Exatron 923 User manual

Model 923 Chip Scale Thermal
Test Handler with Robotic
Alignment, Tape, and Tube
In/Out
USER MANUAL
Version 1.0
June, 2019
2842 Aiello Drive
San Jose, California 95111-2154
408-629-7600 Tel
800-EXA-TRON Toll Free
www.exatron.com

Copyright Notice
Copyright © 2019 Exatron
This document contains proprietary information which is protected by copyright. All rights are
reserved.
EXATRON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL,
INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE.
The information contained in this document is subject to change without notice.

6/2019 Copyright © Exatron, 2019 –Model 923 Thermal Test Handler w/ Robotic Alignment, Laser Mark, Tube and Tape In/Out v1.0 i
Table of Contents
QUICK REFERENCE PASSWORD LIST .......................................................................................................... I
INCLUDED OEM DOCS.............................................................................................................................. A
CHAPTER 1: GENERAL INFORMATION, SAFETY & SUPPORT ......................................................................1
TYPOGRAPHICAL CONVENTIONS IN THIS MANUAL...................................................................................................2
EXATRON SAFETY WARNINGS .............................................................................................................................2
Linear Encoder Safety Warnings .............................................................................................................3
Uncrating the Handler.............................................................................................................................5
Mounting the Handler.............................................................................................................................7
Table Models—Leveling Feet ...................................................................................................................7
Safety Covers...........................................................................................................................................7
Compressed Air .......................................................................................................................................8
Laser Option and Safety ..........................................................................................................................8
Hazardous Materials...............................................................................................................................9
LOCK-OUTPROCEDURES....................................................................................................................................9
FACILITIES REQUIREMENTS ...............................................................................................................................10
Air Conditioning and Environmental Requirements...............................................................................10
Electrical Requirements.........................................................................................................................10
Vacuum/PneumaticRequirements ........................................................................................................11
Internet Access ......................................................................................................................................12
STANDARDWARRANTY ....................................................................................................................................12
Exatron does not warrant the following ...............................................................................................13
Offshore Warranty Service ....................................................................................................................13
OEM Equipment Warranties .................................................................................................................14
OUT OF WARRANTY AND SUPPORT CONTRACTS:.....................................................................................................14
SUPPORT SERVICES .........................................................................................................................................14
Support for Installation .........................................................................................................................14
Self-Diagnostic Support .........................................................................................................................15
Customer In-House Service ....................................................................................................................15
Laser Self Service...................................................................................................................................15
Ongoing Camera and Laser Application Support ..................................................................................15
Exatron Service Work on OEM Equipment............................................................................................15
Spare Parts............................................................................................................................................15
Spare Test Contactors ...........................................................................................................................16
Spare Part Kits.......................................................................................................................................16
Spare Part Long-Term Support..............................................................................................................16
Spare Computer Parts............................................................................................................................16
Recover Disks ........................................................................................................................................16
Software Updates..................................................................................................................................16
Spare Hard Drive ...................................................................................................................................16

