BPM Microsystems, LP

1. BPM Microsystems, LP

2. TUBE STACKER LOADER(Automated Tube Output) BP Microsystems Training Course # TUBL-001Rev. A

3. Teaching Method of the Course • Covers the fundamentals • More details in the 3000 and 4000 Users Guides • Step by Step • Broken down to steps • Start with Installation • Continue through complete operation • Examples • Photos • Diagrams • Self taught or a taught course. • When complete, trainee should be able to install and operate the Tube Stacker Loader.

4. Tools Needed for the Course • Tube Stacker Loader • Tubes of Devices • Loader Tooling Kit to match Devices • SAE Hex Keys (Allen wrenches)

5. Tube Stacker Loader Training Chapters • Identification of parts • Installing and removing Loader Tooling Kits • Loading Empty Tubes in the Tube Loader • Adjusting the Tube Loader • Teaching the Tube Loader • Clearing Jams • Tube Loader Maintenance • Installing the Tube Loader Option • Using BPWin Tube Stacker Control

6. Chapter 1Identification of Parts Training Seminar # TUBF-001 Revision A

7. Tube Stacker Loader

8. Tooling Channel • Tooling bed • Shutter • Air Tube • Channel landing area • Air Valve Cover • Part Count Sensor • Tooling Clamp T handle • Air Tube Airflow Regulator • Air Tube Height Adjuster

9. D. Tube Width Rail Adj Knob E. Count Sensor Fiber optic F. Front Tube Support Assy with Micro Switch • Tube Weight with Chain • Front Tube Width Guides • Tube Width Rails

10. Tooling Channel • Count Sensor Through Hole • Micro Switch Assy • Front Tube Support Block Assy. • Support Block Height Adj • Height Adj Red T Handle • Micro Switch safety hinge • (shown open for identification)

11. Rear Tube Width Guides • Hopper Attachment Knobs • Rear Vertical Plate • Tube Pusher Assy. • Rear Tube Support Plungers • Blade Plunger Assy. • Blade Height Adj Knobs • Height Adj Brass Locknuts • Tube Width Adj Belt • Tube Length Sliders

12. Locking handle for Tube Width and Tube Length Adjustment • Full Tube Hopper • Tube Pusher Plunger D. Tube Pusher Plunger Force Regulator E. Rear Tube Width Lead Screw Pulley

13. Chapter 2Installing and Removing Loader Tooling Kits Training Seminar # TUBL-001 Revision A

14. Install Loader Tooling Kit • Unlock the tooling by using the red T handle. • Remove the existing curved tooling channel if present. • If the new tooling kit contains a special air tube, then install it at this time. Loosen the set screw that secures the air tube and switch them. • Install the new tooling channel by fitting the rear channel slot into the rear pin on the loader tooling bed. • Press the front of the tooling down into the front pin, using care to prevent damaging the copper air tube. • Check that the tooling channel is installed flat to the tooling bed, then lock the channel in place with the red T handle. • Check the air tube position. It should just peek over the front of the tooling channel. This tube aims air at the placed device to blow it down the channel and into the tube. • If the new tooling kit contains a special shutter, replace it at this time by loosening the two set screws that hold the shutter on the rotator shaft. • Adjust the shutter height so that it swings over the tooling without rubbing excessively or leaving air gaps when closed. • Adjust the shutter rotation so that the shutter completely covers the channel top when closed.

15. Typical Loader Tooling Kit

16. Top view of a tooling channel. Note the placement landing on the left end.

17. Bottom view of a tooling channel. Note the alignment Hole and slot on the left side, and the air tube clearance Slot on the right end.

