TM-401 User’s Guide
V-TEK, Incorporated
751 Summit Avenue
Mankato, MN 56001
USA
(P) 507-387-2039
(F) 507-387-2257
www.vtekusa.com
Original Instructions
EC Declaration of Conformity
ISO 9001:2008 Certified
User’s Guide # D292104B
European Representative
QNET BV
Hommerterweg 286
6436 AM Amstenrade
The Netherlands
Significant portions of this documentation wer e pr ov ide d by :
KEYENCE CORPORATION OF AMERICA
1100 North Arlington Heights Road, Suite210, Itasca, IL 60143
Vendor Provided M at e r i a l
1-888-KEYENCE (1-888-539-3623)
www.keyence.com
EC Declaration of Conformity
Manufacturers Name: V-TEK Incorporated.
Manufacturers’ Address: 751 Summit Avenue,
Mankato, Minnesota 56002, USA
Declare that the machinery described below complies with applicable health and safety requirements of Part 1 of
Annex 1 of the Machinery Directive 2006/42/EC and EMC Directive 2004/108/EC. Confidential technical
documentation has been compiled in accordance with Part A of Annex VII of Machinery Directive 2006/42/EC and is
available to European national authorities on written request only. If a request is received documentation will be
delivered on a CD or by post
.
Description: TM-400
Model Number: TM-400
Specification: Component Handling Machine
Serial Number\s:
The following standards have either been referred to or been complied with in part or in full as relevant:
ENISO 12100: 2006 Machinery Safety - Safety of machinery - General principles for design –
Risk assessment and risk reduction
EN13849: 2008 Machinery Safety - Safety Related Parts of Control Systems –
Part 1 General Principals for Design and Part 2 Validation.
EN ISO 13732: 2008 Machinery Safety - Ergonomics of the thermal environment
EN 614-2:2000+A1:2008 Machinery Safety - Ergonomic design principals
EN 13850: 2008 Machinery Safety - Emergency-stop equipment, functional aspects
Principals for Design
EN60204-1: 2010 Machinery Safety - Electrical Equipment of Machines
ENISO 11202/A1 1997 Acoustics - Noise emitted by machinery and equipment - Determination of emission
sound pressure levels at a work station and at other specified positions.
EN61000-6-3:2007 EMC - Generic standards - Emission standard for residential, commercial and
light-industrial environments
EN61000-6-1: 2007 EMC - Generic standards - Immunity for residential, commercial
and light-industrial environments
.
Full Name of responsible person and place of signing Christina James
Place
V-TEK Incorporated Position Compliance Director
Signature Date 02/24/2014
751 Summit Avenue, Mankato, Minnesota 56001, USA
Telephone: (507) 387-2039 Fax No. (507) 387-2257
Introduction
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Machine Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Operator Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii
Safety Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii
Introduction
Thank you for purchasing the TM-401 Component Handling Machine. The TM-401 is a tabletop pick and place tape and reel machine with vision, designed for use in production environments for electronic devices. This machine accepts devices loaded in tubes, and a dual tube
input option is available. It features a 2D over tape vision system for component verification. A
touch screen interface simplifies the setup process, and minimizes set up time and operator
intervention for fast, easy functioning.
Standard Features:
• Touch screen operator interface for easy setup and operation
• Single or Dual Tube input options
• Ability to rotate components +/-90° or 180°
• Output to tape
• Innovative universal adjustable heat and PSA sealer
• Software controlled advance movement of carrier tape (2mm to 144mm pitch)
• Adjustable track assembly for tape widths 8mm to 72 mm
• 2D Vision over tape inspection for Mark, Orientation and Empty Pocket Detection.
• User-friendly safety enclosure with multiple access points provides easy access with
minimal downtime
• Table-top machine with optional 80-20 frame
• Jam in Track and Low Cover Tape Detection automatic sensors
Introduction D292104.2.fm ii
Theory of Operation
Operation of the TM-401 is simple. The operator loads the tube feeder and then configures
the job for the selected part using the TM-401’s
intuitive, touch screen Human Machine Inter-
face (HMI). Job configuration includes selecting and programming inspection criteria.
When the TM-401 is set in motion, the pick
head picks an individual part from the Tube
Feeder and places the part directly into a carrier tape pocket. The 2D Vision System detects
empty pockets and inspects placed parts for
mark and orientation prior to cover tape application. Parts that fail Inspection stop operation
and trigger an error message, allowing the
user to correct the error before continuing
operation.