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Third-Party Service ............................................................................................................................... 17
FACTORY CUSTOMER OPERATOR AND SERVICE TRAINING:...................................................................................... 17
On-Site Training classes........................................................................................................................ 17
HOW TO CONTACT EXATRON SERVICE ............................................................................................................... 18
END-OF-LIFEHANDLER DISPOSAL...................................................................................................................... 18
PREVENTATIVE MAINTENANCE ......................................................................................................................... 19
CHAPTER 2: SYSTEM DESCRIPTION......................................................................................................... 21
SYSTEM REQUIREMENTS ................................................................................................................................. 22
Electrical Requirements........................................................................................................................ 22
Pneumatic Requirements ..................................................................................................................... 22
SYSTEM ORIENTATION.................................................................................................................................... 22
Home Positions..................................................................................................................................... 22
Handler Layout ..................................................................................................................................... 23
HARDWARE OVERVIEW................................................................................................................................... 24
Air Regulator ........................................................................................................................................ 26
System Control Panel............................................................................................................................ 27
900 USB CPU......................................................................................................................................... 28
Vacuum Generators ............................................................................................................................. 28
Rotating Pickup Head ........................................................................................................................... 29
Keyence Ionizer..................................................................................................................................... 29
Trays..................................................................................................................................................... 30
Input Tube Feeder Assembly ................................................................................................................ 31
Output Tube Feeder Assembly ............................................................................................................. 32
Thermal Test Head ............................................................................................................................... 33
Test Site Shutter ................................................................................................................................... 34
Air Dryer ............................................................................................................................................... 35
Detaper................................................................................................................................................. 36
Taper .................................................................................................................................................... 36
Lift Table............................................................................................................................................... 37
Override Buttons .................................................................................................................................. 37
Interlocks .............................................................................................................................................. 38
Mechanical System............................................................................................................................... 39
CHAPTER 3: SOFTWARE AND DIAGNOSTICS ........................................................................................... 41
LOAD SETTING FILE ........................................................................................................................................ 43
HOME SCREEN.............................................................................................................................................. 43
ADMIN SCREEN ............................................................................................................................................. 44
SETTINGS MENU ........................................................................................................................................... 45
Work Mode Tab.................................................................................................................................... 45
Delay Tab.............................................................................................................................................. 48
Tray Sort Tab ........................................................................................................................................ 52
DIAGNOSTICS MENU...................................................................................................................................... 53
USB Sensor/Solenoid Check Tab ........................................................................................................... 53

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Board #1 (X) ..........................................................................................................................................55
Board #2 (X2, Thermo) ..........................................................................................................................56
Board #4 (Laser) ...................................................................................................................................57
Board #5 (Tube)....................................................................................................................................58
Board #6 (Taper) ...................................................................................................................................59
X Y Z Motors Tab ...................................................................................................................................60
Tray Tab ................................................................................................................................................63
Tester Tab ............................................................................................................................................67
Thermal Tab ..........................................................................................................................................72
Calibrating Thermal Test Offsets...........................................................................................................73
Air Pressure Tab ....................................................................................................................................74
Taper .....................................................................................................................................................76
Tube Tab ...............................................................................................................................................81
DeTaper Tab..........................................................................................................................................84
Camera Tab...........................................................................................................................................86
Camera Set Up ......................................................................................................................................91
Camera Calibration Tab ........................................................................................................................93
Laser Tab...............................................................................................................................................94
Tuning Position with Camera Tab .........................................................................................................97
CHANGING PASSWORDS ............................................................................................................................... 100
EXATRON SOFTWARE UPDATES...................................................................................................................... 100
Reformat Job File ............................................................................................................................... 102
HYPERTERMINAL......................................................................................................................................... 103
Configuring a HyperTerminal Session ................................................................................................ 103
Display Typed Commands in HyperTerminal...................................................................................... 104
Testing Communication between Handler and Test/Programmer .................................................... 105
NETWORK INFORMATION.............................................................................................................................. 107
Required IP Addresses ........................................................................................................................ 107
Setting a LAN Connection................................................................................................................... 108
CHAPTER 4: TAPE AND REEL SUPPLEMENT............................................................................................111
TAPER OVERVIEW ....................................................................................................................................... 112
Control Panel...................................................................................................................................... 114
TAPER SETUP.............................................................................................................................................. 115
Mounting a Take up Reel ................................................................................................................... 115
Mounting a Supply Reel ..................................................................................................................... 116
Loading the Sealing Tape................................................................................................................... 116
Feeding the Carrier and Sealing Tape ................................................................................................ 118
Adjusting Thermal Seal Heads ........................................................................................................... 122
Adjusting Pressure Seal Heads (if applicable) .................................................................................... 125
Setting Temperature Controls for Thermal Seal Heads (if applicable) ............................................... 126
Replacing the Tape Track Tooling ...................................................................................................... 127
CHANGING TAPER CHANGEOVER KIT FOR DIFFERENT DEVICE SIZES ....................................................................... 128
Determining Gap Offset ..................................................................................................................... 131
DETAPER SETUP .......................................................................................................................................... 135
Installing the Detaper ........................................................................................................................ 136

