TM-500
User’s Guide
Original Instructions
CE Certified, ISO 9001:2008 Certified
V-TEK, Incorporated (P) 507-387-2039
751 Summit Avenue (F) 507-387-2257
Mankato, Minnesota 56001 service@vtekusa.com
USA www.vtekusa.com
User’s Guide # D292144C
European Representative
QNET BV
Hommerterweg 286
6436 AM Amstenrade
The Netherlands
EC Declaration of Conformity
Manufacturers Name: V-TEK Inc.
Manufacturers’ Address: 751 Summit Avenue
Mankato, MN 56001 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 500 Tape Machine
Model Number: TM 500
Specification: Load measuring range and sizes of sealed carrier tape.
Serial Number: 201XXXXXXX
The following standards have either been referred to or been complied with in part or in full as relevant:
EN ISO 12100:2010 Safety of machinery - Safety of machinery - General principles for design -
Risk assessment and risk reduction
EN ISO 13849-1:2008 Safety of machinery - Safety Related Parts of Control Systems –
Part 1 General Principals for Design
EN ISO 13732-1:2008 Safety of machinery - Ergonomics of the thermal environment - Methods for
the assessment of human responses to contact with
surfaces
EN 614-1:2006+A1:2009 Safety of machinery - Ergonomic design principles - Part 1: Terminology and
general principles
EN 614-2:2000+A1:2008 Safety of machinery - Ergonomic design principles - Part 2: Interactions
between the design of machinery and work tasks
EN 953:1997+A1:2009 Machinery Safety - General requirements for the design and
construction of guards
EN 13850: 2008 Safety of machinery - Emergency-stop equipment, Principals for Design
EN 60204-1:2006/A1:2009 Safety of machinery - Electrical Equipment of Machines
EN ISO 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.
EN 61000-6-3:2007 EMC - Generic standards - Emission standard for residential,
commercial and light-industrial environments
EN 61000-6-1: 2007 EMC - Generic standards - Immunity for residential,
commercial and light-industrial environments
Full Name of responsible person and place of signing
Christina Hogan
Place V-TEK Inc. Position Vice President
Signature Date 04/15/2013
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix
Safety Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii
Introduction
Thank you for purchasing the TM-500 Component Handling Machine. The TM 500 is a multiple
input, pick and place, test, inspection and taping machine designed for high mix/low volume production environments for electronic devices. The flexibility of multiple inputs reduces the need for
additional machines, simplifies and speeds set up and operations, thus delivering a fast ROI.
Options for testing, inspection, as well as 2D and 3D vision systems provide maximum flexibility,
reporting and traceability functions, while a touch screen interface min imizes set up and operator
intervention for fast and easy functioning.
The TM-500 is designed to handle components in multiple packaging formats and offer several
options for re-packaging.
Standard Features:
• Touch screen operator interface for easy setup and operation
• Easily converts between Tray, Tube, and Bowl feed
• Output to Tape or Tray
• Reject to Tray or Bin
• Ability to rotate components +/-90° or 180°
• Innovative universal adjustable heat and PSA sealer
• User-friendly safety enclosure provides easy access with minimal downtime
• Software controlled advance movement of carrier tape (2mm to 144mm pitch)
• Adjustable track assembly for embossed tapes in widths from 8mm to 56 mm
The standard TM-500 also includes five automatic sensors: Empty Pocket Detection, Jam in
Track, Carrier Motion, Low Cover Tape Detection and Low Carrier Tape Detection.
Optional Modules:
The TM-500 offers a variety of input modules and inspection options which can be purchased
independently to allow the user to customize the machine to suit their unique needs.
Input Options
Dual Tray, Manual Tube Input Device (MTID), Automatic Tube Input Device (ATID) & Bowl
Feeder
Process Options
2D Inspection over tape, Upward 2D Inspection, 3D Inspection, Electrical Testing, Ionizing Fan,
Ink Dot Printer
Output Options
Standard Taper output to embossed tape, optional Automatic Tape Cutter, optional output to tray
available when Dual Tray Feeder Input Module is installed.