As the tape advances, it passes sensors which detect jams in tape. Once the carrier tape
reaches the TM-401 sealer assembly, cover tape is applied. The part is then sealed in the pocket
with either a Heat Seal or Pressure Sensitive Adhesive (PSA) cover tape. When the sealing process is complete, the finished tape is routed onto a take-up reel.
During operation, the operator keeps the tube feeder supplied with parts and observes the
inspection process, adjusting operation and inspection settings as needed. In the event of 2D
inspection fails, the operator may re-orient or swap out parts from the output area as needed.
When tape reels are complete, the operator removes the full reel and replaces it with a new reel.
Theory of Operation D292104.2.fm iii
Machine Details
Controls:
Touch screen Operator Interface includes:
• User-friendly Job Wizard and Pitch Setting Wizard for easy set-up
• Customizable job configuration
• Sealer Dwell Adjustment
• Manual/Automatic leader/trailer
• Password protection
Speed:
Placement speed of up to 2,800 UPH
Dimensions:
• Height: 39.5” (100 cm) (includes Tower Light)
• Width: 53” (135 cm)
• Depth: 35.5” (90 cm)
• Working area: 11’ x 9’ (3.5 m x 2.75 m)
Weight:
• 217 lb. (98.5 Kg)
Power Requirements:
• Air consumption: 5 SCFM at 85 PSI
• Electrical: 120/240 VAC, 50/60Hz AC
Note: The TM-401 is designed and tested to meet the CE Directives: 2006/42/EC, 2004/
108/EC. These tests were conducted with the power requirements of 230V 50Hz.
However, the TM-401 can also handle other voltage levels seen in other parts of the
world including voltages from 208V-240V @ 50/60 Hz.
Reference below when wiring the electrical plug:
• Attach the BROWN wire to L1
• Attach the BLUE wire to N/L2
• Attach the GREEN/YELLOW wire to Ground
Machine Details D292104.2.fm iv
Intended Use
The intended use of the TM-401 Taping Machine is to produce taped reels of individually sealed
and consistently orientated components. Use of this equipment in any other way is not recommended.
The TM-401 is designed to accommodate a full range of electronic devices. The Tube Feeder
accommodates all common tube based parts size 0805 or larger. It accepts the following tube
sizes: width from 0.316” - 1.510” (8-38 mm), thickness from 0.15”- 0.465” (3.8-11.8 mm).
Suitable carrier and sealing tapes include any conductive or non-conductive tapes with feedholes that are pitched at 4 mm. Tapes must operate in a temperature range from 120-160° Celsius with a pressure range from 40-60 psi and dwell time between 250-400 milliseconds. The
TM-401 can accommodate tape widths from 8mm to 72mm.
Tape advance speed is set on the machine’s controller and can be set at any speed from 1-100
percent of maximum speed. Feed rates can vary from 2,000 to 2,800 units per hour dependent
on component size.
Caution:
V-TEK® Incorporated takes no responsibility for the safety of the TM-401 if it is
used for any purpose other than the intended purpose as specified in this User’s
Guide.
Operating Environment
The TM-401 is designed to be operated in a temperature and humidity controlled, light, industrial
setting. It requires an ISO Class 9 clean room environment.
The machine should be installed on a flat, dry, stable surface in a well lit area (ambient lighting of
200 to 300 Lux (Lumens/m2).
The recommended climate is between 5 - 75% non-condensing humidity with a room temperature between 0 - 50 degrees Celsius.
Note: Although all of the components used on the machine will withst and th e temperature
range of 0 to 50 degrees Celsius, such temperatures may decrease the life of some of the
components.
The intended electrical environment is Pollution Degree 2 and Over Voltage Category II.
Intended Use D292104.2.fm v
Misuse
Lift Points
The TM-401 weighs approximately 217 lbs. (98.5 kg.) and requires four people to safely carry it.
Operators are cautioned to follow the instructions and illustrations for safely transporting the TM-
401. Failure to do so could result in injury or damage to the machine.
Installation instructions clearly state that the TM-401 should only be installed or operated on a
level surface to prevent toppling.
