J Boat Material Handling System Manual

IConn High Performance Wire Bonder
IConn J Boat
Material Handling System Manual
98888-0000-JB3-01
Copyright © 2013 Kulicke & Soffa Industries Inc (www.kns.com) and all subsequent revision dates. All Rights Reserved. Original English language version.
The information contained in this document is the property of Kulicke & Soffa Industries Inc and is subject to change without notice.
This document may not be reproduced or transmitted in any form, nor stored in a retrieval system of any nature, without the express written authority from:
Kulicke & Soffa Pte Ltd

6 Serangoon North Avenue 5,
#03-16, Singapore 554 910
This page is left intentionally blank
Use of This Manual

General Introduction
The purpose of this manual is to provide technical information for application
design on the K&S IConn High Performance Wire Bonder.
The Table of Contents and the Index at the back of the manual should be used to
quickly locate specific information within the manual.
The following manuals should be referred to if additional information is required:
• IConn Operation Manual
• IConn Maintenance Manual
Terms and Conventions used in this manual
The following format is used in this publication:
• System modes are capitalized. Example: PROGRAM mode
• Control Panel and keyboard buttons are in brackets, capitalized and in bold.
Example: [ENTER]
• Graphical User Interface (GUI) buttons are capitalized and in bold without
brackets. Example: PROGRAM
• Numeric “hot keys” are in brackets and in bold, followed by the function name.
Example: [1] AUTO (Mode); [3] DELETE (Menu Option)
• Monitor messages are in quotes. Example: “Enable eye point reteach”
• Alphabetic displays where any letter may appear are represented by a capital
letter (X).
• Numeric displays where any number may appear are represented using the
pound symbol (#).
The following terminology is used in this manual:
Term Explanation
Chess Moving the XY table or bond head using the mouse or arrow keys.
Select Selection is initiated by:

1) Place pointer on a button or menu item and press [b1](left mouse button).
2) If item is highlighted (box around item), press [Enter].
3) Press menu item’s ‘hot key’.
Click or Placing the pointer on a screen button or menu item. [b1] (left mouse button)
Click On is pressed to initiate the selection.
Drag Repositioning or resizing of an item on the display. This is done by using

the mouse and [b1] (left mouse button) in a held state during the drag.
Releasing [b1] terminates the drag function.
Index Initiating workholder motion.
Scroll Moving a text field in such a way as to have the data move up or down
within the field. Arrow keys or sliders are used to accomplish this function.
Target Using chessing hardware to place the monitor crosshair or scan box at a
specific location in one of the display windows.
98888-0000-JB3-01 S-1
Record of Changes
Change Description Affected Revised

No Pages Date
00 Launch Release ALL 12/2009

01 Safety Information updated with laser safety data and warning Page S-1 3/2013
S-2 98888-0000-JB3-01
Safety Information
S.1 General
Kulicke & Soffa refer to the latest international health and safety standards, specifications and
procedures during design and assembly of the machine. The machine has an inherently safe
design, however, incorrect maintenance or operation could cause injury to personnel or damage
to the equipment. You must keep the machine in accordance with the procedures included in this
manual. During operation and maintenance, you must take all reasonable precautions to prevent
injury to personnel and damage to the machine. Standard safety practices and local safety
regulations apply.
The machine is for use in the production of semiconductors. Do not use the machine for other
functions. Unapproved mechanical or electrical modifications can have an unwanted effect on
the safe and efficient operation of the machine. Kulicke & Soffa accept no responsibility for
injury or damage (direct or indirect) caused if you use the machine for other tasks, make
unapproved modifications, or if you use unapproved tools, materials, equipment or procedures.
You must read and understand this safety chapter before you operate the bonder.
S.2 Symbols and Messages
The symbols and messages used in this manual are shown below:
S.2.1 Warning
WARNING:
The symbol and the word WARNING go before text that is safety related and show a potentially
hazardous situation which, if not avoided, could result in death or serious injury. Warnings
appear before the related task. Read the warnings before you do the task.
All WARNINGs are printed in Bold italic letters.
S.2.2 Caution
CAUTION:
The symbol and the word CAUTION go before text that is safety related and show a potentially
hazardous situation, which, if not avoided, could result in minor or moderate injury. It is also
used to alert against unsafe practices. Cautions appear before the related task. Read the cautions
before you do the task.
All CAUTIONs are printed in Bold italic letters.
S.2.3 Note
Note:
The word Note goes after the text and gives additional data that can help you during a task, or
gives you data about the machine.Notes are printed in BOLD italic letters.
98888-0000-JB3-01 Safety Information S-1

