V-TEK TM-500 User manual

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 [email protected]
USA www.vtekusa.com
User’s Guide # D292142D

European Representative
QNET BV
Hommerterweg 286
6436 AM Amstenrade
The Netherlands
Vendor Provided Material
Significant portions of this documentation were provided by:
SCANNERTECH LLC
5026 S. Roosevelt St.
Tempe, Arizona 85282
Tel: [phone]
Fax: [phone]
[email protected]
www.scannertech.com


751SummitAvenue,Mankato,Minnesota56001,USA
Telephone:(507)387‐2039FaxNo.(507)387‐2257

ECDeclarationofConformity
ManufacturersName: V‐TEKIncorporated
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/s:…………..
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James

PlaceV‐TEKIncorporatedPositionComplianceDirector
SignatureDate04/15/2013



Introduction
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Machine Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Operator Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii
Safety Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii

Introduction D292142.2.fm ii
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 pro-
duction 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 minimizes 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 four automatic sensors: Empty Pocket Detection, Jam in
Track, 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) & Bowl Feeder
Process Options
2D Inspection over tape, Upward 2D Inspection, 3D Inspection, Empty Pocket Detection, Electri-
cal Testing, Ink Dot Printing
Output Options
Standard Taper or Small Parts Taper output to embossed tape, optional output to tray available
when Dual Tray Feeder Input Module is installed.

Theory of Operation D292142.2.fm iii
Theory of Operation
The TM-500 can be easily converted between Bowl, Manual 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 job for
the selected part using the TM-500’s intuitive, touch screen Human Machine 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, capacitance,
chip function and a variety of other electrical tests.
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.
If the optional Ink Dot System is selected, parts are marked before being sealed in tape. An
optional 2D Vision System is also 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.
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 com-
plete, 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.

Machine Details D292142.2.fm iv
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” (1.68 m); 82” (2.08 m) with Tower Light mounted
• Width: 44” (1.12 m); 65” (1.65 m) with Monitor Arm fully extended
• Depth: 70” (1.78 m)
• Working area: 6’ x 6’ (1.83 m x 1.83 m)
Weight:
• Approximately 1,200 lb. (545 Kg)
Power Requirements:
• Air consumption: 5 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

Intended Use D292142.2.fm v
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 recom-
mended.
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 Module accommodates all common tube based parts with tooling
changes. It accepts the following 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 with tooling changes.
Suitable carrier and sealing tapes include any conductive or non-conductive tapes with feed-
holes that are pitched at 4 mm. Tapes must operate in a temperature range from 120-160° Cel-
sius 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 D292142.2.fm vi
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 tempera-
ture between 0 - 50 degrees Celsius.
Note: Although all of the components used on the machine will withstand the 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 lb. (545 Kg) and requires a forklift or other lifting equip-
ment to be raised off the floor. It’s built so its legs can be raised to engage four wheels on its bot-
tom. 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 over-
ride 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 sen-
sors 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 sealer 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 per-
missible 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.

Operator Requirements D292142.2.fm vii
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 under-
stand 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, operating
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 compo-
nent manufacturer for specific placement instructions. Ear protection is not necessary during nor-
mal 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 Stop 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
Caution! The TM-500 should never be operated while under the influence of alcohol or
drugs. V-TEK® Incorporated takes no responsibility for the safety of TM-500 if it is used
for any purpose other than the intended purpose as specified in this User’s Guide.
Operator Work Area
Front

Safety Features D292142.2.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 below the Upper Enclosure. Two are located on the
back of the machine under the Upper Enclosure. When an Emergency Stop
Switch is triggered, all motion will be halted and the machine will require a
reset before operation can continue.
The emergency stop control circuit removes electrical power to all motors,
moving parts, heat sources, pneumatics and energy storing devices. This
includes the stepper motor drive, stepper motors, the servo motor drive,
servo motors, drive circuits, the main control board, the heat sealer and all
pneumatics. The only devices that remain powered are the inspection mod-
ule 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. They include
the Reset button, the Stop button and the Start but-
ton.
When the machine is powered up, it is automatically placed into an emergency stop state to pre-
vent 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 D292142.2.fm ix
Open Doors Stop Operation
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.
lockout/tagout hole

Safety Features D292142.2.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, how-
ever something has interfered with the process, stopping the machine.
A blinking red light and a solid amber light indicates the machine is at the end of a job, the leader
creation sequence is complete and the TM-500 is ready for the next process.

Safety Warning Labels D292142.2.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 precau-
tions 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.

Contact Information D292142.2.fm xii
Contact Information
V-TEK, Inc.
751 Summit Ave
Mankato, MN 56001
TEL: [phone]
FAX: [phone]
email:[email protected]
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: [e-mail].
website: www.ce-authorizedrepresentative.eu

Table of Contents D292142.3a.fm
Table of Contents
EC Declaration of Conformity
Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Machine Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Operator Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii
Safety Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii
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 Bowl Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Installing the UltraVim 2D System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
Enclosure Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Controls, Connections & Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
The Taping Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Taper Connections & Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Bowl Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Optional Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Keithley Electrical Tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
UltraVim 2D Vision System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

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Table of Contents (continued)
Chapter 3: The Human Machine Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
File Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 5
User Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 5
System Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
End Of Job Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Bar Code Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Home All Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Accessibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
The Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Run - Setup Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Head Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Taper Setup Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Bowl Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Test Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Job Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
Chapter 4: Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Quick Start: Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Power Up the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Creating a New Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Nozzle Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Bowl Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Removing Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Install Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Tune Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Load Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Taper Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Loading Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Heat Sealer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
PSA Sealer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Leader/Trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
Setup the Pick Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
Setup Electrical Test (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
Setup Vision Test (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
Configure End of Job Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34
Job Statistics Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

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Table of Contents (continued)
Chapter 5: Vision Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Vision Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Vision Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
UltraVim HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Main Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Select Part Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Inspect Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Data Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Options Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Edit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Passwords Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Print Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Inspection Setup & Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Chapter 6: Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Quick Start: Running a Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Preparing to Run a Pre-programmed Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Setup Input and Output modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Power up the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Activate HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Home Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Select Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Setup End of Job Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Setup Pick Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Setup Electrical Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Setup 2D Vision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
Run the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Creating a New Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Chapter 7: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
System Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Error Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
Linear Track Jam Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
Adjusting Nozzle Vacuum Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
Nozzle Positioning Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
Adjusting Seal Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
Heat Seal Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
PSA Seal Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
Sensor Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
Adjusting the Low Cover Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
Adjusting the Tape Jam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24
Adjusting the Carrier Tape Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24
Adjusting the Empty Pocket Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
Testing Seal Strength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

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Table of Contents (continued)
Chapter 8: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Safe Maintenance Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
Routine Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
General Maintenance Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Pick Head Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
Taping Module Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
Lubricate Linear Bearing Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
Check Actuator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
Ethernet Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12
Appendix A: Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Keyence FS-V21/FS-V22 Sensor Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Watlow EZ-ZONE Temperature Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
SMC ZSE30 Vacuum Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Spare Parts List
Exploded Views
Customer Service Contact Sheet
Document List
Warranty

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 Bowl Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Installing the UltraVim 2D System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12