bit 80 Pressing the Clear button on the handler s front panel will flush the device from the test site and restart operation Press Enter to retest if desired When the handler does receive a proper result in the form of one of the above test Sorts the handler will open the test contacts and flash the output cover LED of the output bin selected The handler will sort the DUT accordingly and start a new handling cycle www exatron com 3 3 Chapter 3 Interface Info Exatron 3000B Handler Binning Setup Introduction EXATRON handlers are designed to accept as many as eight sort messages from your tester programmer equipment Selecting which output bins the handler will then put your devices in is accomplished by programming the handler to match physical output bins to tester sort results The tester sort signals will come into the handler via the Parallel Port or the RS232 Port Please refer to the Interface Information chapter of this manual for further reference on tester handler communication II Designing Bin Assignments A Pass Retest Fail Typically there are three main categories of test results devices that pass test devices that definitely fa
104. er of this manual for the part numbers of all solenoids and springs in your handler Use the solenoid diagnostic routine for proper solenoid movement Please refer to the Handler Diagnostics Chapter of this manual for details www exatron com 7 8 Chapter 7 Preventive Maintenance Exatron 3000B Air Regulator Maintenance Guidelines Some EXATRON Changeover Kits use compressed air If your kit does use compressed air it will also require an air regulator A high quality air regulator with coalescing air filter and shutoff valve 1 supplied as part of your changeover kit NEVER operate any EXATRON equipment which requires compressed air without an approved air regulator and shutoff valve Please refer to FIGURE 7 2 following this section for air regulator mechanical details Additionally please refer to the manufacturer s data sheet in Chapter 10 of this manual if necessary The air regulator assembly consists of WILKERSON AIR REGULATOR PART NC00 440 AND COALESCING AIR FILTER PART GPA 97 075 1 Check the operation of the orange shutoff valve once a month Turn the valve OFF and verify that the air is indeed off Turn the valve back ON 2 Check the PSI setting Some special case changeover kits may require less than 80 PSI However in general set the air regulator to 80 PSI 3 PSI 3 Inspect the moisture trap chamber and the coalescing filter chamber Verify that they are clean empty and dry There should be oil and
105. ers can reach temperatures as high as 170 C DO NOT TOUCH the hot surfaces of your hot chamber handler Use extreme caution when working in the vicinity of the hot chamber Please refer to your Model 5080 Hot Chamber User s Manual for complete hot chamber operating details BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 19 Chapter 1 Introduction Exatron 3000B www exatron com 1 20 Chapter 1 Introduction Exatron 3000B Chapter 2 Installation Basic installation of your new Exatron handler will consist of the following three major steps Unpacking the handling equipment and assembling its peripheral parts ll Powering up the handler and running Diagnostics sequences lll Cycling sample tubes of devices These multi part steps are described in detail below After these steps are completed you will be ready to interface the handler to your tester prom programmer as described in chapter 3 interface information Please read and understand this entire User s Manual before installing or using your Exatron handler The following safety procedures must be followed at all times Exatron Safety Features Electrical Hazards High Voltage Testing Applications It is the policy of Exatron to determine the precise application for every handler we make prior to shipment In some cases the handler will be used to test devices at high voltages I
106. escribes the operator s important contribution to handler productivity keeping the Model 3000B clean and smooth running The following preventive maintenance guidelines are divided into minimum time frames Each maintenance function should be completed at least as often as described below and more often as needed NOTE With the exception of general use items such as isopropyl alcohol all cleaning products and replacement parts described in this guide are available from the Sales Department at Remember there is one common sense rule which applies to the model 3000B handler as it does to all production equipment KEEP IT CLEAN it will work better and last longer IF YOUR HANDLER IS PERFORMING FREQUENT JAM CLEARING OPERATIONS WIGGLING THUMPING ETC CHECK THE MECHANICAL ALIGNMENT OF THE HANDLER S MOVING PARTS AND ADJUST AS NEEDED FOR SMOOTH FUNCTIONING Daily Maintenance arrer HOURS OR MORE OFTEN AS NEEDED 1 Carefully remove all dust and debris from every surface of the handler using blasts of compressed air on front and back from top to bottom of the handler Make certain that the compressed air is clean dry and free from any oil 2 Verify that the handler is free of all loose tube stop pins devices screws and other small objects especially in the shuttle area 3 Clean traditional contacts non Particle Interconnect including contact edges and edge connectors by wiping with isopropyl alcohol on a
107. ess Chip Carriers 18 20 24 28 32 44 52 68 84 Pad LCCs Live Bug only SIP SIL Single In Line Packages D Pak D2 Pak D3 Pak TO 218 TO 220 TO 247 TO 3P TO 3PBL DO 214 SOT23 Custom Hybrid SIPs Others TSSOP Small Printed Circuit Boards ZIP Staggered Lead Form Single In Line Package SIMM Single In Line Memory Modules Other Memory Modules Numerous Custom Devices www exatron com 1 2 Chapter 1 Introduction Exatron 3000B Exatron Support Services Toll Free Telephone Customer Service Line For factory technical support call 1 800 EXA TRON between 8 00 A M and 5 00 P M Pacific time Monday through Friday When calling please have your EXATRON equipment close at hand along with the following information e The exact wording of any messages that appeared on your handler display e A description of what happened and what you were doing when the problem occurred e A description of how you tried to solve the problem Standard Warranty All EXATRON products are under warranty for one year from the date of purchase EXATRON agrees to repair any mechanical or electrical assembly subassembly or entire unit which fails during normal use within its first year The Customer agrees to follow the recommended maintenance procedure as defined in the User s Manual EXATRON DOES NOT warrant test contactors Handler test contactors are fragile and may be easily ruined by operator abuse EXATRON uses the finest materials ava
108. f your handler will be used to test devices with voltages in excess of 80 VDC or 80 VAC the handler will need to be equipped with safety covers If Exatron is notified of high voltage requirements as described above on the written purchase order at the time of order placement we will equip your handler with safety covers having electrical 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 tester will be shut down with no possibility of high voltage at the handler s contacts All safety hardware should be verified for proper operation by the customer s own in house safety officer If you intend to use this handler for high voltage testing notify 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 your Exatron handler is equipped with safety covers never operate the handler without them Never remove the safety covers Never defeat any electrical interlock switch supplied with the handler High Internal Voltages In most cases there are no high voltages used inside the Model 3000B handler electronics with the exception of the Model 3010B Hot Rail High voltage from the building line current is present in the Exatron remote 3000B power supply Only qualified service technicians should do any repair work on the po
109. fic EPROM RAM address setting 2 ROM RAM T B CR Reset all handler tube total counters to zero Handler display will read TOTALS SET TO 0 T C90 FF Accept new RAM settings from PC plus command 90 address space FF new data for address location CR end of string CR Loads handler EPROM default settings into the handler s RAM address from 0090 00FF to E390 E3FF Handler display will read LOAD EPROM gt RAM E CR Send EPROM RAM address labels F CR Send RAM data from handler to PC Handler returns a long string of 8 bit characters one character for each address location from E390 to E3FF ending with a CR G CR Go Index a new DUT start running operations CR Handler returns EPROM default settings addresses 0090 OOFF P CR Pause the handler Press the handler RUN button to restart operation T CR Send RAM data from PC to handler RAM E390 E3FF Z CR Laser mark finished www exatron com 3 18 Chapter 3 Interface Info Exatron 3000B REMOTE RAM COMMANDS A command Request ROM RAM address setting To check a single address setting in both the handler s ROM and RAM send A90 CR A for address 90 to FF for a given address The handler will send back 90 ROM 01 RAM 01 CR This displays the current address location selected the ROM default setting and the curre
110. g machined parts sheet metal printed circuit boards cables and standard vendor parts which have been modified by EXATRON please refer to Parts List located in the Supplement Chapter at the end of this manual This list includes every single part used to manufacture your particular machine AS USED IN EXATRON HANDLERS INFRARED LIGHT EMITTING DIODES L E D s PART OP265 D MANUFACTURE OPTEK c P CASE PLASTIC 125 DIA ANODE ORANGE CATHODE GREEN LEAD SPACING 050 CROSS PART ME Hac CROSS MANUFACTURE SEMO3 001 UT PART OP132 TE MANUFACTURE OPTEK 5 99 CASE METAL 200 DIA ANODE ORANGE 4 LEAD SPACING 100 DE Sarre CROSS PART CROSS MANUFACTURE 051 T www exatron com 9 1 Chapter 9 Replacement Parts Exatron 3000B AS USED ON EXATRON HANDLERS NPN SILICON TRANSISTORS SENSORS PART K 5250 3 COLLECTOR WHITE MANUFACTURE OPTEK 2 BASE CUT OFF CASE METAL 200 DIA l EMITTER BLUE LEAD SPACING 100 CROSS PART CROSS MANUFACTURE PART LPT 110B MANUFACTURE SEIMENS 3 COLLECTOR WHITE 3 CASE PLASTIC 200 DIA 2 BASE CUT OFF LEAD SPACING 100 l EMITTER BLUE CROSS PART CROSS MANUFACTURE SEMO3 100 En PART 506 vere MANUFACTURE JN ou eee CASE PLASTIC 125 DIA EMITTER LEAD SPACING 100 NE en CROSS PART rae
111. g the 6 key Select RUN TYPE3 SOIC by pressing the 7 key Select RUN SOT by pressing the 8 key Press the Enter button to return to HANDLER PAUSED message www exatron com 6 8 Chapter 6 Display Dictionary Exatron 3000B FULL TUBE COUNT Press the 7 key Display will read FULL TUBE The current full tube count setting will be shown Enter desired full tube count changes using the controller keypad number keys The handler allows changes to each digit from lowest to highest in order First enter Ones then Tens then Hundreds then Thousands For example to enter a tube full count of 25 press 5 then 2 then 0 then 0 The display will read 0025 Press the Enter button to return to HANDLER PAUSED message Press the RUN button on the handler controller keypad to exit Pause Mode and return to previous loop HANDLER PORT Please refer to PICK INTERFACE message later in this section INPUT 12345678 One or more of the numbers shown above is displayed following the word INPUT Please refer to the Diagnostics OCTO INDEX CHECK Input Sensor Check section in Chapter 5 of this manual for details INSERTION ERROR The handler has detected a continuity error when trying to insert the device under test into the contacts To resolve this condition 1 If you are using a plunge to board changeover kit check the plunge depth setting incorrect plunge depth setting is the most common rea
112. h 8 Example for Sort 1 PASS send 1 for Sort 2 FAIL send a 2 MARK CR For lasers equipped with optional quad mark firmware only This command will be sent to the PC by the handler immediately after EOT The DUT to be marked will typically be moving into the laser mark site This command will serve as a preload mark command Once the PC receives this command the correct MARK will be loaded into the laser marker and displayed with yellow background on the PC screen There is no response required from the PC FIRE LASER CR The handler has loaded a DUT into the mark site The laser should begin laser marking the DUT No answer is required Do not send the End Of Mark until the handler specifically asks for END LASER www exatron com 3 17 Chapter 3 Interface Info Exatron 3000B END LASER CR The handler is requesting an End Of Mark answer Send an ASCII Z CR when the laser mark is complete ERROR CR The handler has received a command but the command was not understood or is not one of the legal commands used by the handler No answer is required but if you want the handler to perform some operation then retry your previous command COMMANDS FROM THE PC TO THE HANDLER 1 CR SORT 1 2 CR SORT 2 3 CR SORT 3 4 CR SORT 4 5 CR SORT 5 6 CR SORT 6 7 CR SORT 7 8 CR SORT 8 plus Put handler in Listen mode A90 CR Ask handler to send a speci