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Loading the Detaper........................................................................................................................... 137
Adjusting Horizontal Detaper Position ............................................................................................... 141
Detaper Control Panel ........................................................................................................................ 142
CHAPTER 5: KEYENCE IV NAVIGATOR SENSOR SUPPLEMENT ............................................................... 145
INTRODUCTION AND VERSION INFO................................................................................................................. 146
OPENING THE NAVIGATOR SOFTWARE............................................................................................................. 146
UNDERSTANDING RUN AND PROGRAM MODES................................................................................................. 147
Switching to Program Mode............................................................................................................... 147
CHANGING INSPECTION PROGRAMS ................................................................................................................ 148
CHANGING INSPECTION PROGRAMS IN EXATRON SOFTWARE ............................................................................... 148
SENSOR SETUP SETTINGS .............................................................................................................................. 149
STEP1: Image Optimization ................................................................................................................ 149
STEP2: Master Registration................................................................................................................ 152
STEP3: Tool Settings ........................................................................................................................... 153
STEP4: Output Assignment ................................................................................................................. 158
ADVANCED SENSOR SETTINGS........................................................................................................................ 158
Setup Adjustment............................................................................................................................... 158
CHAPTER 6: KEYENCE CAMERAS AND XG-X VISION SOFTWARE SUPPLEMENT ..................................... 159
INTRODUCTION AND SOFTWARE STARTUP ........................................................................................................ 160
Version Info ........................................................................................................................................ 160
Software Startup ................................................................................................................................ 160
Run and Edit Modes ........................................................................................................................... 161
SWITCHING BETWEEN SCREEN LAYOUTS........................................................................................................... 163
EDITING INDIVIDUAL SCREEN LAYOUTS ............................................................................................................ 164
Zooming Display In/Out ..................................................................................................................... 164
VIEWING/EDITING GLOBAL SOFTWARE PARAMETERS ......................................................................................... 167
Ethernet (TCP/IP) Settings .................................................................................................................. 167
System Information ............................................................................................................................ 168
ADJUSTING PARAMETER VALUES .................................................................................................................... 169
XG-X SOFTWARE FILE MANAGEMENT ............................................................................................................. 170
Changing Inspection File .................................................................................................................... 170
Copying and Renaming Inspection Files ............................................................................................. 171
Loading Inspection File from the Exatron Software ........................................................................... 172
COMMON EDIT MODE FEATURES ................................................................................................................... 173
Adjusting ROIs (Regions of Interest)................................................................................................... 173
Common Inspection Unit Features ..................................................................................................... 175
INSPECTION AND FLOWCHART OVERVIEW ........................................................................................................ 176
Flowchart Overview............................................................................................................................ 176
Inspection Overview ........................................................................................................................... 176
UNDERSTANDING INSPECTION VARIABLES ........................................................................................................ 178
Local and Global Variable Table......................................................................................................... 178
KEY INSPECTION UNITS ................................................................................................................................. 180

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Capture Units ..................................................................................................................................... 180
Registering an Image ......................................................................................................................... 185
Calibration –Camera 1: ..................................................................................................................... 187
Calibration –Camera 2: ..................................................................................................................... 191
Camera 1 –Test Site: ......................................................................................................................... 193
Inspection Camera 1 –DETAPE: ......................................................................................................... 203
Camera 1 –Random Sort: .................................................................................................................. 215
Camera 1 –Laser A and B: ................................................................................................................. 220
Camera 1 - Taper................................................................................................................................ 231
Camera 2 –Bottom Inspection........................................................................................................... 243
CHAPTER 7: KEYENCE LASER SUPPLEMENT ...........................................................................................253
INTRODUCTION ........................................................................................................................................... 254
LOCATING DOCUMENTATION......................................................................................................................... 254
SOFTWARE STARTUP.................................................................................................................................... 254
Startup ............................................................................................................................................... 254
FILE MANAGEMENT..................................................................................................................................... 255
Open a File ......................................................................................................................................... 255
Save a File to the Exatron PC.............................................................................................................. 255
MARK BUILDING INFORMATION ..................................................................................................................... 257
Laser Mark Components .................................................................................................................... 257
Centering Mark Position .................................................................................................................... 258
Laser Settings and Parameters .......................................................................................................... 259
CHAPTER 8: NEW JOB, FILE, AND SYSTEM SETUP ..................................................................................263
JOB SETUP PROCESS STEP-BY-STEP................................................................................................................. 264
FILE MANAGEMENT..................................................................................................................................... 265
Copying a Job File............................................................................................................................... 265
Loading a Job File............................................................................................................................... 266
Saving a Job File ................................................................................................................................. 267
CHANGING HANDLER CHANGEOVER KITS ......................................................................................................... 268
Changing Laser Precisor Assembly..................................................................................................... 268
Changing JEDEC Tray to Input Tube ................................................................................................... 269
Changing Output Tube Assemblies .................................................................................................... 271
Changing Pickup Head Tips ................................................................................................................ 273
Calibrating the Laser Stand ................................................................................................................ 273
SETTING KEY PRODUCTION DISTANCES ............................................................................................................ 276
Setting Key Production Distances for 1x1 QFN Kit ............................................................................. 278
Setting Production Distances for 10x10 Kit ........................................................................................ 294
Setting Key Production Distances for MSOP-8 Kit .............................................................................. 302