18. Standard Loader Tooling Kits (Other kits available as Special Order)

19. Chapter 3Adjusting the Tube Loader Training Seminar # TUBL-001 Revision A

20. Tooling Adjustments • The tooling channel requires no adjustment. • Depending on the package, the airflow from the air tube may need adjustment. Use the airflow regulator needle valve to increase or decrease airflow. Closing the air flap by hand will activate the air flow. • If a special air tube was included in the tooling kit, it may need to be adjusted for height. Use the thumbscrew to make the adjustment. • Usually the shutter requires no adjustment if installed correctly. However it may be necessary to adjust either the shutter open speed or shutter close speed. Use the needle valve regulators on the rotator to make the adjustments. Use the Tube Stacker Control to assist in the adjustments by manually opening and closing the shutter during adjustment. • The Tube Pusher has a plunger force regulator. This rarely requires adjustment.

21. Tooling Adjustments • Air Tube Height Adj • Airflow Needle Valve • Shutter Close Regulator • Shutter Open Regulator • Valve Bank with manual • override buttons (orange)

22. The four required adjustments to the Tube Stacker Loader after changing tooling kits: • Adjust for tube width. • Adjust for tube length. • Adjust for Rear tube height. • Adjust for Front tube height.

23. 1. Adjust for correct tube width. • Unlock the rail clamp using the red handle underneath the loader. This allows the adjustment of both the tube width and tube length. • Turn the black knob to adjust the rails for tube width. The belt drives two lead screws which can either widen or narrow the tube guides. • Place one tube in the loader. • Correct adjustment allows the tube approximately 1 mm side-to-side play. If the play is excessive, parts could jam at the mouth of the tube due to horizontal misalignment. • Lock the rails in position using the red handle.

24. 2. Adjust for tube length. • Unlock the rail clamp using the red handle underneath the loader. This allows the adjustment of both the tube width and tube length. • Use one tube as a gauge for setting the length. The tube should have one stopper in the rear position. • Setting tube length correctly is tricky because the tube pusher is involved. Normally the tube pusher is extended while a job is running. However, when the machine is idle the tube pusher is retracted. The length adjustment should be made with the tube pushed extended. Refer to Chapter 9 Tube Stacker Control to extend the tube pusher. • With the tube pusher extended, slide the rear vertical plate into position so that the tube has only 1mm of front/rear play. This adjustment is critical. • Lock the rear plate into position with the red handle.

25. 2. Adjust for tube length. Make tube length adjustment with the Tube Pusher extended. Also note that the stopper tab is pointing up.

26. 3. Adjust for rear tube height. • Place a tube in the loader resting on the rear support blocks. • Unlock the rear height adjusters using the brass Lock nuts. • Adjust the height of the blades using the black plastic knobs. The blades should just slip across the top of the tube. When a full tube is ejected, the blades should slip between the two bottom tubes allowing only the bottom tube to drop. Extend the blades by hand when making this adjustment. (Pinch them together) • When adjusted, lock the height adjusters in place with the brass lock nuts.

27. 3. Adjust for rear tube height.

28. 4. Adjust for Front Tube Height. • Place a tube in the loader. Make sure the micro switch hinge is closed. • Use the red T Allen handle to adjust the height of the front tube support block assy. Turning the T handle will raise or lower the front tube platform. • Align the mouth of the tube to the tooling channel. This will allow the device to slide smoothly into the tube without jamming at the mouth of the tube. • Manually load devices into the tube to test the alignment if necessary.

29. 4. Adjust for Front Tube Height. Note that the micro switch hinge is in the closed position. The hinge should ALWAYS be closed to prevent damage to the micro switch.

30. 4. Adjust for Front Tube Height.

31. Chapter 4Loading Empty Tubes in the Tube Loader Training Seminar # TUBL-001 Revision A

32. Loading Tubes in the Tube Loader • Note: The empty tubes must have the rear stopper • installed. If the stopper has a tab, the tab must be • pointing upward. • Remove the tube weight by sliding up and out. Note the orientation of the weight. It should only install one way. • Check that the hinged flap is closed. • Load empty tubes with the stopper toward the tube pusher. • Re-install the tube weight.

33. Chapter 5Teaching a Tube Loader Training Seminar # TUBL-001 Revision A

34. In the Workflow window, locate the “Destinations” box. Give the tape feeder teach a valid name. NOTE: The teach name must begin with TUBEEXPOUT.