The user is protected from moving parts and exposure to objects being ejected under pressure
by 16 standard wire gauge sheet metal and 3/8 inch clear, polycarbonate enclosures. Door sensors ensure operation automatically stops if the enclosure doors are opened. No attempt should
be made to remove these enclosures or to block, disable or override the door sensors.
The enclosure doors may be left open during basic set-up procedures such as positioning the
pick head at place or pick locations. If the enclosure doors are left open during setup the TM-401
automatically reduces the speed of the pick head to a fraction of its normal operating speed to
prevent operator injury due to collision, etc.
The user is protected from the TM-401’s heat sealer by a metal guard. Operators are cautioned
not to touch the heat seal guard or to try to reach underne ath the guard while the hea t sealer is in
operation.
The TM-401 air supply should be adjusted to operate at a maximum working pressure not
exceeding 7.6 bar (110 psi). The maximum permissible source pressure should not exceed 9 bar
(130 psi). Failure to set the air pressure within these limits could result in a failure in the pneumatic system which could lead to injury.
Intended Use D292104.2.fm vi
Operator Requirements
Work Area
The guidelines provided in the following pages are intended to educate the user about how to
operate the TM-401 safely. They contain important information on avoiding potential hazards to
the operator and to the equipment. Only personnel who have thoroughly reviewed and understand the TM-401 User’s Guide and are aware of the possible hazards should operate or perform
maintenance on the TM-401.
Operators and maintenance personnel are advised not to wear loose fitting clothing or jewelry
when operating or maintaining the TM-401. Protective eye wear should be worn when loading,
operating or maintaining the TM-401.
Caution: Users should always wear protective eye wear when loading,
operating or maintaining the TM-401.
Safe operation of the TM-401 does not require gloves of any type, however some component
manufacturers may recommend gloves be worn when placing parts in tape. Consult the component manufacturer for specific placement instructions. Ear protection is not necessary during n ormal operation.
When running the TM-401, the operator should stand or sit in front of the touch screen to assure
easy access to all controls and the Power/Emergency Stop Button. This position allows the oper-
ator to view all parts of the TM-401 while it is in operation. When loading the TM-401 Manual
Tube Input Device (MTID or changing Taper reels, the operator may also need to access the side
and back of the machine
Caution!
The TM-401 should never be operated while under the influence of alcohol or drugs.
V-TEK® Incorporated takes no responsibility for the safety of TM-401 if it is used for
any purpose other than the intended purpose as specified in this User’s Guide.
Operator Requirements D292104.2.fm vii
Safety Features
Main Power Switch
The Main Power Switch is located on the right side
of the machine. Turning the switch to the right
turns power ON. Turning the switch back to the left
turns the power OFF.
When the Main Switch is in the OFF position, it
exposes a lockout-tagout hole. The switch can be
locked by inserting a lock through the hole. The
switch on the right is pictured in the OFF position.
Emergency Stop Switch
There is one Emergency Stop Switch on the TM-
401. It is located on the left side of the machine
below the Take-up Arm. When an emergency stop
switch is triggered, all motion will be halted and the
machine will require a reset before operation can
continue.
The emergency stop control circuit removes electrical power to all motors, moving parts, heat
sources, pneumatics, and energy storing devices.
This includes the stepper motor drive, stepper
motors, the servo motor drive, servo motors, drive
circuits, the main control board, the heat sealer
and all pneumatics. The only devices that remain
powered are the inspection module cameras, the
enclosure lights, the sensors, and the HMI.
Reset Button
The TM-401’s blue Reset button is located on the left side of the machine above the Emergency
Stop Switch. When the machine is powered up, it is automatically placed into an emergency stop
state to prevent the motors from moving until the operator is ready to begin operating the
machine. The error state is cleared by pressing the Reset button on the front of the machine.
Safety Features D292104.2.fm viii
Open Doors Stop Operation
lockout/tagout hole
All automated motion stops and the machine is unable to enter Run Mode when an enclosure
door is opened. An error message will display at the bottom of the HMI Run screen and a chirping alarm sound will alert the user that the TM-401 door(s) are open.
The enclosure doors may be left open during basic set-up procedures such as positioning the
pick head at place or pick locations. If the enclosure doors are left open during setup the TM-401
automatically reduces the speed of the pick head to a fraction of its normal operating speed to
prevent operator injury due to collision, etc.
System Alarm
The system alarm will sound and halt the Run Mode process of the machine at any time a System Alarm occurs. A description of the System Alarm and suggestions for resolving it will appear
on the HMI Main Screen.