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CHAPTER 9: SYSTEM POWER ON/OFF AND AUTO RUN PROCEDURE .................................................... 309
POWERING UP THE SYSTEM ........................................................................................................................... 310
AUTO RUN WINDOW AND FEATURES .............................................................................................................. 313
PREPARING FOR AUTO RUN........................................................................................................................... 315
AUTO RUN PROCEDURE................................................................................................................................ 315
SHUT DOWN PROCEDURE ............................................................................................................................. 320
CHAPTER 10: MAINTENANCE AND TROUBLESHOOTING ...................................................................... 323
BACKING UP THE COMPUTER (MONTHLY)......................................................................................................... 324
CLEANING THE HANDLER (DAILY) .................................................................................................................... 324
LUBRICATING THE BEARING SHAFTS (MONTHLY) ................................................................................................ 325
When is Lubrication Needed?............................................................................................................. 325
What Should be Lubed?...................................................................................................................... 325
What Should Not be Lubed?............................................................................................................... 326
Lubrication Procedure ........................................................................................................................ 326
CHECKING LEAD SCREW/COUPLING TIGHTNESS (MONTHLY) ................................................................................ 327
REPLACING ETHERNET MOTORS (AS NEEDED) ................................................................................................... 328
Programming a Cool Muscle Motor (Initialize) .................................................................................. 332
Programming a UI Robot Motor (Rotating Pickup Head)(if applicable)............................................. 333
CHECKING MOTOR SERIAL CABLES (MONTHLY).................................................................................................. 336
AIR REGULATOR MAINTENANCE ..................................................................................................................... 336
Checking Incoming Air from House Supply (weekly) .......................................................................... 336
Checking Oil/Water Particulate Traps (weekly) ................................................................................. 336
Checking the Air Regulator Shutoff Valve (monthly) .......................................................................... 338
Adjusting Air Pressure (as needed)..................................................................................................... 339
DIGITAL PRESSURE SWITCH MAINTENANCE ...................................................................................................... 339
Locking/Unlocking Digital Pressure Switch ........................................................................................ 340
Setting Outputs 1 and 2...................................................................................................................... 340
TESTING INTERLOCKS (MONTHLY) ................................................................................................................... 344
Testing Electrical Interlocks................................................................................................................ 344
Testing Pneumatic Interlocks ............................................................................................................. 345
Testing Interlocks during Production.................................................................................................. 346
SOLENOID MAINTENANCE (AS NEEDED)........................................................................................................... 346
VACUUM GENERATOR MAINTENANCE (SMC ZK2)............................................................................................ 347
Checking/Replacing Vacuum Generator Air Filter (monthly) ............................................................. 347
Checking and Setting Vacuum Generator (as needed)....................................................................... 347
SENSOR MAINTENANCE (AS NEEDED) .............................................................................................................. 349
KEYENCE SENSOR CALIBRATION...................................................................................................................... 349
Calibrating Keyence Sensors............................................................................................................... 349
Sensor Modes ..................................................................................................................................... 350
Initializing (Resetting) Sensor............................................................................................................. 350
OMEGA THERMAL CONTROLLER MAINTENANCE (IF APPLICABLE) .......................................................................... 351
Omega Controller Calibration ............................................................................................................ 351
Auto-tuning Omega Controllers ......................................................................................................... 352
CPU MAINTENANCE (AS NEEDED) .................................................................................................................. 355