Introduction D292144.2.fm ii
Theory of Operation
The TM-500 can be easily converted between Bowl, Manual Tube Input Device, Automatic Tube
Input Device, or Dual Tray Input systems. The input modules function independently and only a
single input module may be used at one time.
Operation is simple. The operator loads the desired input module and then configures the jo b for
the selected part using the TM-500’s intuitive, touch screen Human Mac hine Interface (HMI). Job
configuration includes selecting input, output, reject and inspection criteria and programming
selected positions and inspection criteria.
When the TM-500 is set in motion, the pick head picks an individual part from the installed input
module. The part can then be placed directly into a carrier tape pocket or positioned for 3D
inspection or electrical testing prior to placement.
If the optional 3D Vision System is enabled, the part is moved to a 3D camera for inspection prior
to being placed in tape or returned to tray. If the optional Upward 2D Inspection is enabled, the
bottom-side of the part is inspected for orientation or perimeter flaws prior to placement. If the
optional Electrical Testing System is selected, the part can be tested for resistance, ca pacitance,
chip function and a variety of other electrical tests. If the optional Ink Dot System is selected,
parts are marked after inspection and before placement in tape.
Parts that fail Vision/Electrical Testing are placed in a reject bin or returned to tray, depending on
the input option selected. Parts that pass or bypass 3D Vision/Electrical Testing, are placed in
carrier tape or returned to tray.
When output to tape is selected, the loaded carrier tape advances to a sealer assembly where
cover tape is applied to seal the part in the carrier tape pocket. As the tape advances, it passes a
variety of sensors which detect jams in tape, empty pockets, low cover tape supply and low
carrier tape supply.
An optional 2D Vision System is available for in-tape mark and orientation inspection prior to
cover tape application.
Once the carrier tape reaches the TM-500 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. If t he
optional Tape Cutter is enabled, it will automatically run out the tape to a pre-set Leader length,
then cut the tape.
During operation, the operator keeps the selected input system supplied with parts and removes
reject trays or empties the reject bin as needed. When tape reels or inspected trays are complete, the operator removes the full output and replaces reels and trays. If the 2D Tape, Upward
2D or 3D Vision Systems were purchased with the machine, the operator may also observe 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.
Theory of Operation D292144.2.fm iii
Machine Details
Controls:
Touch screen Operator Interface includes:
• Customizable job configuration
• Sealer Dwell Adjustment
• Manual/Automatic leader/trailer
• Lot & End of Reel Reporting
• Vision Inspection display & reporting
• Password protection
• Single window interface for vision & job programming
Placement Speed:
• Tray Input, up to 3,000 UPH
• Tube Input, up to 4,500 UPH
• Bowl Input, up to 4,500 UPH
Dimensions:
• Height: 66” (82” with Tower Light)
• Width: 44” (65” with Monitor Arm fully extended)
• Depth: 70”
• Working area: 6’ x 6’ (36 square feet)
Weight:
• Approximately 1,200 lb. (545 Kg)
Power Requirements:
• Air consumption/Mainframe: 6 SCFM at 85 PSI
• Electrical: 230/240 VAC, 50-60Hz AC
Note: The TM-500 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-500 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 D292144.2.fm iv
Intended Use
The intended use of the TM-500 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-500 is designed to accommodate a full range of electronic devices. Input options vary
with the type of input module installed.
• The Tray Input Module accommodates any standard Jedec Tray sizes.
• The Tube Input Modules accommodate all common tube based parts. It accepts the fol-
lowing tube sizes: width from 6 - 38 mm, lengths from 175 - 581 mm and heights from 2 2 mm.
• The Bowl Input Module accommodates 0805 and 1206 size parts.
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-500 can accommodate tape widths from 8mm to 56mm.
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 4,500 units per hour dependent
on component size and the type of input module installed.