35. Go to the main window, menu selection AUTOHANDLER/TEACH. Select the “TUBEEXPOUT” name and click Teach.

36. When prompted, place a device in the loader tooling channel about in the middle of the landing area and click OK. The Adjust Nozzle Position window will appear. Select the correct Pin 1 position according to the Figures (A or B). Use the arrow buttons to position the downward camera or laser pointer over the device, and press OK. Remove the device when prompted.

37. Chapter 6Clearing Jams Training Seminar # TUBF-001 Revision A

38. If jams occur at the mouth of the tube: • The Device count sensor detects that a part is blocking the sensor and gives an error. • Visually inspect the jam. If the tube is sitting too high or too low, readjust the front tube support height setting. • If the height is OK, then the guide rails could be too far apart. Readjust as necessary. If tubes fail to drop when full: • Check that the tabs on the rear stoppers are pointing up • Check that the tabs are not interlocking. • Check that the tube blades are not binding the tube. Readjust rear tube height as necessary. • Check that the tube pusher is not binding the tube. Readjust tube length as necessary.

39. Chapter 7Tube Loader Maintenance Training Seminar # TUBL-001 Revision A

40. Tube Loaders require very little maintenance. • There are very few user serviceable parts • inside. BP Recommends: • Periodically clean the channel of the tooling. Remove the metal cover and polish the channel with a soft cloth. • Check the Air Mist Separator for water and/or oil. • Defective tube Loaders will need to be sent to • BP Microsystems, LLP for repair. Call technical • support for Assistance.

41. Training Seminar # TUBL-001 Revision A Chapter 8Installing the Tube Stacker Loader Option

42. Important: Power the system down and observe ESD precautions when handling electronic circuit boards.

43. Installation Procedure • Bolt the feeder mounting plate (CPLATUBELOADER) to the host machine table top. This can be any location desired as long as the downward camera (4x00) or laser pointer (3x00) can “see” the loader place point for teaching. • Bolt the loader to the mounting plate. • Feed the communication cables and air line to the nearest access hole on the table top. • Mount the serial peripheral board assembly (WSERIALTUBELOAD) to a secure location inside the machine. • Connect the loader cables to the SP card. They only install one way. • Connect one end of the Telephone cable (CCAB7FTPHONEBLK) to J1 on the SP card, and the other end to J4 on the tube feeder SP card (WSERIALTUBELOAD). This daisy chains the 2 SP cards. • Mount the Mist Separator/Super Mist Separator filter assy to the frame inside the handler. Drilling and tapping mounting holes may be necessary. • Use the contents of the air connector kit (WAIRCONECTCEFDR) to splice into a regulated compressed air line and tee in the air line to the filter assy. • Connect the loader and feeder air lines to the filter assy. • NOTE: Installation on a 4x00 system may require a different plexiglass safety panel (rear or side depending on location).

45. Chapter 9Using the BPWin Tube Stacker Control Training Seminar # TUBL-001 Revision A

46. Tube Stacker Diagnostics Window Usage Go to main menu Autohandler/Diagnostics/Tube Stacker Control.

47. Tube Stacker Diagnostics Window Usage Select the Loader button. This window will allow manual manipulation of the loader. It will also monitor the state of the three sensors on the loader. The use of this window is self explanatory.

48. Tube Stacker Diagnostics Window

49. Review Questions • What parts are included in a typical Loader tooling kit? • What is a valid name for a tube stacker loader teach? • What is the purpose of the air tube? • What is the purpose of the blades? • What is the most common cause of a loader jam? Chapter 5: Turning On and Off

50. Review Answers • What parts are included in a typical Loader tooling kit? Device channel. • What is a valid name for a tube stacker loader teach? “TUBEEXPOUT” 3. What is the purpose of the air tube? Air blows the part down the channel and into the tube. • What is the purpose of the blades? To separate the bottom 2 tubes, allowing the bottom tube to fall when ejected. • What is the most common cause of a loader jam? Incorrect adjustment of the front tube height block.