113. hapter 5 for complete details SENSOR 12345678 Please refer to the Sensor Diagnostics section in Chapter 5 of this manual SENSOR CHECK Please refer to the Sensor Diagnostics section in Chapter 5 of this manual SET P V L MODE The handler is asking you to select a programming operation This message is only displayed when the PROGRAM RS 232 interface is selected Choose one of the following operations 1 PROGRAM DEVICE Sets the handler to bit check and Program the device in the handler 2 VERIFY DEVICE Sets the handler to Verify the device in the handler 3 LOAD DEVICE Sets the handler to Load data from the device to the programmer RAM Enter Sets your selection Clear Resets to the top of the handler s SET P V L MODE SHUT 12345678 One or more of the numbers shown above is displayed following the word SHUT Please refer to the Diagnostics Shuttle Position Sensors 1 Through 8 Check section in Chapter 5 of this manual www exatron com 6 18 Chapter 6 Display Dictionary Exatron 3000B SHUTTLE EMPTY The handler was expecting a device to be in the shuttle but none is detected There has been a miscycle or a flush cycle You may skip past this error by pressing the Enter button You may flush the handler by pressing Clear SHUTTLE IS LOST The handler has tried to center the shuttle back to the Home bin output 5 without success Press the 0 key to turn off the motors Manually center the shu
114. he computer controlling the customer s tester This information adds to the basic Exatron RS 232 commands which we have incorporated into our Series 5000 and Series 3000B handlers The way in which the handler starts and ends each test cycle for the H P RS 232 Interface is the same as for the Exatron RS 232 Interface described in the basic handler CPU test cycle handshake above The following explains in detail the additional RS 232 commands 1 Handler sends G cr Handler is running light pole if present is set to GREEN 2 Handler sends R space 16 ASCII character string cr The light pole if present has turned RED Handler error message 3 Handler sends Y space 16 ASCII character string The light pole if present has turned YELLOW Handler error message 4 Handler sends a B space 16 ASCII character string cr The light pole if present has turned BLUE Bin information will be displayed 5 Handler sends a L space PART DROPPED cr The light pole if present has turned RED Operator to check for handler mis cycle 6 Handler sends a E space EMPTY LOAD PART cr The light pole if present has turned YELLOW Handler is empty the operator should load devices into the handler and press the Enter button The handler will send out message strings at various times during the handling cycle and upon all error jam conditions All of these strings will start with a doll
115. he entire handler As stated previously EXATRON prefers for cosmetic reasons not to do so PLEASE NOTE THAT EVEN HANDLERS WITH INTERNAL POWER SUPPLIES MUST HAVE THE POWER TURNED OFF PRIOR TO CLEANING SERVICING OR MOVING THE HANDLER BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 12 Chapter 1 Introduction Exatron 3000B LABO0G 001 Please use this part number when ordering this label HIGH CAUTION TEMPERATURE Label shown actual size Dimensions 1 Diameter circle Colors Red text on silver metallic background This high temperature caution label may be affixed to your EXATRON handler if it is equipped with a Hot Chamber This sticker will be used on the hot chamber in addition to the larger yellow cautionary sign shown later in this section part number 5000 967 The hot chamber is a completely enclosed double insulated compartment for pre heating devices prior to testing The interior heated tracks of some hot chambers can reach temperatures as high as 170 C DO NOT TOUCH the hot surfaces of your hot chamber handler Use extreme caution when working in the vicinity of the hot chamber Please refer to your Model 5080 Hot Chamber User s Manual for complete hot chamber operating details BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 13 Chap
116. he full tube and re inserting an empty tube The handler will not cycle devices to outputs which have no tubes or which are full Additionally a continuous subtotal count is maintained for each output up to a total of 999 999 devices Sorting is accomplished by use of a stepper motor and a solenoid released shuttle Dual positive binning sensors keep track of the shuttle s position at all times In the event of a sorting problem a message will be displayed on the handler s front panel and the device will not be binned until the problem is corrected The Model 3000B Handler like all EXATRON handlers is guaranteed to properly bin every device even during power down conditions EXATRON has been one of the pioneers in the area of positive binning functions EXATRON test handling equipment meets or exceeds the standards set by MOTOROLA Six Sigma binning requirements Model 3000B Handlers may be configured for all of the following packages DIP Dual In Line Packages Live Bug or Dead 0 300 0 400 0 600 0 900 Body Width 8 to 48 Pins Standard Range 4 to 64 Pins Optional Range 0 070 or 0 100 Pitch Leads SOIC Small Outline Integrated Circuits Live Bug or Dead Bug 0 150 SOJ J Lead Shape 0 170 0 210 0 300 0 330 0 350 0 450 Body Width 0 100 0 079 0 050 0 039 0 025 0 020 Pitch Leads PLCC Plastic Leaded Chip Carriers 18 20 24 28 32 44 52 68 84 Pin PLCCs Live Bug only LCC Leadl
117. ich attach directly to each device Some types of these bumpers will run through a standard Exatron handler In some cases custom rails may be required www exatron com 2 11 Chapter 2 Installation Exatron 3000B Powering Up Running Diagnostics You may find it beneficial to contact your local Exatron Representative to assist you in setting up your handler If you prefer please feel free to call the Exatron Customer Service Department for assistance as needed during set up Our toll free telephone number is 1 800 EXA TRON After you have unpacked and assembled the handler according to the instructions shown above review this entire user s manual before proceeding 1 Bolt your benchtop Model 3000B handler securely to your workbench If your Model 3000B handler is mounted on a FRED verify that it is secure double check all mounting bolts 2 Compare your purchase order to the handler s packing slip and verify that all items ordered have been received 3 If your application requires compressed air bolt the black Wilkerson air regulator part NCOD440 onto the right side of the 3000B frame using two 10 32 x 5 8 bolts With the orange switch in the closed position attach the nozzle of your clean dry compressed air supply to the air regulator WILKERSON AIR REGULATOR OFF POSITION Main Air Flow On Off Switch On Position Shown www exatron com 2 12 Chapter 2 Installation Exatron 3000B 4 DO NOT PLUG THE HANDLE
118. il test and devices that may or may not have failed This last category is best understood as continuity errors missed contacts devices in test during power outages etc These are devices which may in fact be good devices but which need to be retested If the test program in use is designed to differentiate between fail and retest devices then EXATRON recommends bin 5 as the retest bin Assign bins 4 and or 6 as the positive fail bins in this situation Where no differentiation is made between fail and retest devices then assign bin 5 for these devices B Positive Binning Positive binning is the concept of designing the bin assignments to minimize the effects of accidental binning errors All EXATRON handlers have very substantial mis binning protection built in It is impossible to say absolutely that no mis bins will ever occur As a defense against accidental mis binning it is generally considered bad practice to carry fail or retest devices to their bins over the tops of any good device bin It is better to accidentally drop a good device in a fail bin than to accidentally drop a failed device in a good bin ax Shuttle moves over di 1 2 3 4 5 6 r Outside Inside Looking at the above diagram Would Be inappropriate to put anything but retest or fail devices in bin 5 If bin 5 is assigned as a good bin then some other bin must be assigned as a fail bin It would then be necess
119. ilable in our contactor designs All warranty work must be performed at the EXATRON factory or at an authorized Representative Service location As described on the following page in house service by our customers 1 encouraged EXATRON does not warrant the following Damage caused by improper packaging of equipment returned to EXATRON for repair Damage caused by the freight forwarder Damage caused by acts of God flood fire earthquake etc Damage caused by equipment connected to improper power line voltages Operator abuse Interface hardware not manufactured by EXATRON Test contactors Damage caused by equipment connected to improper air supply contaminated with oil water dirt etc gt Q O Customer In House Service Except in the case of Laser Marking Systems EXATRON encourages customer in house equipment service and tries to make in house service as easy as possible to perform There are no Void Warranty warning stickers on EXATRON handlers EXATRON will even honor the warranty on a unit when an in house repair attempt leads to further damage to the unit By using the built in diagnostic software and diagnostic tools it is usually possible for the operator to isolate a problem quickly and effect a repair www exatron com 1 3 Chapter 1 Introduction Exatron 3000B Offshore Warranty Service An EXATRON Handler purchased in the United States and then shipped offshore will be warranted through EXAT
120. ing operation of the Handler Port interface when the handler sends a Start pulse to the tester but the tester either does not see the Start signal or the tester fails to clear the previous Sort signal In the latter case the previous Tester Sort signal is still active at the end of the Handler s current Start pulse The handler correctly responds to the previous Sort signal which means that the current device under test DUT will not be tested and will be mis sorted It may appear to the www exatron com 3 12 Chapter 3 Interface Info Exatron 3000B operator that the handler is making an error when in fact the tester has made an error Therefore it 1 a good idea to set this check to On whenever your application allows for it SECOND START PULSE FEATURE 2ND START WIDTH ADDRESS 00D8 2ND START DELAY ADDRESS 00D9 Exatron has added 2 START PULSE to the EXATRON Handler Port interface This second start pulse is to be used in the event that the tester you wish to use has a problem with the handler s standard start pulse timing Use this 2ND START PULSE only to solve interface problems flagged by the error messages SORT NOT RESET and or MULTI SORT ERROR For correct use of the handler s standard start pulse the tester must reset all sort signals to Logic High on the leading falling edge of the standard start pulse The handler resets its input sort latch on the rising edge of the start pulse At that instant in time if any s
121. is the responsibility of the user to properly train all handler operators in all of the safety practices required for every component of the test system Unpacking Assembling Your Model 3000B handler has been shipped to you in specially designed containers which should be safely stored away If it should become necessary to return the handler to Exatron these original shipping containers must be used Exatron assumes no responsibility for damage during return shipment caused by improper packing of the handler If the shipping cartons become misplaced or damaged new shipping cartons may be ordered from Exatron UNPACKING AMBIENT HANDLERS MODEL 3000B Tools required One standard flat bladed screwdriver One Phillips head screwdriver 1 Open the box with the DELICATE INSTRUMENT label side up and remove the top honeycomb cardboard cushion panel You will see a sealed cardboard carton surrounded on all four sides by cardboard cushion panels Inside the internal carton the handler is bolted to a wooden base held in place for shipping by the internal carton which has no bottom Cut or remove the sealing tape on the top of the internal carton 2 Remove this internal carton by pulling straight up on its sides You can now see the handler bolted to the wooden base The handler and the wooden base weigh approximately forty five pounds 3 Firmly grasp the handler on each side and lift straight up Set the handler on a sturdy bench or table top
122. ist Assemble the base of the FRED first Refer to Figure A 1 Using six 1 4 20 x 1 75 long bolts and six lock washers attach the two uprights to the base plate Note the location of the small holes in the base in relation to the uprights 2 Tighten all six bolts 3 Locate the two riser bars 3000 041 and the rigid support bar 3000 034 Using four 1 4 20 x 2 75 long bolts four block washers and four 1 4 20 hex nuts attach the risers and the rigid support bar to the uprights by inserting the bolts through the upright through the riser and then through the holes in the rigid support bar The large holes in the riser should be at the top Assemble the riser bar in the lowest position initially and then adjust its height as needed place lock washers and nuts on all bolts Do not tighten the bolts yet 4 Place the handler power supply on the base 3000 032 Insert the rubber feet on the power supply into the pre cut holes in the base Please refer to Figure The FRED may be assembled with either of two different pivot points depending upon your application The hardware remains the same in both cases Type A pivot is recommended for handlers using cable type test contact interface Type B pivot is recommended for zero test head interfaces or when docking the handler to a manipulator NOTE The maximum slide angle for PLCC devices is 45 from vertical www exatron com 2 7 Chapter 2 Installation Exatron 5 6