S.3 Equipment-Specific Warnings

WARNING:
TYPE 4 ELECTRICAL HAZARD! THE POWER SUPPLY MODULE SUPPLIES A
HAZARDOUS VOLTAGE OF
420 VDC. THIS POWER IS USED ON THE X AND Y MOTORS AND XY AMPLI-
FIER. BEFORE YOU GET ACCESS AND SERVICE THE POWER SUPPLY
MODULE, THE XY AMPLIFIER MODULE OR THE X AND Y MOTORS OR
THEIR RELATED CABLES, MAKE SURE THAT THE MACHINE POWER IS
OFF. DISCONNECT THE POWER SUPPLY MODULE FROM THE AC MAINS
AND MAKE SURE THAT THE RED SAFETY LED ADJACENT TO THE 420 VDC
CONNECTOR ON THE POWER SUPPLY IS OFF (APPROXIMATELY AFTER
FIVE MINUTES) BEFORE YOU GET ACCESS TO THE POWER SUPPLY MOD-
ULE, XY AMPLIFIER, AND THE X AND Y MOTORS.
WARNING:
TYPE 4 ELECTRICAL HAZARD! DO NOT TOUCH THE ELECTRONIC FLAME-
OFF (EFO) WAND OR THE GOLD WIRE DURING OPERATION OR WHEN
MANUALLY FIRING THE EFO. THE SYSTEM PRODUCES A SPARK
BETWEEN THE EFO WAND AND WIRE WHICH CAN CAUSE AN ELECTRICAL
SHOCK IF CONTACTED DURING EFO FIRING. THE POTENTIAL SHOCK HAZ-
ARD IS NOT USUALLY CONSIDERED LIFE THREATENING (AS GIVEN IN IEC
PUBLICATION NO. 479). HOWEVER, K&S RECOMMENDS THAT PEOPLE
WITH ABNORMAL HEART CONDITIONS OR ARTIFICIAL HEART STIMULA-
TION DEVICES (E.G. PACEMAKERS) MUST NOT BE PERMITTED TO OPER-
ATE OR SERVICE THE EQUIPMENT.
WARNING:
TYPE 4 ELECTRICAL HAZARD! THE EFO PRODUCES UP TO 5 KV ON VARI-
OUS PARTS INSIDE OF THE EFO CONTROL BOX AND ON THE HIGH-VOLT-
AGE CABLE. DO NOT OPEN THE EFO BOX. IF IT BECOMES NECESSARY TO
HANDLE THE HIGH-VOLTAGE CABLE OR REMOVE THE BOX, UNPLUG THE
EFO BOX POWER CABLE AND WAIT AT LEAST FIVE MINUTES. USE HIGH-
VOLTAGE TECHNIQUES AND PRECAUTIONS AT ALL TIMES WHEN YOU
HANDLE THIS UNIT.
WARNING:
ELECTROMAGNETIC FIELDS! SERVO MOTORS USED TO POSITION THE
BOND HEAD AND OPTICS GENERATE STRONG MAGNETIC FIELDS. HEART
STIMULATION DEVICES (E.G. PACEMAKERS) MAY BE ADVERSELY
AFFECTED DURING BOND HEAD MOVEMENT. THEREFORE, PEOPLE WITH
SUCH DEVICES MUST NOT BE NEAR THE EQUIPMENT WHILE IT IS IN
OPERATION.
WARNING:
TYPE 4 ELECTRICAL HAZARD! DO NOT TOUCH THE CLAMP ASSEMBLY
WHEN MACHINE POWER IS ON. THE CLAMP IS OPERATED BY AN ELEC-
TRICAL POTENTIAL OF UP TO 500VDC. WHEN USED WITH HEAVY WIRE OR
COPPER KIT, IT CAN CAUSE AN ELECTRICAL SHOCK IF CONTACTED. THE
POTENTIAL SHOCK HAZARD IS NOT CONSIDERED LIFE THREATENING.
S-2 Safety Information 98888-0000-JB3-01