Lockout/Tagout
The Main Switch can be turned ON and OFF by turning the
red knob back and forth. When the red knob is placed in the
OFF position, the lockout/tagout hole is exposed. The Main
Switch can then be locked out by placing a lock through the
hole.
The Air Regulator can be turned ON and OFF by turning
the top red cap back and forth. When the red cap is
placed in the OFF position, the lockout/tagout hole will be
exposed. The Air Regulator can then be locked out by
placing a lock through the hole.
Be sure to follow your company guidelines regarding
lockout/tagout procedures.
Safety Features D292104.2.fm ix
To w e r L i g h t
The tower light feature allows taping machine operators and production
supervisors in determining the operational state of the taping machine at a
glance.
Color Codes
Green
A solid green light indicates the machine is running a job.
Red
A flashing red light indicates that the machine is on but not running.
Green + Amber
The combination of a solid green light and a solid amber light indicate the
machine is at the end of a job and is in the process of creating a leader.
Red + Amber
The combination of a blinking red light and a blinking amber light indicates
the machine is at the end of a job and attempting to create a leader, however something has interfered with the process, stopping the machine.
A blinking red light and a solid amber light indicates the machine is at th e en d of a job, the leader
creation sequence is complete and the TM-401 is ready for the next process.
Safety Features D292104.2.fm x
Safety Warning Labels
The following warning labels have been placed in various places on the machine to bring safety
issues to the attention of operators and technicians working with or near the machine.
Attention
Indicates an adjustment or danger zone requiring attention.
Electrical Hazards
Indicates that hazardous voltage levels are present. Always disconnect power to
the machine before removing panels or enclosures with this warning label.
Te m p er a t u r e H a z a r d s
Indicates a hot surface. Use care when working near these surfaces and allow
them to cool before performing maintenance.
Pinch Hazard
Indicates areas where moving parts or doors can pinch fingers if safety precautions are not observed.
Consult Manual
Consult User’s Guide for proper procedure.
Disconnect power and air supplies and refer to Chapter 8: Maintenance of this
manual before performing maintenance on the TM-401.
Note: Do not remove or obstruct any of the warning or instruction labels on the
TM-401.
Safety Warning Labels D292104.2.fm xi
Contact Information
V- TEK, Inc.
751 Summit Ave
Mankato, MN 56001
TEL: (507) 389-2039
FAX: (507) 387-2257
email:service@vtekusa.com
website: http://www.vtekusa.com
For customer service, please refer to the Customer Service Contact Sheet at the back of this
manual.
European Representative:
QNET BV
Hommerterweg 286
6436 AM Amstenrade
The Netherlands
KvK Zuid-Limburg 14091511
email: qnet@ce-authorizedrepresentative.eu.
website: www.ce-authorizedrepresentative.eu
Contact Information D292104.2.fm xii
Table of Contents
EC Declaration of Conformity
Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-ii
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iii
Machine Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-v
Operator Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vii
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-viii
Safety Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-xi
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-xii
Table of Contents
Chapter 1: Assembly & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Preparing the Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Table Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Unpacking the TM-401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Assembling the TM-401. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Chapter 2: Machine Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Right Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Controls, Connections & Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
The Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Pick & Place Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Tube Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2D Vision System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Table of Contents D292104.3b.fm
Table of Contents (continued)
Chapter 3: The Human Machine Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
HMI Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Job Ta b. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Job Wizard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Taper Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
Head Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
MTID Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Run Ta b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
Chapter 4: Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Quick Start: Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Power Up the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Home Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Load the Manual Tube Input Device (MTID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Selecting the Correct Nozzle & Nozzle Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Installing Nozzle & Nozzle Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Taper Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Load Carrier Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Load Cover Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Load Take-up Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Configure HMI Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Te st Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Chapter 5: Vision Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Quick Start: Vision Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Connect Vision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Setup HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Connect Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Connect Keyence Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Configure Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Configure Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Configure Keyence Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28
Table of Contents D292104.3b.fm
Table of Contents (continued)