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Opening CPU for Part Replacement ................................................................................................... 355
LINEAR MOTOR DRIVER CONTROLLER MAINTENANCE (TRIENNIALLY) .................................................................... 357
Replacing Controller Battery .............................................................................................................. 357
TROUBLESHOOTING ..................................................................................................................................... 358
Air Regulator Issues ........................................................................................................................... 358
Vacuum Generator Issues .................................................................................................................. 358
Pickup Head Issues ............................................................................................................................. 359
Motor Issues....................................................................................................................................... 360
Tray Issues.......................................................................................................................................... 361
REMOTE SUPPORT PROCEDURES .................................................................................................................... 362
Connecting via TeamViewer 11.......................................................................................................... 362
Finding TeamViewer Help .................................................................................................................. 363
CHAPTER 11: SPARE PARTS AND PARTS LIST .........................................................................................365
OBTAINING REPLACEMENT PARTS .................................................................................................................. 365
Commonly Replaced Parts ................................................................................................................. 365
Motors (prefix MOT) .......................................................................................................................... 367
Motor Controllers (If RS-232 motors used) ........................................................................................ 370
Springs................................................................................................................................................ 371
GUIDE TO THE PARTS LIST ............................................................................................................................. 372
House Part Number............................................................................................................................ 372
Part Quantity Columns....................................................................................................................... 372
Manual............................................................................................................................................... 372
Description ......................................................................................................................................... 372
Size ..................................................................................................................................................... 373
Assembly ............................................................................................................................................ 373
Finish .................................................................................................................................................. 373
LIST OF PARTS ............................................................................................................................................. 374
CHAPTER 12: HANDLER PRINTS.............................................................................................................387
CHAPTER 13: CPU PRINTS .....................................................................................................................453
INDEX ...................................................................................................................................................459

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6/2019 Copyright © Exatron, 2019 –Model 923 Thermal Test Handler w/ Robotic Alignment, Laser Mark, Tube and Tape In/Out v1.0 1
Chapter 1: General
Information, Safety & Support
Please read and understand the entire User Manual before installing or using the Exatron
handler.
Chapter Overview
TOPIC
PAGE
Typographical Conventions
2
Exatron Safety Warnings
2
Uncrating the Handler
5
Lock-Out Procedures
9
Facilities Requirements
10
StandardWarranty
12
NotCovered byWarranty
13
OffshoreWarrantyService
13
OEMEquipmentWarranties
14
Out ofWarranty and Support Contracts
14
Exatron Support Services
14
Factory Customer Operator and Service Training
17
Contact Exatron Service
18
End-of-Life Handler Disposal
18
Preventative Maintenance
19

2Copyright © Exatron, 2019 –Model 923 Thermal Test Handler w/ Robotic Alignment, Laser Mark, Tube and Tape In/Out v1.0 6/2019
Typographical Conventions in this Manual
When a specific section within a chapter is referenced, it appears in bold font.
(e.g.: See the Fine Tune Tab)
When a specific button or label within the Exatron software is mentioned, it appears in bold font.
(e.g.: Home All Motors)
When a specific chapter is referenced, it appears in bold and italic font. (e.g.: See Software and
Diagnostics.)
When a specific software message or file path is referenced, it appears as follows: C:\Exatron
When a specifically labeled group within a page in the Diagnostics or Auto Run menus is referenced, it
appears in bold, 14 pt font. (e.g.: Tape and Reel:)
Exatron Safety Warnings
CAUTION: Always reset all motors before running the machine. Do not run machine
without homing the motors.
CAUTION: Never lean against or put weight on output taper. Tape may be damaged.
DANGER!Keep fingers, hair, and clothing away from any moving parts on the handler.
Motors are very powerful and can cause severe injury
DANGER! Never try to stop handler action with your hands or any other device. To stop
the handler, press the EMO (emergency stop) button or
click Pause on the screen.
WARNING: Make sure all motors are off and all
test/preheat assemblies are cool to the touch before
changing changeover kits.
WARNING: Turn off Air Regulator when connecting or
disconnecting air lines, and when inserting or removing
air line plugs. Failure to do so can result in injury to operator and damage to handler.
WARNING! Make sure handler is sitting solidly on the leveling feet. NEVER LEAVE
THE HANDLER ON ITS WHEELS.
Typically, the handler is simply one part of a largertest system.It is the responsibilityof the
customer to properly train all handler operators in all of the safety practices required for every
component of the test system.
Figure 1-1: EMO (Emergency Stop Button)