WARNING:
CLASS I LASER HAZARD! THE BOND HEAD Z-AXIS ENCODER HAS A
CLASS I LASER (AND IN CERTAIN MODELS, THE X-AXIS AND Y-AXIS
ENCODER). WHILE THE ENCODER SENSOR HEAD IS MOUNTED ON THE
BOND HEAD OR X AND Y TABLE, THE LASER IS NOT DANGEROUS TO YOU
OR MAINTENANCE TECHNICIAN. HOWEVER, WHEN THE SENSOR HEAD IS
REMOVED AND THE MACHINE POWER IS ON, THE LASER LIGHT CAN
CAUSE EYE DAMAGE IF VIEWED DIRECTLY ON AXIS. ALWAYS TURN OFF
THE MACHINE POWER BEFORE YOU REMOVE THE ENCODER SENSOR
HEAD FROM THE BOND HEAD OR X AND Y TABLE.
WARNING:
HAZARDOUS MATERIAL! THE BOND HEAD LINK IS MADE FROM A BERYL-
LIUM ALLOY THAT IS CONSIDERED A POTENTIAL CARCINOGEN. HAZARD-
OUS DUST IS PRODUCED WHEN THIS MATERIAL IS MACHINED, FILED, OR
GROUND. DO NOT MACHINE OR OTHERWISE ATTEMPT TO REWORK THE
BOND HEAD. DO NOT GOUGE THE LINK WHEN YOU WORK AROUND THE
BOND HEAD AREA WITH SMALL, SHARP TOOLS AS THIS MAY PRODUCE
CHIPS OR SPLINTERS THAT CAN PENETRATE SKIN. A MATERIAL SAFETY
DATA SHEET FOR BERYLLIUM AND ITS SAFE USE IS AVAILABLE FROM
K&S UPON REQUEST.
WARNING:
INJURY HAZARD! DURING OPERATION, PARTS OF THE MACHINE MOVE
WITHOUT WARNING. KEEP HANDS, TOOLS, AND LOOSE ITEMS OF CLOTH-
ING AWAY FROM THE MHS, XY TABLE, AND BOND HEAD AREAS.
WARNING:
BURN HAZARD!
HOT SURFACES CAN CAUSE BURNS. THE WORKHOLDER IS HOT DURING
AND AFTER OPERATION. USE HEAT-RESISTANT PROTECTIVE GLOVES OR
LET SURFACE TEMPERATURES DECREASE TO LESS THAN 60°C BEFORE
YOU TOUCH THE WORKHOLDER.
S.4 General Precautions

The general safety precautions that follow must be observed whenever you operate, adjust, or
service this equipment:
• Components of the workholder are very hot
Do not let your fingers, or any material with a low melting point to contact heated areas.
• Observe all WARNINGS and CAUTIONS noted in the texts of the technical publications
for the bonder
• Always disable all motors before you put your hands near the bond head, XY table, MHS
and other powered systems
• Keep hands clear of the bond area during machine operation
• Operate the bonder with covers installed at all times
• Disconnect the electrical service to the bonder before you remove the rear covers or open
the card rack door, unless machine power is required to do a specific maintenance task
• Standard precautions related to live electrical circuits must be taken at all times when you
adjust or service the equipment
• Never put the tools or materials on the MHS or bonder when you do maintenance
• Observe the manufacturer's recommended safety precautions when you use chemical
substances
• Solvents and aerosols, if used, must be compatible with the bonder operational
environment and the process

S.5 Trained Operators and Service Technicians

The users for operation and service maintenance must receive training in machine operation and
maintenance given by Kulicke & Soffa. The Performance Based Equipment Training (P.B.E.T.)
given by Kulicke & Soffa makes sure that the participants master job skills to meet measurable
objectives. There are two levels of training:
• Level One
Level One training includes basic machine operation and simple maintenance. Machine
operators must successfully complete this training before you operate the machine.
• Level Two
Level Two training covers advanced machine operation and maintenance. Service
technicians must successfully complete both the Level One and Level Two training
courses.
Data on the training courses and locations can be found on the K&S website "www.kns.com".
S.6 Servicing Electrical Equipment
CAUTION:
Before you apply AC power to the machine, read through the items outlined
in the safety checklist below.
• Read through section S.6.1 Types of Electrical Hazards thoroughly