Chapter 6: Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Quick Start: Running a Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Preparing to Run a Pre-programmed Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Power up the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Home Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Setup the Manual Tube Input Device (MTID). . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Setup the Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Select Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Setup the Pick Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Setup Vision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
Run the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Chapter 7: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Activating an Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Clearing an Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
System Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Error Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
Adjusting Nozzle Vacuum Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
Tips on Part Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
Sensor Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26
Adjusting the Low Cover Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26
Adjusting the Tape Jam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26
Adjusting Heat Seal Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
Heat Seal Shoe Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
Seal Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
Sealer Dwell Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
Adjusting PSA Seal Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
Materials Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
Seal Roller Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
Table of Contents D292104.3b.fm
Table of Contents (continued)
Chapter 8: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Safe Maintenance Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Routine Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Air Pressure Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Pick Head Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Nozzle Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Vacuum Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Replace the Vacuum Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Check Actuator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
Taping Module Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
Heat Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
Loading Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
PSA Sealer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
Cover Tape Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
Appendix A: Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Keyence FS-V21/FS-V22 Sensor Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
SMC ZSE30 Vacuum Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Spare Parts List
Exploded Views
Customer Service Contact Sheet
Document List
Warranty
Table of Contents D292104.3b.fm
Chapter 1: Assembly & Installation
Contents
Preparing the Work Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Table Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Unpacking the TM-401. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Assembling the TM-401. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-2 TM-401 User’s Guide
Minimum
Width = 11 feet
Minimum
Height
7 feet
Preparing the Work Area
Space Requirements
The TM-401 is a table-top machine which needs to be placed on a flat, stable surface in a well lit
work area that is a minimum of 7’ high x 11’ wide x 9‘deep (2.2 m x 3.5 m x 2.7 m) to provide sufficient space for the assembled machine when it is fully loaded with a variety of tape reel sizes.
The TM-401 is pictured mounted on the optional 80/20 Frame in the minimum required work area
below.
Preparing the Work Area D292104.4.fm
Chapter 1: Assembly & Installation 1- 3
Minimum clearance
3’ on all sides
Minimum Work
Space Depth
9 feet x 11 feet
Table Requirements
The TM-401 should be placed on a user-supplied table or bench that is capable of supporting a
minimum of 230 lb. (104.5 Kg). An optional 80/20 frame (pictured above) is also available for
mounting the TM-401.
Choose a table that is at least 30” wide by 30” deep to provide sufficient space for the assembled
machine when it is fully loaded with a variety of tape reel sizes.
Ideally the table height should be adjustable so the machine height can be easily adjusted to suit
operators of varying heights. The objective is to position the TM-401 controls so they are easily
accessible for operation and maintenance. The suggested level is 36” (900 mm) above the floor,
but this may vary from one operator to another.
The table’s working surface should have a slope of no mo re tha n 5 degree s. Ensure that the TM401 feet is positioned on a table or the optional 80/20 frame so the machine is fully supported,
immobilized and level during operation.
Clearance
Allow at least three feet of clearance on all sides of the machine for easy access and operation.
A birds-eye view of the TM-401 with minimum clearance on all sides is shown below.
D292104.4.fm Preparing the Work Area
1-4 TM-401 User’s Guide
When positioning the TM-401, choose an area that is not located below overhead gan tries, walkways or power lines to ensure objects or liquids cannot be dropped on the machine from overhead.
Power Requirements
The TM-401 will also require access to a 85-110 PSI air pressure system and a 120/240 VAC,
50/60 Hz power supply. Locate the machine so electrical power cables can be routed away from
areas where personnel are expected to move.
Note: It is recommended that cables be routed overhead or underground. If cables must
be routed over the floor, cover them with rubber ramps.
Preparing the Work Area D292104.4.fm
Chapter 1: Assembly & Installation 1- 5
A
B
C
Unpacking the TM-401
Prior to shipment, the TM-401 is partially disassembled, then shrink wrapped, placed in a crate,
and strapped to the crate floor. The disassembled TM-401 parts, which include the Carrier Tape
Arm, the Take-up Assembly, the Tower Light and the Spare Parts Kit, are individually bubble-
wrapped and packed around the base machine. The TM-401 crate should contain the base
machine along with the following items.
A. Carrier Tape Arm
B. 80/20 Frame (optional, shipped disassembled)
C. Take-up Arm
D. Laptop Computer (optional, not pictured)
A User ’s Guide, Standard and Metric Hex Wrench Sets, and a Spare Parts Kit are also included
but not pictured above.
D292104.4.fm Unpacking the TM-401
1-6 TM-401 User’s Guide
Assembling the TM-401
Equipment Required
• Adjustable wrench (needs to fit 1 1/16” to 1 3/32” nut)
• Hex wrench set (provided with machine)
• 85-110 PSI air pressure system
Note: Read the TM-401 User’s Guide before assembling the TM-401.