Multiple 2D and 3D Vision Systems are available for device inspection. Camera resolution varies
depending on which module is selected. 3D Camera Resolution ranges from 1288 x 964 x 4 to
2330 x 1750 x 2. 3D Vision Systems are able to detect BGA and Leaded Device errors to within
+/- 20 microns.
Caution:
V-TEK® Incorporated takes no responsibility for the safety of the TM-500 if it is
used for any purpose other than the intended purpose as specified in this User’s
Guide.
Intended Use D292144.2.fm v
Operating Environment
The TM-500 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.
Misuse
The TM-500 weighs approximately 1,200 pounds (545 kg) and requires a forklift or other lifting
equipment to be raised off the floor. It’s built so its legs can be raised to engage four wheels on its
bottom. When the wheels are engaged it can be rolled by a minimum of two people to a new
location. Operators are cautioned to follow the instructions and illustrations for safely transporting
the TM-500. Failure to do so could result in injury or damage to the machine.
Installation instructions clearly state that the TM-500 should only be installed or operated on a
level floor to prevent toppling. When positioned for operation, the four legs should be lowered
and adjusted so the machine is level and immobile to ensure safe and stable operation.
The TM-500 has been designed to make operation impossible during service, maintenance or at
any point when the machine’s cabinet doors are open. Do not block, disable or attempt to override the cabinet door sensors.
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 all operation automatically stops If the top enclosure doors are opened. No attempt
should be made to remove these enclosures or override the door sensors.
The user is protected from the TM-500’s heat sealer by a metal guard. Operators are cautioned
not to touch the heat seal guard or to try to reach underneath the guard while the heat seale r is in
operation.
The TM-500 air supply should be adjusted to operate at a maximum working pressure not
exceeding 7.6 bar (110 psi). The recommended source pressure is 100 psi. The maximum permissible source pressure should not exceed 9 bar (130 psi). Failure to set the within these limits
could result in a failure in the pneumatic system which could lead to injury.
The Ionizing Fan air regulator should be adjusted to operate at a maximum working pressure not
exceeding 2.8 bar (40 psi). Failure to set it within these limits could damage the fan.
Intended Use D292144.2.fm vi
Operator Requirements
The guidelines provided in the following pages are intended to educate the user about how to
operate the TM-50 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-500 User’s Guide and are aware of the possible hazards should operate or perform
maintenance on the TM-500.
Operators and maintenance personnel are advised not to wear loose fitting clothing or jewelry
when operating or maintaining the TM-500. Protective eye wear should be worn when loading,
operating or maintaining the TM-500.
Caution: Users should always wear protective eye wear when loading, op erating or maintaining the TM-500.
Safe operation of the TM-500 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-500, the operator should stand or sit in front of the computer to assure
easy access to all controls and the Power/Emergency S top Button. This position allows the oper-
ator to view all parts of the TM-500 while it is in operation. When loading or unloading the TM-500
or changing input modules, the operator may also need to access the front and side enclosure
doors.
Operator Requirements D292144.2.fm vii
Caution!
Operator Work Area
Adjustable
Front
Monitor
Arm
The TM-500 should never be operated while under the influence of alcohol or
drugs. V- TEK® Incorpo rated t akes no re sponsib ility for the safe ty of TM-500 if it is
used for any purpose other than the intended purpose as specified in this User’s
Guide.
Operator Requirements D292144.2.fm viii
Safety Features
Main Power Switch
The Main Power Switch is located on the right side of the machine below the
polycarbonate enclosure. 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 Switches
There are three Emergency Stop Switches on the TM-500. One is located on
the front of the machine under the upper enclosure. Two more are located on
the back of the machine under the upper enclosure. When an Emergency
Stop Switch is triggered, all motion will be halted a nd 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.
Control Buttons
The TM-500 Control Buttons are located on the front
of the machine in the top, right corner and on the right
side of the machine in the top left corner. They include
the Reset button, the Stop button and the Start button.
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.