• Read through section S.6.2 Servicing Power Supply thoroughly
• Read through section S.6.3 Lockout/Tagout Procedure thoroughly
S.6.1 Types of Electrical Hazards
At times, it may be required to access certain areas of the machine in order to do setup
procedures, calibrations or regular maintenance routines. If the work to be done in these areas
relate to components near exposed energized circuits; the steps to do the work, as outlined in the
ATPremier Plus machine manuals, will define the type of electrical hazard. The types of
electrical hazards are:
• Type 1: Equipment is fully de-energized (electrically cold)
• Type 2: Equipment is energized
Live circuits are covered or insulated.
Live circuits are exposed and accidental contact is possible. Potential exposures are less
than 30 volts RMS (42.2 volts peak).
Live circuits are exposed and accidental contact is possible. Potential exposures are
greater than 30 volts RMS (42.2 volts peak) or radio frequency is present.
Measurements and/or adjustments require physical entry into the equipment or equipment
configuration does not allow the use of clamp-on probes.
Note: Work in electrical hazard types 3 through 5 are brought to the readers attention in the
ATPremier Plus user manuals.

S.6.2 Servicing Power Supply
CAUTION:
You may cause damage to the machine if you apply power that is below the
specified voltage range. Do not connect the machine to source power unless
the source power is within the range of 200 VAC to 240 VAC. If the source
power is below this range, a step-up transformer is required (see NOTE
below).
Note: If the customers source input voltage is within the range of 100 VAC to 120VAC, a step-
up transformer is required to raise the input voltage to the required 200 to 240 VAC
range. The step-up transformer is installed between the ATPremier Plus power supply
and the source input voltage. Contact your local Kulicke & Soffa sales representative
for more data about this feature.
DC power to all components on the ATPremier Plus are distributed by the power supply via the
Power Distribution Unit (PDU) except the +420VDC to the XY Amp which is sourced directly
from the power supply via an appropriately rated cable.
CAUTION:
There is a red safety LED adjacent to the 420 VDC connector on the power
supply, which, when lit indicates the presence of voltage above 60 VDC.
Make sure this safety LED is off before you disconnect the power supply, XY
amp, or X and Y motors. See figure below for location.
A Safety LED Location

Figure S-1 Safety LED on the Power Supply
The power supply does not need to be configured to comply with the source AC line voltage as
long as the source AC line voltage is within the range of 200 VAC to 240 VAC. Source input
voltage frequency differences are also handled automatically.
S.6.3 Lockout/Tagout Procedure
Kulicke & Soffa strongly recommends that you use a power connector locking device. When you
shut down power from the machine, implement user-supplied locking device on the power cable
to prevent unintentional or accidental restoration of power to the machine during servicing. The
attachment of a tagout device on the lockout device is also recommended. This gives a prominent
warning to all personnel that the machine may not be operated until the tagout device and the
lockout device are removed. Refer to OSHA Standard 29 CFR 1910.147 for detailed data on the
control of hazardous energy with lockout/tagout procedures.

S.7 Safe Use of Heated Material and Equipment

The workholder heaters are typically heated to a temperature that will immediately burn
unprotected skin if contact is made with the heaters, or with machine components close to the
workholder. Precautions must be taken when you load/unload heated materials and parts or
service equipment in the area around the workholder (work area) to avoid injury.
S.7.1 User's Responsibilities for Personal Safety
It is your responsibility to operate and service the machine safely. You must know all the hazards
and their related safety precautions. Examine all of the safety information given with the
equipment and read the WARNING notices within the technical manuals that support the
machine, and note the areas of the machine that are labeled as hazardous.
S.8 Potential Ergonomic Hazard – Microscope Use
There is a potential ergonomic hazard related with use of the microscope mounted on the
machine. The eyepieces of the microscope are 1380 mm (54.3 inches) above floor level. For
some machine users, this eyepiece height will be too low to use without bending; for others, the
eyepiece height will be too high for them to view the work through the microscope. The height of
the microscope is not adjustable. To prevent discomfort and the possibility of repetitive stress
injuries, obey the precautions that follow when you use the microscope.
WARNING:
DO NOT STAND ON TIPTOE WHEN YOU LOOK THROUGH THE MICRO-
SCOPE; THIS IS AN UNSTABLE POSITION THAT MAY RESULT IN A LOSS OF
BALANCE.
A. If the eyepieces are too high: Stand on a portable step while you view the work area through
the microscope. The portable step height should allow you to comfortably look through the
eyepieces, but the portable step height should not exceed 100 mm (4 inches).
B. If the eyepieces are too low: Make sure that the time spent to view through the microscope in
a bent position is no more than 20 seconds at a time. If the task requires more than 20 sec-
onds to do, make sure that you stand up straight for approximately 10 seconds after each 20
second view session through the eyepieces. To prevent repetitive stress injury to the back,
the number of sessions at the microscope in a stooped position should not exceed two per
shift, with rest after each 20 second view session.
S.8.1 Servicing Heated Equipment