Unpack the TM-401 Crate
1. Move the Crate to the Work Area. Use a fork lift to move the TM-401 crate to the prepared work area. Ensure the fork is centered under the crate before lifting.
Note: Use a forklift with a minimum load capacity of 300 pounds (136 kg) and a fork
length that is a minimum of 35 inches (89 cm) so the fork fully extends beyond the crate
on the other side. The forklift should only be operated by a licensed/certified operator.
2, Unpack the Crate.
a. Remove the top and sides from the TM-
401 crate. Set aside.
b. The TM-401 is shipped partially disas-
sembled, with the Tower Light, Take-up
Arm and Carrier Tape/Feed Arm detached
and wrapped in bubble wrap. Remove the
smaller items one at a time from the crate
and place on a flat, stable surface for
assembly.
c. Remove and discard the protective wrapping from each part.
3. Remove the TM-401 from the Crate.
a. The TM-401 is bolted to the bottom of the crate for shipping. Reach below the crate to
unfasten the bolts.
Note: If the optional 80/20 Frame was purchased, follow the assembly instructions in the
80/20 Frame Exploded Views document which can be found in the Exploded Views section at the end of this manual before proceeding.
Assembling the TM-401 D292104.4.fm
Chapter 1: Assembly & Installation 1- 7
Lift Points
b. Moving the TM-401 Base Machine. The machine may be manually lifted from the
crate. The base machine weighs 217 lb. (98.5 Kg) so the task will require four people.
Position one person at each corner of the machine using the lift points illustrate d above to
safely distribute the machine’s weight. Lift the machine from the crate and place it onto
the prepared work table/bench.
4. Position the TM-401 in the work area so there is at least 3 feet of clearance on all sides.
(See the Preparing the Work Area section earlier in this chapter for details.)
5. The TM-401 is shipped with zip ties securing the pick head, the 2D Camera and any
mobile portions of the machine. Cut and remove all zip ties.
D292104.4.fm Assembling the TM-401
1-8 TM-401 User’s Guide
Re-assemble the TM-401
1. Position the Tower Light
Lift Tower Light, snapping it in place in an upright position perpendicular to the TM-403..
2. Connecting the Carrier Tape Arm
a. Remove the black knob from the right side of the Track Support Bracket.
Assembling the TM-401 D292104.4.fm
Chapter 1: Assembly & Installation 1- 9
Position Holes
Knob
b. The Carrier Tape Arm has a dowel pin which locks into position holes on the Track
Support Bracket. Slide the Carrier Tape Arm onto the threaded rod, engage the dowel pin
into the desired position, and secure it into place with the black knob.
4. Positioning the Take-up Arm
a. The Take-up Arm has a dowel pin which
locks into position holes on the Tra ck Support Bracket. Loosen the black knob on the
back of the Take -u p Arm and position it at
about a 45 degree angle from the baseplate
assembly. Engage the dowel pin into the
desired position and secure it into place with
the black knob..
b. Plug the electrical connector into the
take-up motor receptacle.
D292104.4.fm Assembling the TM-401
1-10 TM-401 User’s Guide
Air Line
Connect
Here
5. Connect the Air Supply.
a. Attach the air supply line to the air regula-
tor, then connect it to the air supply.
b. Set the regulator to 85 psi, if necessary. It
can be adjusted by lifting the adjustment knob
and turning it. Once it reads 85 psi, push the
knob back in to lock it into place
NOTE: It is recommended that the air hose be
routed overhead or underground. If it must be
routed over the floor, cover the hose with rubber ramps.
6. Inspect the TM-401.
a. Inspect the fully assembled TM-401, verifying that all twist ties have been removed
and all cables are secure.
b. Connect the power cord to the power
receptacle on the back of the TM-401, then
connect the other end to a 120/240 Volt single
phase power supply
Note: It is recommended that the power cord
be routed overhead or underground. If it must
be routed over the floor, cover the cords with
rubber ramps.
Protective earth grounding of the TM-401 is included in the manufacture of the TM-401 at
V-TEK. The TM-401 is fully tested before shipping. No further grounding or testing is
required during re-assembly and installation.
The TM-401 is ready to power up. Follow the instructions in Chapter 3: Machine Setup to setup
the machine for operation.
Assembling the TM-401 D292104.4.fm
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