Once a job has been selected or programmed, it can be started and stopped from the HMI or by
pressing the Start and Stop buttons.
Safety Features D292144.2.fm ix
Open Doors Stop Operation
lockout/tagout hole
All automated motion stops when an enclosure cabinet door is opened. The only exception to
this is the Tape Advance function which allows the user to load and unload the taper. The pick
head, nozzle, tape and trays can only be moved manually as long as the doors are open.
Once a job has been selected or programmed, it can be started and
stopped from the HMI or by pressing the Start and Stop buttons.
Buzzer Alarm
The buzzer 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 company guidelines regarding lockout/
tagout procedures.
Safety Features D292144.2.fm x
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-500 is ready for the next process.
Safety Features D292144.2.fm xi
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 e r 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 Hawk.
Note: Do not remove or obstruct any of the warning or instruction labels on the Hawk.
Safety Warning Labels D292144.2.fm xii
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 D292144.2.fm xiii
Contact Information D292144.2.fm xiv
Table of Contents
EC Declaration of Conformity
Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Machine Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Operator Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii
Safety Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii
Table of Contents
Chapter 1: Assembly & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Preparing the Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Unpacking the TM-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Assembling the TM-500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Installing Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Installing the Dual Tray Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Installing the UltraVim 2D & 3D Vision Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Chapter 2: TM-500 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Right Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Ionizing Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Enclosure Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Controls, Connections & Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
The Taping Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Pick & Place Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Dual Tray Feeder Input/Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Chapter 3: The Human Machine Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 2
The Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 5
Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 6
File Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 6
User Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 6
Table of Contents D292144.3a.fm
Table of Contents
Chapter 3: The Human Machine Interface continued
System Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
End Of Job Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Bar Code Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Home All Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Accessibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
The Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 16
Run - Setup Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Head Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Taper Setup Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Tray Setup Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
2D Camera Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
Job Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
Chapter 4: Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Quick Start: Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Power Up the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Input, Output & Test Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Tray Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Taper Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Loading Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Heat Sealer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
PSA Sealer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Leader/Trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
Setup Vision Test (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Nozzle Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44
Setup the Pick Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46
Configure End of Job Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Job Statistics Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Chapter 5: Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Quick Start: Running a Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Preparing to Run a Pre-programmed Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Setup Input and Output modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Power up the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Activate HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Home Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Select Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Set End of Job Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Setup 2D Vision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Setup Pick Head5-13
Run the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Creating a New Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Table of Contents D292144.3a.fm
Table of Contents
Chapter 6: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Activating an Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Clearing an Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
System Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Error Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Adjusting Nozzle Vacuum Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Nozzle Positioning Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Adjusting Seal Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Heat Seal Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
PSA Seal Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
Sensor Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Adjusting the Low Cover Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Adjusting the Tape Jam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
Adjusting the Carrier Tape Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
Adjusting the Empty Pocket Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
Testing Seal Strength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
Chapter 7: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Safe Maintenance Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Routine Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Pick Head Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Taping Module Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Heat Sealer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
PSA Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Cover Tape Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Loading Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Remove/Replace Heat Shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Check Actuator Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
Ethernet Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Appendix A: Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Keyence FS-V20 Series Sensor Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Keyence FS-N40 Series Sensor Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Watlow EZ-Zone PM Express Temperature Controller . . . . . . . . . . . . . . . . . . . . . .A-8
SMC ZSE30 Vacuum Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13
Exploded Views
Spare Parts List
Document List
Warranty
Table of Contents D292144.3a.fm
Table of Contents D292144.3a.fm
Chapter 1: Assembly & Installation
Contents
Preparing the Work Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Unpacking the TM-500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Assembling the TM-500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Installing Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Installing the Dual Tray Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Installing 2D & 3D Vision Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-2 TM-500 User’s Guide
Minimum
Width = 13.5 feet
Minimum
Height
7 feet
Preparing the Work Area
Work Space Requirements
The TM-500 is an automated pick & place machine which needs to be placed on a flat, stable
surface in a well lit area. It requires a minimum work area of 7’ high x 13.5’ wide x 9‘ deep (2.2m
x 4.1m x 2.7m) to provide sufficient space for the assembled machine when it is fully loaded with
a variety of tape reel sizes. The minimum work area is pictured below.