123. ite programmers and BP Programmer Contactors part 6000 537 A mounted onto a programmer socket Handler Contactor Assemblies A Remove the four 6 32 08 Allen bolts which hold the assembly onto the handler B Place the contact assembly on a protective surface such as non conductive i c packaging foam to protect the pins on the bottom from possible damage while cleaning or re conditioning the contacts BP Programmer Contactor Assemblies A This contact assembly is mounted onto a programmer socket with 84 pins holding it in place Gently loosen each of the four sides of the contact assembly by hand and pull straight up to remove it www exatron com 7 16 Chapter 7 Preventive Maintenance Exatron 3000B If you encounter resistance while attempting to remove the contact assembly by hand gently insert a thin bladed screwdriver between the base of the Pl contactor and the programmer socket adapter Carefully pry the assembly up along two sides until it pops loose for removal B Handle the contactor assembly with care and place it a protective surface such as nonconductive c packaging foam to protect the pins on the bottom from possible damage while continuing the mantling process Remove the four 4 40 05 Allen bolts on the frame of the contactor assembly Remove any stand offs Set these bolts and stand offs aside ULTRASONIC P I CLEANING You may find that a convenient way to clean your P contacts is to place the en
124. job and start over again CHK OUTPUT DOOR The output door is open and the handler will not operate until the door is closed CHK VAC ADJUST The handler has tried to pick up a device and has failed to detect that the device was already suctioned up by the plunger s vacuum To resolve this condition 1 Press the PAUSE button HANDLER PAUSED Wiggle the plunger manually to slightly shift the device Watch the red LED on the vacuum generator When the LED lights up stop wiggling the plunger Press any button on the handler s controller The handler will automatically resume operation if the device is now detected 2 Verify that the vacuum line is installed from the vacuum generator to the plunger Verify that the plunger fitting is not leaking www exatron com 6 4 Chapter 6 Display Dictionary Exatron 5 6 30005 Verify that the plunger is mechanically adjusted correctly Perform the Self Adjust Z procedure described in Chapter 5 Diagnostics Pressing the Enter button will skip past this error but BE CAREFUL IN SELECTING THIS OPTION because pressing the Enter button will cycle the plunger down which may destroy the device it is holding Pressing the Clear button will flush all devices from the handler Use Diagnostics Solenoid Check to verify that the vacuum is working properly COUNTS RESET 0 This indicates that all output tube counts and all total counts have been reset to 0000 For your reference
125. label print to vacuum on delay for 3000BL Sets label print to vacuum on delay for 3000BL Sets label print to vacuum on delay for 3000BL Sets label print to vacuum on delay for 3000BL 00E3 00 to FF Sets a time delay before the handler sends an available second start pulse to the tester Counts down in HEX in 1 millisecond steps The second start pulse feature 15 used in the event that the tester has a problem with the handler s standard start pulse timing Use this 2 Start feature only to solve interface problems flagged by the 00E4 00 5 5B Electronics FF 5B FF Sets the handler to do self tests on handlers equipped with Type 5 electronics Extra RS 232 port FF No 5B checks 00 Pickup 10000 30to39 For Type 5B CO Kits only Sets 10000 s digit Home sensor to pick up point www exatron com 4 11 Chapter 4 Handler Setup Exatron 3000B ADRS DESCRIPTION ROM RAM COMMENTS OPTIONS lll PN Sets 1000 s digit Home sensor to pick up point me mew ll Sets 100 s digit Home sensor to pick up point a Sets 10 s digit Home sensor to pick up point Sets 1 s digit Home sensor to pick up point E eo p Pr _ Sets 10000 s digit Home sensor to Test Site point Sets 1000 s digit Home Sensor to Test Site point Sets 100 s digit Home Sensor to Test Site point E orase Sets 10 s digit Home Sensor to Te
126. label to be fully picked up by the pick up head Counts down in Hex in 10 msec steps 00B6 Shuttle Delay 00 to FF Delays shuttle solenoid being turned off after device has exited the shuttle into the output tube Allows more time for device to completely exit the shuttle mm down in HEX in 10 msec steps ud ul XTAL MN Size turns this option off For Type 5B CO Kits Only XTAL Devices only 50 Sets the handler to run CA devices 51 Sets the handler to run JA devices 52 Sets the handler to run JC devices 00B9 Label Yes No Turns on all of the label apply software Handler must be a 3000BL 00 Turns label option OFF 01 Turns label option on label Sort 1 only 02 Turns label option on label Sort 2 only 08 Sort Label apply HEX decode Label Out Delay Adds delay to DUT exiting the label site more time for the stop pin to remain open For 3000BL handlers only OOBB Stop Fail Sort 00 to FF Tells the handler which sort s to stop the system upon Fail from tester 00 No stop on fail FE Stop on fail all sorts EXCEPT bin 1 02 Stop on fail sort 2 onl 00BC Double Test Sort 00to FF Tells the handler which test sorts to double test if desired 00 Double Test is OFF for all sorts FE Double Tests all sorts except Sort 1 02 Double test sort 2 only 00BD Send on Retest Sets the handler to send the ASCII character to the tester at the start of each retest cycle as it doe
127. label will be affixed to your handler only if it is a laser marking system Eye protection must be worn when operating this equipment Please refer to your Model 1910 Laser User s Manual for complete laser operating details BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 9 Chapter 1 Introduction Exatron www exatron com 3000B F LABO3 006 Please use this part number when ordering this label CAUTION DO NOT OPERATE THIS MACHINE WITHOUT m GUARDS IN PLACE Label shown actual size Dimensions 134 x 21 2 Colors Black on yellow background Your EXATRON handler is an automated electronic system with a variety of moving parts and subsystems which require safety covers and guards during operation All guards and covers including Power Supply covers must be securely in place before operating your handler The warning label shown above is a good example of the type of label which could theoretically blanket the entire handler As stated previously EXATRON prefers for cosmetic reasons not to do so PLEASE NOTE THAT EVEN COVERS WITH NO LABELS MUST REMAIN IN PLACE DURING HANDLER OPERATION BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL 1 10 Chapter 1 Introduction Exatron 3000B F LABO3 007 Please use this part number when ordering this label WATCH
128. le is wired one to one 1 1 to the RS 232 port on the back of a PC using a 25 pin RS 232 connector your PC uses 9 pin RS 232 port then typically use a straight through interface cable Laser Only Kit model 5000 only This special interface is a sub set of the Exatron super interface It is intended to be used with change over kits which do not have a test site i e kits which are for laser marking only Please refer to the EXATRON SUPER section above for additional information on how to use this interface As with the EXATRON SUPER interface the communications settings are fixed in the firmware at 9600 baud no parity 8 data bits 1 stop The following address in the handler s battery backed up RAM may be edited to fine tune the handler for your specific programmer tester and sorting requirements This address is not part of the standard power up selections and may be modified only by Changing The RAM as described in the Handler Set Up Chapter of this manual REMOTE GO ADDRESS 0099 00 On FF Off This address must be set to On for the controlling computer to have access to the handler s RAM If this address is not set properly the handler will display the message WAITING FOR PC www exatron com 3 16 Chapter 3 Interface Info Exatron 3000B EXATRON SUPER RS 232 CONTROL COMMANDS 5000 SERIES ONLY This information is subject to change without notice Contact EXATRON for latest revision The following RS 232
129. ler by pressing the PAUSE button Remove the red thumbscrew on the plunger assembly Lift the plunger assembly off the handler and manually free the jammed device so that it slides down into output 5 Move the remaining device up to block the sensor in the test site Replace the plunger Press Enter then press Clear to flush the second device into output tube 5 DUT SHUT LOST The handler has tried to sort a device but the shuttle did not arrive at the correct output bin Press the 0 key to turn off the power to all motors and manually center the shuttle at the output with the flashing LED Press the 0 key again to restart the handler You may also press the Clear button to center the shuttle back at output 5 and flush the handler of all devices EMPTY ALL TUBES The handler has just powered up It is detecting output tubes There may be devices in those tubes The handler has a battery backed up RAM which holds the current tube full count You may Press Enter to continue operation The handler will use its RAM count data to fill the tubes Remove all tubes with devices in them and then press Enter to continue operation Remove all output tubes and replace them with empty ones CAUTION Before pressing Enter verify that no tubes with devices were installed while the handler was off If any devices were added at that time the handler will overfill the tube s EMPTY LOAD PART The handler has run out of devices to te
130. levels of wear due to device materials this will generally occur at specific points on the handler If you wish you may send worn out equipment parts back to Exatron for evaluation In many cases the excessive wear can be reduced by design changes or material finish changes It is possible that the point which wears out can be modified into an insert which can be easily replaced as required Tilt Mechanism Table Top Mounting A tilt mechanism is built into your Model 3000B table top handler The slide angle may be adjusted from 12 to 60 from vertical The tilt mechanism is easily removed as needed for large test head interfaces The Free Rolling Exatron Dolly FRED has its own built in tilt mechanism The slide angle may need to be adjusted when large ceramic devices are to be tested This is because ceramic devices may chip or crack upon impact with other devices Decreasing the slide angle increases drag and slows the device down as it passes through the handler and into the output tube which minimizes chipping from impact Depending upon the mass and shape of a specific ceramic device the angle may need to be reduced The handler cycle timing is sensor controlled so the cycle speed will be automatically slowed to match that of the devices The recommended angle for all plastic devices is 12 from vertical The maximum slide angle for PLCC devices is 45 from vertical NOTE Ceramic device damage may be minimized by use of bumpers wh
131. mally be off Turn on the vacuum using the handler s yellow vacuum override button The red indicator LED will remain off Cover the vacuum hole in the handler plunger apply head with one device You may also cover the vacuum hole with the end of your finger although this may not be as accurate You will hear a noticeable change in the sound of the vacuum as it intercepts the device or your finger and the red indicator LED should turn on If the red LED does not turn on adjust as needed by carefully turning the potentiometer clockwise until the red LED comes on 3 If the valves in the vacuum generator assembly become plugged with dirt you may send the assembly back to EXATRON Customer Service where it will be repaired if possible for a fee REMEMBER Damage caused by a dirty air supply is not covered by the EXATRON warranty If you are experiencing dirt clogged vacuum generator valves check the air regulator Verify that it is clean and properly installed Please refer to the Air Regulator Maintenance Guidelines section earlier in this chapter and as always contact the EXATRON factory for assistance as needed Our toll free telephone number is 1 800 EXA TRON www exatron com 7 13 Chapter 7 Preventive Maintenance Exatron 3000B FIGURE 7 3 VENTURI VACUUM GENERATOR VALVE WIRES RED 24 VDC VAC SENSOR BLACK GROUND WIRING RED 24 VDC WHITE SENSOR ON O BLACK GROUND GREEN NOT USED SHIELD GROUND TT NOTE MIS