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Linear Encoder Safety Warnings
WARNING! Any person having electronic medical devices such as a pacemaker
MUST NOT APPROACH the magnetic track of the linear servomotor.
Failure to observe this warning may result in malfunction of the electronic medical
device.
WARNING! Be sure to use NONMAGNETIC TOOLS when installing or working
close to the linear servomotor.
(Example: a beryllium-copper allow hexagonal wrench set, made by NGK Insulators,
Ltd.)
Failure to observe this warning may result in injury.
WARNING! Perform wiring AFTER installing the linear servomotor.
Failure to observe this warning may result in electric shock.
IMPORTANT: While wiring, be certain to wire the linear servomotor main circuit
cables correctly.
Failure to observe this warning may result in malfunction or production failure
WARNING! Ground the grounding terminals of the linear servomotor according to
local electrical codes.
Incorrect grounding may result in electric shock.
IMPORTANT: Keep the wiring distance as short as possible and wire high-voltage
lines separate from low-voltage lines.
If noise enters signal lines, oscillation or faulty operation my result.
(Continued)

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WARNING! Always turn off the power supply and wait at least five minutes before
performing wiring or inspection work.
Failure to observe this warning may result in electric shock.
WARNING! Do not damage, press, exert excessive force or place heavy objects on
the cables.
Failure to observe this warning may result in electric shock, stopping operation of the
product, or burning.
WARNING! Do not remove the cables, connectors, or optional items while the
power is ON.
Failure to observe this warning may result in electric shock.
WARNING! NEVER touch the moving coil of the linear servomotor during operation
and NEVER approach the moving range during operation.
Failure to observe this warning may result in injury.
WARNING! DO NOT MODIFY THE LINEAR SERVOMOTOR.
Failure to observe this warning may result in injury or damage to the product.

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Uncrating the Handler
The Model 900 series handler usually arrives in a wooden crate requiring some
disassemblybefore removing the machine
Before Opening Crate
Carefully check the outside of the handler crate for damage before opening. Check all
“Tip & Tell” and/or shock indicators. If rough handling is indicated or if there is any
obvious damage to the crate, CONTACT EXATRON AND YOUR SHIPPER FOR
INSTRUCTIONS BEFORE OPENING THE CRATE.
Take photos of any damage and send to Exatron and shipper.
Exatron is not liable for damage to handler due to shipping errors or
mishandling upon arrival.
After Opening Crate
If handler is vacuum sealed, it MUST be allowed to warm to room temperature BEFORE opening the
sealed bag. Exatron recommends allowing the handler to sit for 24 HOURS before opening the sealed
bag.
CAUTION: If handler does not sit for a full 24 hours, water may condensate on cold
metal parts and bearings, causing serious damage.
Please inspect the system upon removal. If you see any damage, contact Exatron and the shipping
company immediately. Take photos of any damage and email them to Exatron ASAP.
Moving and Transporting the Handler
To move the handler, one must first raise the yellow leveling feet. (See Figure 1-2)
If handler features an optional hydraulic lift, the lift must be extended before rolling the handler. To do
this the handler must first be plugged in and 24V powered on.
WARNING! Make sure handler is plugged into the correct voltage. See System
Description for handler-specific voltage requirements.
WARNING! Whenever the wheels are not needed (if handler is on floor or being
transported), make sure handler is sitting solidly on the leveling feet. NEVER LEAVE
THE HANDLER ON ITS WHEELS.
If moving the handler by means other than rolling on its wheels, Exatron recommends using a forklift,
NOT A PALLET JACK.
(Continued)