Preparing the Work Area D292144.4.fm
Chapter 1: Assembly & Installation 1- 3
Minimum clearance =
3’ on front & sides
Minimum Work
Space Depth
9 feet
Allow at least three feet of clearance at the front and sides of the machine for easy access and
operation. A birds-eye view of the TM-500 with minimum clearance on front and sides is shown
below.
When positioning the TM-500, 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.
Caution!
Operators should use caution when working in front of the TM-500. Be aware of Takeup
Arm and Carrier Arm positions to avoid tripping.
Power Requirements
The TM-500 will also require access to a 85-110 PSI air pressure system and a 230/240 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.
Stabilizing the TM-500
Ensure that the four TM-500 feet are extended beyond the wheels so the machine is immobilized
and level during operation.
D292144.4.fm Preparing the Work Area
1-4 TM-500 User’s Guide
A
D
C
B
E
Unpacking the TM-500
The TM-500 is partially disassembled, then shrink wrapped, placed in a crate for shipping and
strapped to the crate floor.
The disassembled TM-500 parts, which include the Carrier Tape Arm, the Take-up Assembly, the
Monitor Arm, the Taper Tape Guides, the Monitor, Mouse and Keyboard and various Input Mod-
ule options, are individually bubble-wrapped and packed around the base machine.
The packaged machine will appear similar to the photo on the right.
The TM-500 crate should contain the base machine along with the following items:
A. Carrier Tape Arm D. Monitor & Keyboard Arm & Monitor
B. Take-up Arm E. Tower Light
C. Taper Tape Guide Wheel (2 parts)
A User’s Guide, Standard and Metric Hex Wrench Sets, a Track Width Guide, a Keyboard, a
Mouse, and a Spare Part Kit are also included but not pictured above.
Unpacking the TM-500 D292144.4.fm
Chapter 1: Assembly & Installation 1- 5
Assembling the TM-500
Caution: Users should always wear protective eye wear when operating or
maintaining the TM-500.
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-500 User’s Guide before assembling the TM-500.
1. Unpack the Crate.
a. Remove the smaller items one at a time from the crate and place on a flat, stable sur-
face for assembly.
b. Remove and discard the protective wrapping from each part.
2. Remove the TM-500 from the Crate.
a. Unfasten the two straps that anchor
the base machine to the crate
The base m achine weighs approximately
1,200 pounds (545 kg) and is mounted
with four wheels and four stationary legs.
During shipment, the legs are extended
and locked in place to prevent movement
within the crate.
b. Use a forklift to lift the TM-500 out of
the crate. Ensure the fork is positioned
between both sets of legs and centered
under the machine before lifting.
Note: Use a forklift with a minimum load capacity of 1,200 pounds (545 kg) and a fork
length that is a minimum of 50 inches (130cm) so the fork fully extends beyond the base
machine on the other side. The forklift should only be operated by a licensed/certified
operator.
D292144.4.fm Assembling the TM-500
1-6 TM-500 User’s Guide
3. Moving the TM-500 to the Work Area.
a. Using an adjustable wrench, gradually raise
the TM-500 legs, rotating around the machine
until all four legs are raised above the wheels
and the machine rests on its wheels.
b. Position two people at opposite corners of
the machine to guide it and roll the TM-500
from the crate to the prepared work area for
assembly.
Caution!
The TM-500 should only be rolled along a flat, level surface. Do not attempt to roll it
up or down a ramp.
c. Position the TM-500 in the work area so there is at least 3 feet of clearance on the
front. left and right sides. (See the Preparing the Work Area section earlier in this chapter
for details.)
d. Using the adjust able wrench, lower the TM-500 legs until they are extended below the
plane of the wheels so the wheels are once again immobilized. Use a level to adjust the
legs so the machine is stable and level.
e. The TM-500 is shipped with twist ties securing the pick head and any mobile portions
of the machine. If the optional Tray Input Module or 2D Vision System were purchased,
they will also be secured with zip-ties. Cut and remove all twist ties.