132. msec steps 00AC Package Type 50 28 DIP CO Kits 40 PLCC Plunge to Board Type 4 11 SOIC Type 3 One test site 12 SOIC Type 3 Two test sites 50 SOIC Type 4 Plunge to Board 5B SOIC Type 5B 00 Test ASCII Out S This is the ASCII letter which the EXATRON RS 232 interface uses as an output on a double test Set to S Normal Set to D Handler will issue S on First OOAE Add LCC Option FF Adds a special delay used by only some PLCC Type 4 CO kits running Thin LCC packages 00 Turn delay on FF Turn delay off OOAF Add Air Blast Adds a blow off cycle to the exit cycle on PLCC SOIC 00 turns blow off on FF turns blow off off 00B1 P Up Jog 00 to 19 Jogs octoloader right or left upon power up allows Octo RL Octoloader to be aligned on power up 0 Jog Left 1 Jog Right FOR EXAMPLE 02 Jog Left 2 steps 13 Jog Right 3 steps 9 Steps Maximum Test Cycle and D on Double Test Cycle Type 4 CO Kits only 00BO PUp Jog Shut RL 00 to 19 Jogs shuttle right or left on power up allows shuttle to be aligned on power up 0 Jog Left 1 Jog Right FOR EXAMPLE 02 Jog Left 2 steps 13 Jog Right 3 steps 9 Steps Maximum www exatron com 4 8 Chapter 4 Handler Setup Exatron 3000B ADRS DESCRIPTION ROM COMMENTS Delay Counts down in HEX in 10 msec steps 0085 L Apply Delay r FF Adds a delay after the label has been detected by the vacuum on the label pick up head Time to allow the
133. nd push the remaining four shorter bolts into place The two people holding the handler frame should not let go of the handler until all six bolts are properly inserted Double check that the FRED is properly assembled and verify that the tilt angle is correct After you have confirmed the assembly is satisfactory tighten all the bolts TRAY OPTION Using three 1 4 x 20 x 2 50 long bolts three lock washers and three 1 4 x 20 hex nuts bolt the tray extension frame to the bottom edge of the FRED frame Tighten all three bolts 2 8 Chapter 2 Installation Exatron 3000B General Operating Specifications Electrical Requirements 4 Handlers shipped either within the United States or off shore have built in electrical supply capability for 100 to 240VAC 50Hz to 60Hz except in the case of the Model 3010B Hot Rail The Hot Rail thermocouple card contains either a 50Hz crystal or 60 Hz crystal which must be specified by the customer Model 3010B Hot Rails operating at 240 VAC require an optional step down transformer for the handler s heaters Connect the power cord to earth grounded power outlets only If the handler is to be used in an electrically noisy environment or near large electromechanical 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 Ambient handlers require 3 Amps at 110 VAC
134. nded Warranties e Service Contracts Other Options Available as Requested The Model 3000B handler operation is constantly monitored by its STD Bus CPU Once a device enters the handler it is tracked by sensors as it passes through every step until it is positively placed in the correct output tube If a device jam should occur an appropriate error message will be displayed on the handler controller s front panel microterminal Most jams may be cleared by pressing the RUN or Clear buttons on the front panel www exatron com 1 1 Chapter 1 Introduction Exatron 3000B The handler may be operated in either of two modes AUTO or MANUAL MANUAL operation allows for Handler Diagnostics sequences to be run Handler Set Up changes to be entered and mechanical adjustments to be made at the operator s convenience before during and after automatic Handler operation AUTO operation continuously cycles devices through the handler The handler will stop when empty but re start automatically when more devices are loaded Each output tube may be filled to any pre set amount with individual counters keeping track of quantities in all outputs When an output tube fills the handler automatically begins to fill any other unfilled tube assigned to the sort signal received from the tester When all output tubes are filled the handler will stop and a message will be displayed such as ALL OUTPUTS FULL The tube counter is automatically reset by removing t
135. ndler will use to place the DUT into the test contacts Each step of the motor is approximately 003 Be careful not to drive the DUT too far into the handler s contacts when setting this feature The device s leads should not become bent but you will cause unusually frequent handler jams to occur The life of the test contacts will be decreased as well if too much plunge is used www exatron com 4 3 Chapter 4 Handler Setup Exatron 8 10 3000B Enter changes to the plunge depth using the controller keypad number keys The handler allows changes to each digit from lowest to highest in order First enter Ones then Tens then Hundreds then Thousands For example to enter a plunge depth of 625 steps press 5 then 2 then 6 then 0 The display will read 0625 The minus key will set the count to 0000 Enter Sets your selection Clear Resets to the top of the handler s PLUNGE XXXX loop E The handler will now display FULL TUBE 0045 Or some other four digit number This is the number of devices the handler will place into each of the handler s output tubes Be careful not to set the count for more parts than will fit into the handler s output tubes Enter changes to the full tube count using the controller keypad number keys The handler allows changes to each digit from lowest to highest in order First enter Ones then Tens then Hundreds then Thousands For example to enter a full tube count of 25 devices p
136. no water in either chamber If they are dirty physically disconnect the incoming air pressure supply from the air regulator and clean the trap and filter as needed If you find it necessary to clean the trap and or filter more often than once a month you should correct the problem at your in house air compressor Check your manufacturer s manual for the exact procedure necessary www exatron com 7 9 Chapter 7 Preventive Maintenance Exatron 3000B FIGURE 7 2 PRESSURIZED AIR REGULATOR www exatron com 7 10 Chapter 7 Preventive Maintenance Exatron 3000B FIGURE 7 2 A AIRPRESSURE METER AIR PRESSURE ADJUSTMENT C ON OFF VALVE Orange color Some newer versions will have the orange switch as shown below Main Air Flow On Off Switch On Position Shown AIR OUTPUT Connects to handler E AIRINPUT Connects to factory air supply Air regulators from EXATRON are equipped with pneumatic Quick Disconnect part P341 A mating quick disconnect may be purchased by ordering EXATRON part D341 If you choose to use a different type of quick disconnect replace the EXATRON supplied part as necessary EXATRON stocks only one type of air regulator quick disconnect COALESCING AIR FILTER G MOISTURE TRAP H MOUNTING BLOCK www exatron com 7 11 Chapter 7 Preventive Maintenance Exatron 3000B Vacuum Generator Maintenance Guidelines Some Changeover Kits contain a vacuum generator a k a
137. nt RAM setting command Pause Handler First send a plus to the handler wait for the handler to return a plus The handler is now ready to receive a command Send P CR to the handler The handler will complete its current sub cycle and will PAUSE the handler as soon as possible The display will read HANDLER PAUSED To restart the handler press the RUN button on the handler s control panel Exatron RS 232 The Exatron RS 232 interface allows the handler to be interfaced to virtually any computer based piece of test equipment The user must write a program which communicates with the handler using the commands listed in this section This interface is unlike EXATRON S other control interfaces The connector on the handler is a 25 pin RS 232 type connector with female pins The mating connector on the interface cable must use male pins The RS 232 side panel port uses the following pins Pin 1 GROUND Pin 2 RECEIVE input to handler Pin 3 SEND output from handler Pin 7 GROUND The baud rate stop bits data bits and parity may be selected by setting an address RAM address 009B baud rate 009 data format in the handler s EPROM Please refer to the General Interface Firmware Address section at the beginning of this chapter for Baud Rate and Data Format settings The standard EXATRON RS 232 settings are 9600 Baud No Parity 8 Data Bits 1 Stop www exatron com 3 19 Chapter 3 Inte
138. o accomplish this depending upon application and type of changeover kit A direct dock interface which connects the tester directly to the handler contacts provides the best performance although other interface methods are available In most cases the hardware required for the DUT Interface will be built and installed at EXATRON Therefore the DUT Interface will not be discussed in this section of the user s guide 2 The second basic part to every interface is the Control Interface The Control Interface allows the handler to send a Start to the tester and subsequently allows the tester to instruct the handler how to process the device under test The handler is equipped with a variety of ways to accomplish this task using two basic means of access a parallel port 5 Handler Port and an RS 232 serial port RS 232 PORT HANDLER PORT The handler has a number of operating features which relate to the handler s tester control interface Both the Handler Port and RS 232 Port have several distinctive options from which to choose These various control interfaces available from EXATRON are the subject of the following discussion They have been organized into three categories A General Interface Options common to both Handler Port and RS 232 Port B Handler Port Interface Options C RS 232 Interface Options Please read through all of the firmware options in this chapter to determine exactly which interface will
139. o not run the handler with the programmer tester undocked If you do the handler will release parts out of the test site onto the floor 2 Verify that the proper changeover kit is installed on the handler Check A Octoloader input tube holder plate B Main test site rail assembly C Correct size plunger bar Plunge to board change kits Shuttle assembly May be insert only E Proper extruded aluminum output tubes or output tube holder with plastic tubes www exatron com 4 1 Chapter 4 Handler Setup Exatron 3000B 3 Turn the handler ON by pressing the RED mushroom style power button on the front of the power supply NOTE You may turn OFF the power to the handler at any time except within the first ten seconds of having turned the handler ON Always turn the handler OFF when you move either the handler or the power supply NOTE The handler uses a BURR BROWN Microterminal control panel fully integrated into the Model 3000B system This microterminal unit has its own power up procedures and set up conditions Please refer to Section 3 2 SETUP Category Description of the Microterminal User s Guide located in Chapter 10 of this manual for further information if required 4 Asthe handler powers up it will display its model number and current control program with revision date When calling in for assistance or software updates please give this revision date to EXATRON s Customer Service Department 5 The handler s front
140. o specify right and left hand parts AM or HR will indicate parts for Ambient Machines or Hot Rails We use 62 or 75 to indicate specific sizes of solenoid plungers There are other special notations which may be used as part of our numbering system and which may change with time Please contact the EXATRON factory for assistance with any questions regarding special letters or numbers attached to part numbers 2 SECOND FIELD This column title usually hidden to save space on printout This indicates the quantity of the specific part used in the manufacture of this system This information may be helpful in determining the correct part number and is used to build an assembly kit when your system was originally built www exatron com 10 1 Chapter 10 Supplement Exatron 3000B 3 DESCRIPTION This is the name assigned to the part In most cases this description will easily define the pat you wish to locate Please include this description when ordering replacement parts 4 ASSEMBLY Indicates which major system sub assembly the part belongs to In most cases the Assembly can be ordered as a complete replacement part 5 OPTIONS Some parts lists contain system options Options indicates special parts which may be used in your system 6 SIZE These are dimensions in inches The dimensions are listed left to right from smallest to largest This is the starting size of the part prior to being machined B x C Imagine a cube
141. oader Motor 08 Label Apply Motor For example 05 Octoloader Motor Shuttle Motor No 2 Motor as in DIP Changeover Kits 07 Octoloader Motor Z Motor Shuttle Motor as in Plunge to Board Change Kits full tube in ASCII digits full tube in ASCII digits tube in ASCII digits tube in ASCII digits 0096 Test Sol Delay 10 00 to FF This delay allows settling time for the DUT eliminating any bouncing motion in the test site before the test contacts are turned on Counts down in HEX in 10 millisecond steps APPLIES TO DIP AND OTHER NON PLUNGE STYLE KITS Start Test Delay 01 00 to FF Time delay for the test contacts to close before the handler sends a start test signal to the tester Allows the test contacts to fully close before issuing a start pulse Counts down in HEX in 1 millisecond steps Start Pulse Width 14 00 to FF Adjusts the start test pulse width This is allowed to provide flexibility in interfacing between the handler and tester programmers Counts down in HEX in 1 millisecond steps BEEN www exatron com 4 6 Chapter 4 Handler Setup Exatron 3000B ADRS DESCRIPTION ROM RAM COMMENTS OPTIONS 009 Count Mask 00toFF Allows the operator to designate a bin or bins that will ignore the pre defined full tube count This is useful when using bulk bucket outputs A total count is maintained but the output tube selected will never fill For example bit map 10 Sort 5 00 No masking 08