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If handler features an optional hydraulic lift, no pressure can be put on the floating wheel plate (See
Figure 1-2); the forklift must rest solely on the handler frame.
To accomplish this:
1. With the handler wheels on the ground, screw the yellow leveling feet up such that the top
locking nut is flush with the handler frame (Figure 1-3) .
2. Using the pneumatic lift controls, lower the handler until the lift is fully retracted. The floating
wheel plate should be above the lower edge of the frame (Figure 1-3).
IMPORTANT! If transporting handler off-site, Exatron strongly recommends hiring a
professional shipping company. Exatron is not liable for damage caused during
shipping.
Figure 1-3: Correct Forklift Position _Feet Up, Floating Wheel Plate above the Handler Frame
Floating Wheel Plate
Handler Frame
Figure 1-2: Incorrect Forklift Position_Feet Down, Floating Wheel Plate below the Handler Frame

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Mounting the Handler
The Model 900 series handler can be ordered either with a built in table, or as a bench top
system. Bench top systems must be mountedon and bolted securely to a sturdy work bench.
The system includes several motors which move at high speeds, and a flimsy bench will vibrate
and shake. Exatron cannot be responsible for reliability and functionality of the operating
systemif not properly mounted.
To conform to any local seismic regulations an optional tie-down kit is available for order from
Exatron. This will permanently attach the handler to the floor so it cannot be moved. Call for a
quote.
Table Models—Leveling Feet
If you have a table model, the anti-vibration, leveling feet must be extended to make the handler level.
When the handler is in the desired position, lock the wheels by pressing down on each wheel’s lever,
then engage the leveling feet.
Each anti-vibration foot (Figure 1-2) is attached with a right-handed thread. Level the handler by
screwing each foot down, using a carpenter’s level for best results.
WARNING! Make sure handler is sitting solidly on the leveling feet. NEVER LEAVE
THE HANDLER ON ITS WHEELS.
Safety Covers
To avoid operator contact with moving parts, handlers are equippedwith both fixed and moving
covers. The fixed covers are screwed in place and should never be removed except for
maintenance, and then only by qualified maintenance technicians. Removedcoversmustbe
replacedpriortohandleroperation.The movable covers are supplied with interlocks, though any
cover requiring a tool to move s not.
Exatronspecificallydisclaimsresponsibilityand/or liabilityfor any injurywhich occurs as a result
of any interlock being defeated and/or bypassed, or for any injury which occurs as a result of
any fixed cover being removed during operation.
DANGER! If your Exatron handler is equipped with safety covers, never operate the
handler without them. Never remove the safety covers. Never defeat any electrical
interlock switch supplied with the handler. Always properly replace all covers before
operating this handler. All covers requiring a tool to remove are not interlock protected
WARNING: Interlock repair should be done only by qualified technicians. Exatron is
not responsible for damage to handler if interlocks are defeated and/or damaged due
to attempted repair by client.