If you need to do maintenance in the work area, set the heaters to off and allow sufficient time for
the workholder heaters to cool completely before you start the maintenance procedure.
To make sure that the workholder heaters have cooled:
A. In the Temperature Configuration dialog, set 1 TURN ALL ZONES to OFF.
B. Monitor the heat zone temperatures shown on the monitor screen.
C. When the shown temperatures equal the ambient temperature (approximately 25 °C), start
the maintenance procedure.

S.9 Fire Safety
This section gives the fire suppression equipment required for the ATPremier Plus Stud Bumper
and the storage of flammable supplies.
S.9.1 Fire Suppression
It is assumed that the machine will be operated in a clean room equipped with fire detection and
fire suppression equipment. The only requirement for the wire bonding machine is that the fire
extinguishing agent must be suitable for suppression of electrical fires. The machine contains no
combustible liquids or gases, nor are any used in the process done by the machine. If there is no
area fire suppression system in place where the machine operates, fire extinguishing equipment
must be available close to the machine. Use an extinguishing device suitable for electrical and
electronic equipment and compatible with the products used with the machine. Only personnel
trained to fight fires must use fire extinguishers. In the event of a fire, the machine will produce
only those substances that ordinarily result from the combustion of electrical or electronic
equipment. Standard venting and clean-up methods must be used.
S.9.2 Flammable Maintenance Supplies
Some machine preventive maintenance procedures specify use of isopropyl alcohol and grain
alcohol for cleaning and degreasing, which are flammable liquids. Large quantities of alcohol
(more than 1 liter) must be stored in accordance with local regulations. At a minimum, the
alcohol must be kept in approved containers that are clearly labeled, and the containers must be
stored outside of the production area in fireproof lockers. When alcohol is required for machine
maintenance, small amounts must be taken to the machine in labeled and tightly closed
containers. When in use, keep the alcohol away from open flames or other sources of ignition.

S.10 Emergency Off Switch

The ATPremier Plus Emergency Off Switch is on the front right-hand side of the upper console
(see Figure S-6). It is a latching switch with a large red knob surrounded by a yellow label. The
switch is large, highly visible and conveniently in position to make sure that Trained Operators
or Trained Service Personnel can easily find and use it, if an emergency power down of the
system is required.
Push the switch knob in to start an emergency power down process. This causes the main power
supply contactor to open and to remove all AC power from the equipment. To power up the
bonder after an emergency power down, release the Emergency Off Switch, push the Machine
OFF Switch, and then push the Machine ON switch to power up the machine.
CAUTION:
When you push the Emergency Off Switch during bonding, operation may
result in the loss of the process program and possibly cause damage to the
product. Make sure that you clear all leadframes from the workholder before
you restart the bonder after an emergency off condition.
S.10.1 Emergency Off Switch Specifications

• Switch Location: Front, right-hand corner of the upper console.
• Switch Description: Latching switch with large red knob, surrounded by a yellow label
imprinted with the words "EMERGENCY OFF". When activated, the switch latches in the
active position. The switch knob must be rotated clockwise to unlatch and de-activate the
switch.
• Functions:
• Emergency Off- Push the emergency off switch:
When you push in the switch, it cuts off all A.C. power to the system by the release
of the main power supply contactor.
• When the emergency off switch is pushed:
The emergency off switch remains in the latched position to prevent unauthorized
use of the machine. If the “ON” switch button is pushed with the emergency off
switch still latched down, the machine power will still remain off. Go to the next
step to restart from emergency off.
• Restart from emergency off:
Turn the switch knob clockwise to release the switch and reset the emergency off
switch. This will release the switch to reset to the “out” position. Push the machine
OFF switch and then push the machine ON switch button to power up the machine.
Note: The equipment will not restart unless the emergency off switch is reset to the
“out" position.
S.10.2 Test Emergency Off Switch Operation
A test of Emergency Off Switch operation must be done regularly as part of the scheduled
machine preventive maintenance. The test must also be done immediately after the machine is
installed at your site, during initial power-up.
In this test the trained service technician must operate the switch to make sure that power is
immediately removed from the machine and make sure that the Main Power switch will not
return power to the machine when the Emergency Off Switch is activated (latched down).