142. om 5 13 Chapter 5 Diagnostics Exatron 3000B v1 ALL MOTOR CHECK Shuttle Motor Check This diagnostic tests input port C4 output port C4 C9 located on PCB 5000 397 PAL 397 3 U7 TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 4 key Handler displays ALL MOTOR CHK Press the 1 key Handler displays SORT MOTOR NOTE The handler s output cover LEDs will indicate the current location of the shuttle The correct pattern for an empty shuttle at each output bin is as follows LED 1 2 3 4 5 6 7 8 BIN 1 O O O O O O O 2 O O O O O O O O 3 O O O O O O O O 4 O O O O O O O O 5 O O O O O O O O 6 O O O O O O O O 7 O O O O O O O O 8 O O O O O O O O O Indicates flashing LED O Indicates LED turned off Press the 1 key 1 LEFT STEP The Shuttle will move one tube to the left Press the 2 key the handler will display the current motor settings in RAM This display is helpful when trying to increase the motor s speed Press the 3 key 1 RIGHT STEP The Shuttle will move one tube to the right Press the 4 key 2 LEFT STEPS The Shuttle will move two tubes to the left Press the 6 key 2 RIGHT STEPS The Shuttle will move two tubes to the right Press the 7 key JOG LEFT The Shuttle will move one step to the left about 006 Press the 8 key the shuttle will try to automatically center itself at Home bin 5 Press the 9 key JOG RIGHT The Shuttle will move one step to the right
143. on at the beginning of this chapter for further details Handler Port Pin Out Sort Input 1 Sort Input 2 Sort Input 3 Sort Input 4 Sort Input 5 Sort Input 6 Sort Input 7 Sort Input 8 2 Start Output 1 Start Test Pulse Handler Vcc 5 VDC Handler Ground 3X SPECIAL PAL REQUIRED FIGURE 3 1A Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 HANDLER INTERFACE PORTS DETAIL OPTIONAL OPTO ISOLATION PORT SEE 5000 D76 FOR DETAILS MATING CONNECTOR T amp B 72609 2030 Sort 1 Sort 2 Sort 3 Sort 4 Sort 5 Sort 6 Sort 7 EOT 2 Start Start Test Pulse 10 Handler Vcc 5VDC 11 Tester Ground 12 O O N www exatron com O Pin13 Input 9 End Test Pin14 Not Used Pin 15 Not Used Pin16 Not Used Pin 17 Output Pin 18 Output Pin 19 Output Pin 20 Output Pin 22 Output Pin 22 Output 2 Start Test Level Pin 23 Handler 5 VDC Pin 24 Handler Ground 5 Ul 0 Not Used NOTE NEVER CONNECT Not Used OPTO GROUND TO Not Used HANDLER GROUND OR Not Used OPTO Vcc TO HANDLER Output 8 Vcc Output 7 Output 6 Output 5 Output 4 Start Test Level Handler Vcc 5VDC Tester Ground 3 9 Chapter 3 Interface Info Exatron FIGURE 3 1B HANDLER INTERFACE PORTS DETAIL HANDLER PORT SEE 5000 A89 FOR DETAILS MATING CONNECTOR CINCH 57 30240 O Sort1 1 13 5012 2 14 Sort3 3 15 Sort4 4 16 Sort5 5 17 Sort6 6 18
144. on the front of the 24 volts power supply the larger of the two power supplies C With a small thin bladed screwdriver slowly turn the pot adjustment screw until the voltage reading moves into the acceptable range D Turn the handler power OFF and check and or calibrate the 5 volts supply using the same method as described above for the 24 volts supply Substitute the post marked 5 V in place of the post marked 24 V in the instructions NOTE The 5 volts power supply is smaller than the 24 volts power supply and the pot adjustment screw of the 5 volts power supply must be turned even more slowly and carefully than the pot of the 24 volts power supply If the 5 volts pot is adjusted too quickly the power supply will overload and shut down for several minutes www exatron com 7 5 Chapter 7 Preventive Maintenance Exatron 3000B To order replacement parts or receive assistance with any repair you may call the EXATRON factory toll free at 800 EXA TRON 800 392 8766 Direct 408 629 7600 Or feel free to fax us at 408 629 2832 with your request Most orders are shipped within twenty four hours of receipt of the order EXATRON S Sales Department and Customer Service Department are open from 8 00 AM to 5 00 PM Monday through Friday EXATRON also offers our customers a complete Service Agreement package providing extended service support from EXATRON factory personnel or certified independent service technicians
145. only CPU ERROR 1 CPU ERROR 2 CPU ERROR 3 CPU ERROR 4 CPU ERROR 5 All of the above errors are critical The handler s control program has detected a large problem and has stopped operation Use the following procedure to resolve this problem 1 2 Write down exactly which CPU ERROR message is displayed Write down exactly which output cover LEDs are on and whether they are flashing Write down to the best of your knowledge what message s was displayed by the handler just before the error Write down to the best of your knowledge what the handler was doing just before the error Power down the handler Power the handler back up and answer all of the MOD SET UP YS questions Resume handler operation Fax your notes to EXATRON as soon as possible We will answer your fax with an explanation of what occurred and a free software update to permanently correct the problem www exatron com 6 5 Chapter 6 Display Dictionary Exatron 3000B DIAGNOSTICS You have pressed the DIAGNOSTICS button Please refer to the Diagnostics Chapter 5 of this manual for further details on using the Diagnostics Mode DOUBLE PART ERR The handler has miscycled and placed two or more devices into the test site Make sure you are using the correct changeover kit and that it is in good working condition Press Clear to flush all miscycled devices into output 5 If that does not solve the problem and one of the devices then jams pause the hand
146. or Type 4 Plunge to Board CO Kits Only www exatron com 4 12 Chapter 4 Handler Setup Exatron 3000B ADRS DESCRIPTION ROM RAM COMMENTS OPTIONS OOFA Soft Full Half 02 00 02 Sets the Z motor to use full 0 006 steps or half 0 003 steps in this special reduced impact plunger sequence 00 Full step setting 02 Half step setting For Type 4 Plunge to Board CO Kits Onl OOFB Up Steps 100 30to39 Sets 100 s Digit on Self Adjust Z on Type 4 Plunge to board CO Kits board CO Kits board CO Kits OOFE Self 7 Extra 30 to 34 This feature provides from 0 to 4 additional Up steps to the Self Adjust Z Motor sequence on Plunge to Board Changeover kits Creates a slightly larger gap so the device under test can more easily slide under the pick up head Set as ASCII number For Type 4 Plunge to Board CO Kits Onl ii www exatron com 4 13 Chapter 4 Handler Setup Exatron 3000B Chapter 5 Handler Diagnostics OVERVIEW This chapter describes the operation of the handler s extensive built in diagnostics These Diagnostics allow every sensor solenoid switch motor and l O Port in the handler to be individually tested Use these checks to troubleshoot any problem the handler may have ENTERING DIAGNOSTICS MODE Although no tools are required an EXATRON LED checker part 3000 052 small blue plastic box will be helpful in troubleshooting broken sensor LED pairs and for testing the handler control
147. ort signals are still present from the tester they will be latched into the handler s sort latch This could cause the handler to sort an untested device to an output bin based on the previous tester bin result In many cases the mechanical motion of the handler will allow both the previous bin result plus the new bin result to be latched into the handler s sort latch This will result in a MULTI SORT ERROR message The handler s output cover LEDs will flash the input error combination Typically a Pass and a Fail input will flash at the same time lt may be that your tester does not respond to either edge of the handler s start pulse This is common problem with PC based testers In this case making the standard start pulse longer may correct the problem may be that your tester resets the sorts on the rising edge of the handler s standard start pulse In this case making the standard start pulse longer will have no effect You now have the option to use the 2P START PULSE You may from the handler s front panel adjust the second start pulse to start before the standard start pulse and or end after the standard start pulse You may now use the rising edge of the second start to reset the tester independent of the rising edge of the standard start Care must be taken to be absolutely sure that the tester s sorts are completely reset before the end of the start pulse used by the tester Please refer to FIGURE 3 3 on the following
148. p UNPACKING THE FRED AMBIENT ASSEMBLY Tools required One standard flat bladed screwdriver One Phillips head screwdriver Size 6 Allen wrench www exatron com 2 3 Chapter 2 Installation Exatron 3000B Open the fred shipping box and remove all parts of the metal fred Inside the box you will find one additional set of FRED assembly instructions Detail Figures A B and C and one FRED parts list Assemble the base of the FRED first Refer to Detail A FRED DETAIL A 3 WALES UP THE BASE PLATE FROM A BENCH TOP HANDLER USE 4 20 1 PLCS 2 75 APS OLER SUPPLY SMALL HOLES FEET INTO de SHELF uy PLACES i 0 IN 3000 032 BASE 3174 70 x 1761 PLACES www exatron com 2 4 Chapter 2 Installation Exatron 3000B 1 Using six 1 4 20 x 1 75 long bolts and six lock washers attach the two uprights to the base plate Note the location of the small holes in the base in relation to the uprights 2 Tighten all six bolts 3 Locate the two riser bars 3000 041 and the rigid support bar 3000 034 Using four 1 4 20 x 2 75 long bolts four block washers and four 1 4 20 hex nuts attach the risers and the rigid support bar to the uprights by inserting the bolts through the upright through the riser and then through the holes in the rigid support bar The large holes in the riser should be at the top Assemble the riser bar in the lowest position ini
149. panel microterminal controls are defined as Enter Starts operations sets your selections Clear FLUSH devices from handler Delete Remove characters from display when making changes RUN READY TO RUN Mode also starts operations MANUAL MANUAL Mode SET UP MOD SET UP YES NO CHANGE RAM YES NO PAUSE HANDLER PAUSED TOTALS Display output bin totals DIAGNOSTICS Handler Diagnostic Mode 0 All MOTORS OFF then Enter ALIGN MOTORS 1 Jog Octoloader 1 step left 3 Jog Octoloader 1 step right 4 Move plunger up 1 step 6 Move plunger down 1 step 7 Jog Shuttle 1 step left 9 Jog Shuttle 1 step right 6 The handler will now display MOD SET UP NO From this point on the handler controller presents options and advises cycling status If you do not wish to make any changes to the handler s set up press the ENTER button to view the current settings The display will scroll through the current settings for INTERFACE STOP ON FAIL ON OFF PACKAGE TYPE PLUNGE TO TEST SITE STEP SETTING Where applicable OUTPUT TUBE FULL SETTING www exatron com 4 2 Chapter 4 Handler Setup Exatron 3000B 7 If you do wish to change any or all of the above settings press the SET UP button to toggle the readout to MOD SET UP YS Now press the ENTER button to make changes A The handler will now display PICK INTERFACE Select HANDLER PORT by pressing the 1 key Select EXATRON SUPER b
150. pper motor The plate automatically moves both left and right positioning each tube of devices over the handler input track When the input track is emptied the octoloader automatically searches for tubes with devices The octoloader has a sensor mounted at its junction with the input track The octoloader can see a device jam and stop its own movement to prevent breaking the jammed device The octoloader also has an automatic wiggle jam clearing operation which it will implement immediately in an effort to remove the jam without operator assistance Model 3000B octoloaders use a Snap On plate which is specifically fitted with tube holders for a given device application All Model 3000B Handlers not intended to be used on a FRED Free Rolling EXATRON Dolly are supplied with bench top base plates which must be bolted directly to a bench or table top to secure the handler Each plate includes two sets of tilt bars which enable the handler s tilt angle to be altered for specific applications The tilt angle is critical for ceramic DIPs and LCCs since too much drop angle may cause chipping of the packages www exatron com 1 4 Chapter 1 Introduction Exatron 3000B The Model 3010B with One Elevated Temperature Track The Model 3010B Hot Rail adds a single track hot rail to the input of the handler This track holds twenty inches of devices in order to preheat them prior to test The temperature range of the Hot Rail is ambient to 125