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Compressed Air
Using compressedair can be hazardous.It is the responsibilityof the companypurchasingthe
handler to properly train all handler operators in every aspect of safety practices associated
with the use of compressed air.
DANGER! Never operate any Exatron system which requires compressed air without
an approved air regulator and shutoff valve, such as that originally supplied with your
system.
DANGER! Never unplug a pressurized air hose while the air regulator is turned on
Laser Option and Safety
Customer must provide proper laser safety training to all users of this equipment. Exatron
installation training will be limited to basic laser set up, use, and safety procedures. This
manual is to be used only as a supplement to laser documentation included with handler.
All Exatron laser OEM (original equipment manufacturer) partners offer additional laser set up,
use and safety procedures. This additional training must be specifically ordered as a separate
line item on quotes and customer purchase orders. This is NOT included in standard Exatron
installations. Use properly trained laser service ONLY.
Customer must follow all federal and state laser safety regulations. Follow the safety procedures
listed in the laser OEM ’smanual. All Exatron handlers equipped with laser markers are self-
certified by Exatron to meet CDRH Class 1 requirements. Exatron offers certified third party
laser safety inspections at substantial additional cost and possible shipping delay. (Continued)
Exatron will repair or upgrade the handler if requested by a third party inspector before the
handler/laser is shipped to the customer.
Should a certified third party inspection occur in the field, Exatron will repair or upgrade the
handler/laser as required once the machine is returned to Exatron. Customer pays all round trip
shipping and crating costs. Exatron can upgrade in the field with no additional cost for parts,
but all travel and labor costs must be paid by the customer.
NOTE: All laser markers will generate a small amount of smoke. This smoke needs to be
vented out of the work area. Typically we offer a filtration system as a separate line item in our
quote. It is up to the customer to determine what the local, state, and federal facility
requirements are.
DANGER! Only basic laser safety training is supplied by Exatron. It is up to the
customer to provide full laser training to all users of this equipment as may be required
by local, state, and federal law.
DANGER! If your Exatron handler is equipped with a laser, it will have special safety
covers. Never operate the handler without them. Never remove safety covers. Never
defeat any electrical interlock switch(es) supplied with the handler
DANGER! Only replace safety windows with parts supplied by Exatron.

6/2019 Copyright © Exatron, 2019 –Model 923 Thermal Test Handler w/ Robotic Alignment, Laser Mark, Tube and Tape In/Out v1.0 9
Hazardous Materials
Model 900 handlers without options do not generate any hazardous wastes.
Handlers equipped with lasers will generate smoke during the lazing process. It is up to the
customer to remove this smoke as required by local, state, and federal laws.
Handlers equipped with chillers will require various types of fluids. It is up to the customer to
store and dispose of these fluids in a way that meets all local, state, and federal laws.
Lock-Out Procedures
Lock-out/tag-out procedures should be followed when servicing or repairing the handler. This
prevents an operator from turning on the handler when the machine is partially disassembled,
preventing damage and injury.
Before servicing or repairing your handler, turn off the air regulator and lock it in the OFF
position as shown in Figure 1-4. This prevents the machine being turned on while in an
inoperable or unsafe condition.
NOTE: Locking devices such as padlocks are provided by the customer.
The handler has a lockable disconnect switch (Figure 1-5) that shuts off all AC power to the
handler and computer(s).When using lockout procedures, turn off and lock this switch also. All
computers connected to the handler should be shut down before turning off this switch.
Figure 1-5: Lockable Disconnect Switch—In ON Position (Left), in OFF Position with Lock (Right)
Figure 1-4 Air Regulator—In ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right)

10 Copyright © Exatron, 2019 –Model 923 Thermal Test Handler w/ Robotic Alignment, Laser Mark, Tube and Tape In/Out v1.0 6/2019
Facilities Requirements
Air Conditioning and Environmental Requirements
The Model 900 handler should be installed in a dust-free, temperature and humidity-controlled
environment to prevent dust and dirt particles from contaminating moving parts, especially those
parts which come into contact with the devices being tested. The life of your handler is greatly
enhanced by keeping it as clean as possible.
Handlers equipped with laser markers must have a smoke extraction/filter system. If no laser is
present, there are no special ventilation requirements.
Electrical Requirements
CAUTION: Connect the power cord to earth-grounded power outlets only.
The required power supply was most likely specified at time of order. Whenever possible,
Exatron includes power cords with appropriate plugs to match offshore standards. This may or
may not apply to added OEM equipment.
The handler is typically wired for 110 VAC 50/60 Hz. Most, but NOT ALL, supplies used in our
handlers can be connected 100-240 VAC as is. Most new Exatron built PC’s features self-
sensing power supplies, but older PCs must be “switched” to run with 208-240 VAC or 100-120
VAC. See the back side of the Exatron PC for switch location. Check with Exatron service
should the need arise to switch power supplies on the handler.
NOTE: Service calls made to the customer facility to correct problems caused by
improper electrical supply are not covered by the Exatron warranty.
Handlers typically use less than 3 amps at 110 VAC. This does not include any major added
OEM equipment options.
Handlers can also be special ordered to run on 440-480 VAC (Continued)
Figure 1-6: PC Power Supply Switch