4. Connect the Tower Light
a. Remove the front Wire Cover from
the inside of the roof enclosure.
b. Position a ladder securely next to the
front of the TM-500.
c. There are two bolts on the bottom of
the Tower Light. Unscrew the bottom one
and set it aside.
d. Thread the To wer Ligh t wires and the
bottom of the Tower Light through the
hole in the top front corner on the top of
the enclosure.
Assembling the TM-500 D292144.4.fm
Chapter 1: Assembly & Installation 1- 7
e. Replace the bottom bolt on the inside of the enclosure so the enclosure roof is sand-
wiched between the two bolts. Tighten the bolts until the Tower Light is secure.
f. Plug the Tower Light wire 4 Pin Molex Connecto r into the matching receptacle inside
the enclosure.
g. Replace the front wire cover.
5. Connecting the Carrier Tape Arm & Low Carrier
Tape Sensor
a. Use an 4 mm hex wrench to connect the Carrier Tape Spindle to the Carrier Tape Arm.
b. Use an 8 mm hex wrench to connect the Car-
rier Tape Arm to the front right corner of the
machine.
c. Open the lower front enclosure and locate the
Low Carrier Tape Sensor wire. Cut the zip tie holding it in place and thread the wire through the
space between the upper and lower enclosures
near the Carrier Tape Arm.
d. Use an 3/32” hex wrench to connect the Low
Carrier Sensor to the Carrier Tape Arm, then con-
nect the sensor wire to the sensor. Pivot the sensor in the slot to the desired position. (This will vary
with reel and tape size.)
6. Connecting the Take-up Arm
a. Use an 1/4” hex wrench to connect the Take-
up Arm.
b. Plug the power cord into the power receptacle on the front of the machine.
D292144.4.fm Assembling the TM-500
1-8 TM-500 User’s Guide
7. Setting up the Monitor Arm.
a. Attach the Monitor Arm to the to the front
right corner of the machine using the provided bolts.
b. Attach the Keyboard/Mouse Tray to the
Monitor Arm.
c. Place the Monitor on the Monitor Arm.
d. Place the keyboard and mouse on the
Monitor Arm Tray. Open the wire guide on
the Monitor Arm and thread the cords down
through the guide.
8. Install Input and Optional Modules.
If the selected Input Module or an optional Inspection Module or Electrical Testing Module
was un-installed for shipping, follow the module installation instructions at the end of this
section to install.
9. Connect the Air Supply.
a. Attach the air supply line to the air
regulator, then connect it to the air supply.
b. Set the regulator to 100 psi, if nec-
essary. It can be adjusted by lifting the
adjustment knob and turning it. Once it
reads 100 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.
NOTE: There is a separate air regulator
for the Ionizing Fan. This is located
inside the back enclosure cabinet. The
maximum psi for the Ionizing Fan regulator is 40 psi.
Assembling the TM-500 D292144.4.fm
Chapter 1: Assembly & Installation 1- 9
10. Inspect the TM-500.
a. Inspect the fully assembled TM-500, verifying that all twist ties have been removed
and all cables are secure.
b. Connect th e power cord to a 240 VAC sin-
gle 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-500 is included in the manufacture of the TM-500 at
V-TEK. The TM-500 is fully tested before shipping. No further grounding or testing is
required during re-assembly and installation.
The TM-500 is ready to power up. Follow the instructions in Chapter 3: Machine Setup to setup
the machine for operation.
As with any computer system, V-TEK, Inc. recommends users create a
computer Recovery Disk prior to operation and conduct periodic backups as needed. Visit the computer manufacturer’s website for instructions on creating a recovery disk.
V-TEK, Inc. does not create or maintain recovery information for this
laptop. Creating a recovery disk is solely the users’ responsibility.
D292144.4.fm Assembling the TM-500
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