151. quirements This address is not part of the standard power up selections and may be modified only by Changing The RAM as described in the Handler Set Up Chapter of this manual BIT CHECK ADDRESS 00D1 00 Bit check On FF NO bit check Off This address is used by the PROGRAMMER RS 232 interface only The user may set the handler to perform an Illegal Bit test at the start of the programming cycle or not EXATRON recommends leaving this option turned On whenever possible P V L ADDRESS 0003 This address is used by the PROGRAMMER RS 232 interface only The user may select the default program verify or load master operation in the handler The possible defaults are data 02 Program data 04 Verify data 08 Load master www exatron com 3 23 Chapter 3 Interface Info Exatron 3000B Programmer RS 232 Troubleshooting Guide Follow all troubleshooting steps in sequence 1 When I click the RunALL icon at the start of a new job the monitor displays FE ERROR message This error occurs when using a DATA l O programmer only The error message has been sent by the DATA I O programmer and is being displayed on your EXATRON equipment This message is described in the DATA I O user manual as Undefined Error An error occurred that the CRC program could not categorize Document the method in which the error occurred and call DATA I O to report the problem You may be able to correct the error without
152. r The message MOD SET UP NO will appear If you now wish to modify any of the set up information you just entered press SET UP to toggle the YES NO option of the MOD SET UP message to YES and make the necessary corrections TIP Make certain to write down and retain any changes you make to the handler RAM If you do not you will regret this later Permanent selections should be programmed into the EPROM Please contact EXATRON for assistance with programming the EPROM Our toll free telephone number is 1 800 EXA TRON 7 If no modification is needed press Enter again to return to the previous mode www exatron com 4 5 Chapter 4 Handler Setup Exatron 3000B RAM ADDRESS LISTING The following table describes each address in numerical order This information is current as of the revision date of this manual however the handler firmware changes regularly Please refer to the Change Over Kit Supplemental Chapter of this manual for addresses features specific to your system as shipped from the Exatron factory Exatron offers free firmware updates upon request for the life of the equipment ADRS DESCRIPTION ROM RAM COMMENTS OPTIONS 0090 Handler Type 00 Model 3000B with Octoloader 11 Model 3000 old model Black Main Plate 2B Model 2000B 31 Model 3010 Hot Rail 0091 Motors 05 Hex Sets the number of motors inherent in the handler Decode 01 Output Shuttle Motor 02 Plunge to Board Z Motor C O Kits 04 Octol
153. r lines are allowed to become discolored or the moisture traps become overfilled damage 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 Handler damage due to improper air supply is not covered by the Exatron warranty House Shop vacuum is not required Changeover kit vacuum requirements are supplied by built in venturi vacuum generators www exatron com 2 9 Chapter 2 Installation Exatron 3000B Environmental Operating Specifications Location ALL BENCHTOP ALSO KNOWN AS TABLE TOP PLATE MOUNTED HANDLERS MUST BOLTED SECURELY TO THE TOP OF THE BENCH The handler s center of gravity is fairly high in relation to the benchtop This makes the handler unstable if not bolted down which could result in the handler being knocked over This can cause serious damage to the handler and injury to the user This machine should be installed in a dust free environment to preclude dust and dirt particles from contaminating its moving parts especially those parts which come into contact with the devices being tested The life of your handler is greatly enhanced by keeping it as clean as possible This Model 3000B handler should be placed as close as possible to your tester test socket since cable length from the contactor to the tester is critical in most applications Please refer to Chapter 3 Interface Inform
154. ress 5 then 2 then 0 then 0 The display will read 0025 The minus key will set the count to 0000 Enter Sets your selection Clear Resets to the top of the handler s FULL TUBE XXXX loop After making your selection press the Enter button to display SELF ADJUST Z if your changeover kit is Plunge to Board Style or READY TO RUN if your changeover kit is not Plunge to Board Load devices into any or all of the octoloader s eight input slots Press the RUN button to begin testing programming if your changeover kit is not Plunge to Board Style If your changeover kit is Plunge to Board Style press the RUN button The handler will now run the Automatic Z Adjust Cycle as described in Chapter 5 Diagnostics When this procedure is finished the Z plunger top position will be adjusted to accommodate the devices to be run and the sample device used will be flushed to output bin 5 Press the Clear button to exit SELF ADJUST Z The handler will now display READY TO RUN Press the RUN button to begin testing programming www exatron com 4 4 Chapter 4 Handler Setup Exatron 3000B CHANGE RAM The Model 3000B system allows the operator to change the RAM of the handler CPU To access the Change RAM Mode of the Model 3000B 1 2 Press the SET UP button on the handler controller The message CHANGE RAM NO will appear Press SET UP again to toggle the YES NO option to YES The message CHANGE R
155. rface Info Exatron 3000B BASIC HANDLER CPU TEST CYCLE HANDSHAKE Summary EXATRON uses only standard upper case ASCII characters HANDLER SENDS AN H CR TESTER SENDS R READY HANDLER CLOSES TEST CONTACTS ONTO THE DEVICE UNDER TEST DUT HANDLER SENDS AN S CR START TEST FIRST TEST CYCLE TESTER SENDS TEST SORT RESULT 1 THROUGH 8 OR 0 FOR REMOTE RETEST HANDLER OPENS TEST CONTACTS DUT CYCLES TO AN OUTPUT TUBE A NEW CYCLE STARTS NOaRWN gt SPECIAL NOTE REMOTE FLUSH The tester can send an asterisk 2 in HEX as a handler reset command the handler receives an asterisk the test will be aborted and the device will be flushed to the Home bin output tube 5 SPECIAL NOTE REMOTE RETEST You may send a zero 0 to the handler as a test result This will cause the handler to pick up the device and replunge retest it A new 5 will be sent to the tester You may use the 0 response as many times as you wish To end a test cycle send the handler a 1 through 8 as a sort command BASIC HANDLER CPU TEST CYCLE HANDSHAKE With Explanation 1 HANDLER SENDS AN H CR The handler establishes proper communications at the outset of every cycle except Retest cycles To do so and a carriage return CR are sent by the handler to the tester at the start of each test cycle The handler is seeking an R Ready from the tester The display will read
156. rom spilling 4 While blocking the open end of the tube with your finger invert the tube and rest that end of the tube and your finger against the Octoloader main plate next to the tube gate at an approximately 45 angle 5 While continuing to hold the tube with your right hand move the index finger of your left hand out of the way of the open end of the tube Keep the open end of the tube resting against the Octoloader to prevent spilling the devices and raise the bottom end of the tube until it is completely upside down Press the tube into place in the track of the Octoloader 6 Close the tube gate over the tube to complete installation Repeat this process for each additional tube OCTOLOADER OCTO INDEX GAP www exatron com 2 15 Chapter 2 Installation Exatron 3000B www exatron com 2 16 Chapter 2 Installation Exatron 3000B Chapter 3 Interface Information OVERVIEW The test site on the Handler may be interfaced to virtually any programmer and or tester available Some interfaces require custom configuration prior to shipment but the only requirement for a given programmer or tester is that it be capable of issuing and accepting commands to and from the handler or the system controller There are two basic parts to the handler s interface with your programmer tester 1 The first part is the DUT Interface The DUT Interface connects the handler s test contacts to the tester s test socket There are many ways t
157. ron 5044 572 84 PIN PLCC LIVE DEAD BUG 5000 E12 LIVE BUG MICROPAK 100 WIDE BODY 6000 510 LIVE BUG SOIC 150 WIDE BODY 3000B 5000 954 LIVE BUG SOIC 500 WIDE BODY 5000 11 LIVE BUG SOJ 300 WIDE BODY 5000 968 DEAD BUG TSSOP 210 WIDE BODY STANDARD EXATRON EXTRUDED TUBES STANDARD LENGTH 21 SCALE 2 1 JUNE 1996 www exatron com 9 33 Chapter 9 Replacement Parts Exatron 5000 0693 DEAD BUG SOT 23 130 WIDE BODY 2400 820 DEAD BUG DIP STANDARD GULL WING DS 30 WIDE BODY PET 320 LIVE BUG TSOP 3000B 6000 479 DEAD BUG CUSTOM KODAK 800 WIDE BODY 6000 410 DEAD BUG CUSTOM KODAK 400 WIDE BODY 311 CUSTOM HUGHES HALL EFFECT DEVICE STANDARD EXATRON EXTRUDED TUBES STANDARD LENGTH 21 SCALE 2 1 JUNE 1996 www exatron com 9 34 Chapter 9 Replacement Parts Exatron 2710 54 LIVE BUG TSSOIC 170 WIDE BODY ES 2710 B85 LIVE BUG TSSOIC 160 WIDE BODY STANDARD EXATRON EXTRUDED TUBES STANDARD LENGTH 21 SCALE 2 1 JAN 1997 www exatron com 9 35 3000B 350 129 2400 52 LIVE BUG CERAMIC 350 WIDE BODY Chapter 9 Replacement Parts Exatron 3000B CONNECTORS 100 PITCH MALE SOLDER EDGE CONNECTOR 20 PIN PS10 4201 0 34 PIN PS17 4201 0 40 PIN PS20 4201 0 50 PIN PS25 4201 0 60 PS30 4201 0 FOR WIRE WRAP LENGTH PINS o ADD WIRE WRAP TO
158. s 30008 Exatron la tail E 5 230 9 72 0005 17 REN UE RR ATEWASSY Z nos 904 NAH 008 629 90 11156 UDS TIGE vY6 Z 21 NOWIYX3 30 2443904 e 3725 104 00 AYWVLIRIJOYA ON INMAC 2 51108 9 9 3sn M3A02 YOLOW Z HOLMS Z 108 301 Z Chapter 5 Diagnostics 2 gt 5 y gt i 0 ON N3dO WANIYA 440 31 438 fu Y Divd 937 038 En lt INI USMPOY 405435 WnnovA MOTIZA 56 ea El m DD LO c WnnovA 5 N 9 e E x Exatron 3000B Chapter 6 Display Dictionary Model 3000B Handler Status and Error Messages Messages which appear on the handler controller s display are alphabetically listed below in boldface print Symbols and numbers appear first Each entry in this section explains why the message is displayed and where applicable how to resolve the condition If further explanation is required the operator is referred to the appropriate section elsewhere in this manual for details We constantly adding messages to the handler s operating code If the one you need is not listed here please contact EXATRON S Customer Service Department for prompt assistance For free updates to the firmware please
159. s at the start of each first test cycle to establish communication This may be used for certain device count applications FF Send H on test send H on retest 00 Send H on test none on retest AA Never send H test or retest OOBE SOL Shut Down 00 Handler will automatically shut off all solenoids after 30 seconds of inactivity Recommended for handlers using solenoids in their CO Kits Will prevent some melt downs FF Handler will leave Solenoids in active state until the operator intervenes www exatron com 4 9 Chapter 4 Handler Setup Exatron 3000B ADRS DESCRIPTION ROM RAM COMMENTS OPTIONS FF OOBF Output cover LEDs will blink output Bin locations Output cover LEDs will blink output Bin locations Output cover LEDs will blink output Bin locations 00C3 Sort4 Bins 1 8 10 00 to FF Input Sort 4 to handler output bins BIT MAP A 10 Sttoutcover LEDs wli birik output Bin 00C4 Sort 5 Bins 1 8 10 00 to FF Input Sort 5 to handler output bins BIT MAP A 10 Oun cover LEDs wi binik ouput Bin cations 00C5 Sort6 Bins 1 8 10 00 to FF Input Sort 6 to handler output bins BIT MAP A 10 Oun cover LED wi binik ouput Bin cations 00C6 Sort 7 Bins 1 8 10 00 to FF Input Sort 7 to handler output bins BIT MAP A A Oun cover LEDs wi binik output Bin cations 00C7 Sort8 Bins 1 8 10 00 to FF Input Sort 8 to handler output bins BIT MAP
160. son for this condition Please refer to the Automatic Z Adjust Feature in Chapter 5 for details 2 Inspect your P contactors and clean the contact pins if necessary Please refer to the Particle Interconnect Contact Maintenance section in Chapter 7 for details 3 Inspect your device for bent leads INTERFACE CHECK Please refer to the Diagnostics INTERFACE CHECK section in Chapter 5 of this manual for details INTO SHUT JAM A device which has exited the test site has jammed as it arrived at the top of the output shuttle Open the output door and visually inspect the shuttle area Verify that the shuttle is fully seated in the handler Securing the shuttle onto the shuttle car by pressing it down with finger pressure until it snaps into place often resolves this error condition Close the output door and the handler will resume operation Alternatively the shuttle may have become slightly out of alignment with the output track Press the 0 key on the handler controller keypad to turn ALL MOTORS OFF Press the Enter button to display ALIGN MOTORS Align the shuttle by Pressing the 7 key to jog the shuttle one step left Pressing the 9 key to jog the shuttle one step right When alignment is complete press the RUN button to resume operation www exatron com 6 9 Chapter 6 Display Dictionary Exatron 3000B INTO T SITE JAM The handler has tried to load a device into the test site but the device has failed to arrive
161. st Reload any of the octoloader s input tubes and the handler will automatically resume operation END TEST The handler has requested an End Of Test command from the PC Enter will abort the test cycle TEST ABORTED and sort the device to a fail bin Clear will abort the test cycle TEST ABORTED and flush both the device in the test site and the device in the mark site to the flush tube bin 5 www exatron com 6 6 Chapter 6 Display Dictionary Exatron 3000B EXATRON RS 232 Please refer to PICK INTERFACE message later in this section EXATRON SUPER Please refer to PICK INTERFACE message later in this section FAIL PROGRAM Failed programming cycle FAIL VERIFY Failed verify cycle FAIL CHECK Failed illegal bit check cycle FAIL LOAD Failed to load master device The handler is using the PROGRAM RS 232 interface The device has failed a given cycle of the programmer operation and will be sorted to a fail output When any of the four messages shown above is displayed it will be followed by a two digit number The number at the end of the message indicates the error code reported back from the programmer Please refer to the error code section of the programmer manufacturer s manual for error code details FOUND PICK UP The handler is in the Automatic Z Plunger Top Position Adjustment routine At this point the plunger has picked up the DUT and is preparing to jog up to its top position
162. st Site point Sets 1 s digit Home Sensor to Test Site point Sets 10000 s digit Home sensor to exit point INNEN mes Sets 1000 s digit Home sensor to exit point Sets 100 s digit Home sensor to exit point Sets 10 s digit Home sensor to exit point Sets 1 s digit Home sensor to exit point 0025 Password On Off 00 FF Sets the controller password protection for the handler Set to 00 password is required to make changes to the handler set up Set to FF password is not required FACTORY SET PASSWORD IS 789 00726 Check I Lock 00 No Check 00 Will check optional CO Kit cover interlock will stop the handler if the interlock is open 00F7 Plunge Power 44 40 44 40 Standard Power 44 More Torque Standard Power cuts power to the coils when the Z motor stops This is a power saving function More Torque leaves full power on the coils when the Z motor stops For Type 4 Plunge to Board CO Kits Onl 00F8 Plunge Delay 00 to FF Time delay between each step during Z motor plunge Delay may be set in 25 millisecond increments 01 25 msec delay 02 50 msec delay etc For Type 4 Plunge to Board CO Kits Onl 0029 Soft Plunge Step OA 00 to FF Sets the number in HEX of full steps in this special reduced impact plunger sequence FOR EXAMPLE OA 10 full steps If the handler is set to Half Step see below this number is automatically doubled DO NOT USE MORE THAN 100 STEPS F
163. t EM Electro mechanical solenoid modification COPPER Copper material www exatron com 10 2 Chapter 10 Supplement Exatron 3000B 8 FINISH This designates the finish used on the part CLEAR Clear anodizing silver in color BLUE Blue anodizing BLACK Black anodizing RED Red anodizing NEDOX Conductive hard finish silver in color HCR Non conductive hard finish dark green in color NICKEL Bright nickel plating silver chrome in color NONE No finish natural material PAINT Painted part colors may be beige black or blue 9 KIT Indicates the quantity of this part that is supplied in a standard EXATRON spare parts kit www exatron com 10 3 Chapter 10 Supplement Exatron 3000B www exatron com 10 4 Chapter 10 Supplement
164. t process and sort the device to a fail tube WAITING FOR PC The handler is using the EXATRON SUPER interface A device is in the handler s index section The handler has sent a Go command to the PC but no answer has been received From the PC load and run a job Please refer to Chapter 3 Interface Information for further details WAITING FOR R The handler is using the EXATRON RS 232 INTERFACE Proper communications between the tester and the handler must be established at the start of every test cycle At this point the handler is waiting for an R Ready or an asterisk for Remote Flush Command from the tester If an R is received the handler will close the contacts or plunge the device onto the contacts and no operator action is required Please refer to Chapter 3 Interface Information for further details Z ADJUST ERROR This message will appear after the operator has started the Self Adjust Z routine if an error has been detected and the handler has stopped operation Verify that there are full tubes and available devices in the octoloader Press the RUN button again to re try the self adjust cycle Z DOWN PART TOP The handler is in the Automatic Z Plunger Top Position Adjustment routine At this point the plunger has moved down until the pick up head has tripped the test site sensor and is preparing to jog up to allow a DUT to fall into position This message is FYI in troubleshooting Self Adjust Z cy
165. t site vacuum sensor functionality by running Test Site Sensors 1 Through 8 Diagnostic as described in Chapter 5 of this manual PART IN SHUTTLE The handler has detected a device in the shuttle which should not be there The handler will automatically flush the device to output tube 5 PART IN T SITE The handler has detected a device in the test site which should not be there Press the Clear button to flush the device into output tube 5 PASS PROG PASS VERIFY The handler is using the PROGRAM RS 232 interface The device under test has passed the programmer s program verify cycles The current sum check will be displayed at the end of the above messages www exatron com 6 15 Chapter 6 Display Dictionary Exatron 3000B PICK INTERFACE The handler is asking you to select one of the following four interface choices 1 HANDLER PORT 2 EXATRON SUPER Use this interface when the handler is being controlled by a PC using EXATRON supplied software 4 PROGRAM RS 232 Use this interface to connect the handler directly to the programmer according to the following application notes a The programmer must be in REMOTE CONTROL b The programmer must be set up manually using the programmer s terminal software There is no EXATRON PC control with this interface 5 EXATRON RS 232 Enter Sets your selection Clear Resets to the top of the handler s PICK INTERFACE loop PICK PACKAGE The handler is
166. ta the flashing lights will change as well Use this visual confirmation for the tubes you have selected 9 0 If necessary change the data at this address 9 1 Press the Space key to increment the first data digit the most significant data bit 9 2 Press the Delete key to increment the second data digit the least significant data bit 9 3 Press the 0 key to set the data at that address to 00 9 4 Press the key to set the data at that address to FF 9 5 Press the Clear key to load the EPROM default data at that address 10 0 When finished editing this address press the SET UP key until the next relevant address is shown Consult the handler memory address chart below 11 0 Edit this address as described above in section 9 0 12 0 Continue this process until all addresses have been changed to proper data Note that if your tester programmer uses less than eight signal outputs you should assign the fail bin to all remaining sort signals 13 0 When finished editing press the Enter key to exit editing and set the new DATA into RAM www exatron com 3 5 Chapter 3 Interface Info Exatron 3000B Memory addresses in handler memory for output binning data Sort Address 00 0 00 1 00C2 00C3 00C4 00C5 00C6 00C7 1 2 3 4 5 6 7 8 www exatron com 3 6 Chapter 3 Interface Info Exatron 3000B Test Signal Bin Sort Data Worksheet Instructions Write the number of the sort signal you
167. ter 1 Introduction Exatron 3000B LABO9 001 Please use this part number when ordering this label THIS UNIT SOLD AND SERVICED BY CALL FOR SERVICE THIS UNIT IS NOT UNDER EXATRON WARRANTY THIS UNIT NOT TO BE SERVICED BY EXATRON Label shown actual size Dimensions 177 x 4 Colors Black on yellow background Your EXATRON automated handling system may be integrated with a variety of equipment made by other manufacturers such as programmers testers tube loaders and other peripherals To avoid confusion regarding service and warranty issues this label will be affixed to non EXATRON manufactured equipment upon delivery by EXATRON In order to assist our customers obtain proper service for peripheral units EXATRON provides this convenient name and telephone number sticker in at least one location on each peripheral unit You may wish to purchase additional stickers to facilitate service for other electronic equipment in use at your location as well BE SURE TO READ AND UNDERSTAND ALL EXATRON SAFETY REGULATIONS CONTAINED IN CHAPTER 2 AND THROUGHOUT THIS MANUAL www exatron com 1 14 Chapter 1 Introduction Exatron 3000B LAB09 002 Please use this part number when ordering this label WARNING DONT REMOVE WITH HANDLER POWER ON Label shown actual size Dimensions 1 x 14 Colors Black text on white background In general none of the various electrical cable connections on your EXATRON handler should
168. tially and then adjust its height as needed Place lock washers and nuts on all bolts Do not tighten the bolts yet 4 Place the handler power supply on the base 3000 032 Insert the rubber feet on the power supply into the pre cut holes in the base Please refer to Figure B The FRED may be assembled with either of two different pivot points depending upon your application The hardware remains the same in both cases Type A pivot is recommended for handlers using cable type test contact interface Type B pivot is recommended for zero test head interfaces or when docking the handler to a manipulator NOTE The maximum slide angle for PLCC devices is 45 from vertical 1 Locate the two blue pivot plates 3000 035 2 Using two 3 8 x 16 x 2 75 long bolts four 3 8 x 16 x 1 75 long bolts six 3 8 lock washers and six 3 8 x 16 hex nuts attach the pivot plates to the riser bars according to the pivot point selected Place lock washers and nuts on all six 3 8 bolts Do not tighten the bolts yet Or 13 TILT ANGLES 59 STEPS NOTES pa gt GO USE s MX CX DN C o 27 HANDLERS _ MINIMUM ZZ MAXIMUM POWER SUPPLY CHAMBER OPTIONAL FRED DETAIL POWER SUPPLY HANDLER Wa Sie ae TUIS E TAN 2 5 Chapter 2 Installation Exatron 3000B Please refer to Figure C 3 Locate the two plate hanger blocks 3000 037 4 Using two 1 4
169. tion LOAD EMPTY TUBE An output tube was removed after the handler selected an output bin but before the sort shuttle arrived at that tube Place an empty tube at the output that has the flashing output cover LED LOAD EPROM gt RAM The handler has reloaded its RAM set up data with settings stored in EPROM For your reference only LOAD REMOTE RAM The PC has sent new handler set up data to the handler s RAM Any settings previously made by the operator will be changed No action 1 required although we recommend verifying that the settings are correct after this message turns off LOADER GO LEFT The octoloader is moving to the left LOADER GO RIGHT The octoloader is moving to the right LOADER JAM The handler is detecting devices at the output of the octoloader input to the handler although no devices are at the index section 1 There are devices jammed at the output of the octoloader 2 Clear the jammed device s manually When you have done so the handler will automatically restart 3 Or press the Clear button to wiggle the octoloader and possibly clear the jammed device s 4 Or press the 0 key ALL MOTORS OFF then press Enter to display ALIGN MOTORS 2 and realign the octoloader plate to the handler input Press Enter again to turn the motors back on 5 Or use Diagnostics OCTO INDEX Check Input Sensor Check to verify that input sensors 6 7 8 are working correctly Please refer to Diagnostics Ch
170. tire contact assembly in a small ultrasonic cleaner such as the ones used to clean jewelry In this method use clean de ionized water as the cleaning solution After drying the P contact assembly if you use compressed air for drying make sure that the air is clean so that you do not spray oil all over your clean P contacts it is a good idea to bake the P contacts in an oven at 200 degrees Fahrenheit 90 degrees Centigrade for 15 minutes so that any remaining water is removed from the contacts www exatron com 7 17 Chapter 7 Preventive Maintenance Exatron 3000B www exatron com 7 18 Chapter 7 Preventive Maintenance Exatron 3000B Chapter 8 Drawings MECHANICAL 3000 200 B 3000B MAIN ASSEMBLY 3000 209 B 3000B POWER SUPPLY ASSEMBLY 3000 210 A 30008 SIDE VIEW STANDARD MOUNT 3000 215 A 3000B BASE PLATE 3000 276 2 A 3000B POWER SUPPLY ASSEMBLY 3000 325 A 3000B LABEL SYSTEM 3000 429 A 1 POWER SUPPLY CALL OUT ILLUSTRATION 5000 935 C 5000 TYPE SHUTTLE ASSEMBLY ELECTRICAL 3000 055 C 8085A CPU ASSEMBLY 3000 055 C3 8085A CPU SCHEMATIC 3000 202 3 A CARD CAGE BUS PCB ASSEMBLY 3000 202 A CARD CAGE BUS PCB SCHEMATIC www exatron com 8 1 Chapter 8 Drawings Exatron 3000B ELECTRICAL Continued 3000 223 B 3000B I O PORT PCB ASSEMBLY 3000 223 2 B2 30008 I O PORT PCB SCHEMATIC 3000 858 A CE 3000B POWER SUPPLY WIRING 3000 892 A 1 3010B ALARM WIRING 3000 A57
171. to SENSOR CHECK 4 Y MOTOR HOME to return to SENSOR CHECK 5 N A to return to SENSOR CHECK 6 N A to return to SENSOR CHECK 7 N A to return to SENSOR CHECK y To return to DIAGNOSTICS Menu 2 N A 3 SHUTTLE SENSORS Sensors 1 8 correspond to location of output shuttle as indicated by the red LED s on the blue output cover 4 FULL TUBE Sensors 1 8 indicate if corresponding tube is full of completed parts 5 TUBE Sensors 1 8 indicate if tube is present in the tube holder www exatron com 5 2 Chapter 5 Diagnostics Exatron 3000B 2 key OUTPUT CHECK then 1 key SOLENOID CHECK The following outputs will cause the corresponding solenoid to cycle continuously until the Enter key is pressed Corresponding Override Switch 1 Solenoid 1 Vacuum Valve 2 Solenoid 2 Air Blast 3 Solenoid 3 Exit Valve 4 Solenoid 4 Pickup Head Valve 5 Solenoid 5 N A 6 Solenoid 6 N A 7 Solenoid 7 Stack Solenoid 8 Solenoid 8 Index Solenoid 9 All Solenoids ON 0 All Solenoids OFF YELLOW BUTTON WHITE BUTTON ORANGE BUTTON BLACK BUTTON GREEN BUTTON GREY BUTTON RED BUTTON BLUE BUTTON To return to DIAGNOSTICS Menu 2 key SOL TOGGLE CHECK then The following keys will cause the corresponding solenoid to either toggle on or off It will not continuously cycle Corresponding Override Switch 1 Solenoid 1 Vacuum Valve 2 Solenoid 2 Air Blast 3 Solenoid Z3 Exit
172. tor under consideration has moved one full step to the left 1 RIGHT STEP The motor under consideration has moved one full step to the right 2 LEFT STEPS The motor under consideration has moved two full steps to the left 2 RIGHT STEPS The motor under consideration has moved two full steps to the right ADJ Z SWITCH The handler is in the Automatic Z Plunger Top Position Adjustment routine At this point the plunger has moved up from the test site to its top position but the number of steps required to do so 1 not within acceptable range between 10 and 50 steps The Z Plunger Top Position switch itself must now be moved so that the plunger will stop within the defined range Please refer to Diagnostics Chapter 5 for complete details ALIGN MOTORS The operator may now jog any of the handler s motorized components by just one step using the keypad keys as described below 1 Jog the octoloader left 3 Jog the octoloader right 4 Jog the plunger up 6 Jog the plunger down 7 Jog the shuttle left 9 Jog the shuttle right 0 Turn all motors off ALL MOTORS OFF ALL MOTOR CHECK Please refer to the Diagnostics section in Chapter 5 of this manual ALL MOTORS OFF You have pressed the 0 key The power to all motors is now OFF You may realign or move any of the motors manually Press any handler controller button to continue ALL OUTPUTS FULL The handler is waiting to sort a device but all output tubes
173. tted to older versions of the same model The date on the parts list indicates the date of the last revision of the list not necessarily the last revision of the system hardware Most systems will have two parts lists One list is for the base system This is the main section of the system and includes the power supply and the main electronics card cage The second list is for the Changeover Kit This kit assembles to the base to create a complete Handler The changeover kit is basically the custom tracks test site lead ins and tube holders which are unique in design to the specific device to be handled Since it is quite possible to have several changeover kits for one base system you will need a parts list for each changeover kit Parts List Guide Descriptive Column Categories 1 PART NUMBER This is the number assigned by EXATRON to a specific part The first four digits indicate the model number of the system for which the part was originally designed We use parts from different models to lower inventory costs and to speed the design of custom handlers The next three digits are simply the numerical count of the part as it was designed These are the three numbers which are stamped or laser marked onto most machined parts The revision letter of the part is listed next This letter should be included when ordering replacement parts EXATRON occasionally uses additional letters or numbers to indicate special features We use R and L t
174. ttle at output 5 Press the 0 key again to resume handler operation SHUTTLE OUT JAM The handler has tried to bin a device The device is jammed at the output of the shuttle Manually clear the jam and the handler will automatically restart Or you may press the Clear button to wiggle the output shuttle and possibly free the jammed device Verify that the output tube is not overfilled SOLENOID CHECK Please refer to the Solenoid Diagnostics section in Chapter 5 of this manual SORT ERROR The handler has received an illegal sort command from the tester The output door LEDs will flash the received sort Press the Clear button on the handler controller keypad to restart operation If this message appears frequently check your tester interface Please feel free to contact EXATRON for additional assistance Our toll free telephone number is 1 800 EXA TRON SORT INPUT Please refer to the Diagnostics INTERFACE CHECK Input Sort section in Chapter 5 of this manual SORT MOTOR CHK Please refer to the Diagnostics ALL MOTOR CHECK Shuttle Motor Check section in Chapter 5 of this manual SORT RESET ERR The handler has sent a start test pulse out of the Handler Control Port One or more of the input sorts remained low All input sorts must return to logic high within 100 msec of the handler issuing a start test pulse You may turn this check on or off by changing the handler s RAM 00 5 00 Sort reset check ON 00 5 FF Sort
175. turn block in place and slide it gently to the right until the shuttle chain tension is sufficiently tight Re tighten the two Allen screws to secure the return block at its new location Clean the shuttle bearing rail part 5000 368 with cotton swabs dipped in isopropyl alcohol Allow each cleaned area to dry before moving the shuttle back over that part of the bearing rail Check the shuttle spring for wear A Remove the shuttle car by pulling it out of its Snap On fitting B Remove the power roller block part 5000 938 from the shuttle car by removing its two screws The stainless steel shuttle spring part LC 016B 10 SS will now be visible C Remove the spring and the brass insert below the spring D Clean the brass insert with isopropyl alcohol Check the shuttle spring for springiness If it is worn replace the spring Inspect the two chamber filter on the WILKERSON Model NC00440 air regulator or equivalent AIR REGULATOR MAINTENANCE IS DISCUSSED IN GREATER DETAIL AND A CALL OUT ILLUSTRATION IS PROVIDED IN THE AIR REGULATOR MAINTENANCE GUIDELINES SECTION LATER IN THIS CHAPTER A Remove the charcoal filter air cleaning chamber and inspect If the black filter element is full of particles which have been extracted from the air supply replace this filter B Remove the air drying chamber and pour out any liquid which has been extracted from the air supply www exatron com 7 3 Chapter 7 Preventive Maintenanc
176. turning after properly placing a device in output tube 1 having received a sort 1 command and there is now 1 device in output tube 1 The counter is for CURRENT TUBE FULL count only The handler also keeps a TOTAL count To obtain TOTAL counts press the MANUAL button then press the TOTALS button for total counts from output bin keys 1 through 8 The tube full count rolls over at 9999 devices for output taping machine options BIN 5 0 FLUSH The handler is flushing one or more devices from the machine This message is for the PC It tells the PC not to count the device s being flushed CHANGE RAM NO Exits routine without making any changes to the handler s RAM set up parameters Enter Exit with no changes SET UP Toggle back to CHANGE RAM YS CHANGE YES Allows the operator to override the handler s set up parameters Enter Allows changes to the RAM Please refer to Chapter 4 Handler Set Up for further instructions SET UP Toggle back to CHANGE RAM NO www exatron com 6 3 Chapter 6 Display Dictionary Exatron 3000B CHECK CONTACTS This message indicates that the Z plunger has somehow become out of step and has moved too far up in the Z motor assembly At this point the display may read Z MOTOR CRASH only or it may first read Z MOTOR CRASH and then blink CHECK CONTACTS If the message CHECK CONTACTS is displayed the handler may have inadvertently dropped the device under test onto
177. ube 1 Switch 2 Tube 2 Switch 3 Tube 3 Switch 4 Tube 4 Switch 5 Tube 5 Switch 6 Tube 6 Switch 7 Tube 7 Switch 8 Tube 8 Switch NOTE The handler will display TUBE CLEAR WORK for two seconds whenever any of the output tubes is removed The message may flash when inserting a new tube This is an indication that the tube count clearing pulse is being received by the handler s CPU If this signal is not present check pin 2 PAL A89 10 on PCB 5000 A89 This pin should pulse whenever any tube is removed from the handler Pressing the Clear button will flash the terminal s displayed message to confirm the handler is still in this specific diagnostic check Press the Enter button to EXIT this diagnostic check www exatron com 5 9 Chapter 5 Diagnostics Exatron 3000B v Solenoid Check This diagnostic tests port 03 located on PCB 5000 398 PAL 398 72 U5 U6 TO ENTER THIS CHECK Handler displays DIAGNOSTICS Press the 2 key Handler displays SOLENOID CHECK Please refer to the following table Press each of the handler terminal s keypad keys 0 through 9 Each key will turn on off the handler s output cover LEDs and will set the corresponding handler solenoid into an on off test cycle Please refer to Changeover Kit Supplement for specific solenoid information Terminal Output Corresponding Key Cover LED Override Switch 1 Solenoid 1 1 YELLOW BUTTON 2 Solenoid 2 2 WHITE BUTTON 3 Solenoid 3 3 OR
178. wer supply Make sure to use qualified service technicians when attempting to repair any portion of the handler that uses high electrical voltages www exatron com 2 1 Chapter 2 Installation Exatron 3000B Compressed Air Your Exatron handler may require a compressed air supply If your specific changeover kit requires compressed air connect the handler to an 80 PSI 3PSI air source Please refer to the Air Requirements section of the Model 3000B General Operating Specifications for further details Using compressed air can be hazardous It is the responsibility of the customer to properly train all handler operators in every aspect of the safety practices associated with the use of compressed air NEVER operate any Exatron equipment which requires compressed air without an approved air regulator and shutoff valve Moving Parts Most moving parts of the Model 3000B handler have structural covers NEVER OPERATE THE HANDLER WITH ANY COVER REMOVED Be careful to keep your fingers away from any moving parts on the handler Keep all loose fitting clothing away from moving parts as well Do not attempt to service the handler in any way when any part of the handler is in motion Use the PAUSE button on the handler controller to stop the handler s operation or turn the handler off before attempting to access any moving part of the handler Overall System Safety Typically the handler is simply one part of a complete test system It
179. with identical type of wire standard or flex same gauge insulation color etc When cleaning solenoids check the plungers to be sure there are no burrs of any kind on their shafts When mounting SP75 or SP62 open frame solenoids use 40 40 screws It is very important to not use screws which are too long and may therefore cut into the solenoid s coil Since the handler is grounded metal screws touching the coil would create a massive short circuit when the solenoid is turned on NEVER put a metal washer between the plunger coil of a SP75 or SP62 open frame solenoid and the return spring This will cause solenoid jams The washer will be attracted magnetically to the body of the solenoid and will act like a brake on the solenoid plunger Wherever possible adjust the solenoid travel movement to be as short as possible The solenoid power is exponentially proportional to the solenoid travel When replacing wiring on solenoids which travel such as those on door assemblies and shuttles always use high flex wire We recommend 22 AWG 150 strand high flex wire Solenoid life is proportional to the handler environment and how often the solenoids are cleaned We recommend that all solenoids be replaced every two million cycles as part of a good preventive maintenance program Replace any bent or damaged solenoid return springs with new parts from the EXATRON factory Refer to the hardware specifications of the Replacement Parts Chapt
180. y pressing the 2 key Select PROGRAM RS 232 by pressing the 4 key Select EXATRON RS 232 by pressing the 5 key Enter Sets your selection Clear Resets to the top of the handler s PICK INTERFACE loop B The handler will now display STOP ON FAIL The handler can either stop on device test fail or continue operation If STOP ON FAIL YS is selected the handler will stop operation at every device under test DUT test failure which the handler receives The handler offers many helpful troubleshooting options while the DUT is in the contacts and STOP ON FAIL is displayed by the handler Answer Yes by pressing the 1 key Stop on fail is now ON Answer No by pressing the 2 key Stop on fail is now OFF Enter Sets your selection Clear Resets to the top of the handler s STOP ON FAIL loop The handler will now display PICK PACKAGE 2 Select RUN PLCC FAST by pressing the 1 key Select RUN SOIC FAST by pressing the 2 key Select RUN DIPS FAST by pressing the 3 key Enter Sets your selection Clear Resets to the top of the handler s package set up loop PICK PACKAGE NOTE On some custom machines there are more options available inside MOD SETUP See the supplement at the end of this manual for all the functions available on your particular handler TYPE 3 AND TYPE 4 CHANGEOVER KITS D The handler will now display PLUNGE 0640 Or some other four digit number This is the number of steps the ha

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