S.11 Cover Panels
The MHS workholder cover, the input magazine handler and output magazine handler covers;
the upper console cover panel; and lower console cover panel protect trained operators from
many of the hazards presented by the movement of the mechanical parts, heating elements and
electrical subsystems of the equipment. The covers must be in place and attached during all
normal operations. They must be opened or removed by trained service personnel only.
S.12 Machine Emissions
This section gives the various types of machine emissions for ATPremier Plus Stud Bumper.
S.12.1 Ionizing and Non-Ionizing Radiation
• Ionizing Radiation:
There are no sources of ionizing radiation in the machine.
• Non-ionizing Radiation:
The machine has been tested to show compliance with EN 61000-6-4, "Generic Emissions
for Industrial Environments".
S.12.2 Vibration
If the machine is installed as given in the ATPremier Plus Stud Bumper Machine Installation
Guide, with the machine on its leveling feet and with no contact between the machine and site
walls or other equipment, the machine will not let out any appreciable vibration when in
operation.
Elastomer vibration isolators are used on the leveling feet to support the machine and prevent
vibrations produced by the bonding and material handling equipment to transmit to the floor.
S.12.3 Noise
Continuous acoustical noise emitted by the machine will not be more than 85 dB(A), measured
from the operator position as prescribed in ANSI S1.13 “Methods for the Measurement of Sound
Pressure Levels."
S.12.4 Gases, Vapor, Dust
The machine produces no gases, vapors, or dust as a result of its operations.

S.13 Warning and Safety Labels

This section gives the safety and identification labels on the ATPremier Plus Stud Bumper. The
safety labels inform trained operators and trained service personnel that a hazardous condition
may exist in the general area of each of those labels. This requires caution if actions must be
done in those areas. The identification labels are informative and intended to help trained
operators and trained service personnel to do their duties safely.
A: S.13.2 Burn Hazard Warning

B: S.13.3 Pinch Point Hazard Warning
C: S.13.4 Electrical Hazard Warning
D: S.13.5 General Hazard Warning S.13.1 Emergency Off
A B C D
S.13.3 Pinch Point

Hazard Warning
S.13.3 Pinch Point

Hazard Warning
S.13.8 Operator ESD

Connection Point
Label
Figure S-2 Machine Front and MHS Safety Label Tags

S.13.4 Electrical
Hazard Warning
Machine Rear View With Covers
S.13.4 Electrical Hazard S.13.5 General

Warning Hazard Warning
S.13.7 Equipment
Grounding IEC
Lower Console Rear View Without Cover
Figure S-3 Machine Rear Safety Label Tags

S.14.3 FDA Explanatory/

Certification Label
S.14.2 Equipment
Identification/Manufacturer’s
Identification Label
S.13.6 Disconnect Power Label
Lower Console Front View

S.13.4 Electrical Hazard (without cover)
Warning
S.13.4 Electrical Hazard

Warning
Card Cage Front View

(when cage door is opened)
Clamp Driver Board
Zoom-in Card Cage Front View
Figure S-4 Lower Console Front Safety Label Tags

S.14.1 EFO Box Ordering Notice Label
S.13.4 Electrical Hazard Warning
S.13.3 Pinch Point Hazard Warning
Upper Console Rear View

(without rear cover)
S.13.9 Beryllium Product Warning
Bond Head Link Bottom View
Figure S-5 Bond Head, EFO, and MHS Safety Labels

S.13.1 Emergency Off
Figure S-6 Emergency Off Label

• Label: Emergency Off Label
• Description:
The label further identifies and increases the visibility of the Emergency Off Switch to
make sure that the Trained Operators and Service Personnel are fully aware of its location
and function.
• Color: Black on Yellow Background
S.13.2 Burn Hazard Warning
Figure S-7 Burn Hazard Warning Label

WARNING:
HOT TEMPERATURES CAN EXCEED 200°C.
• Label: Burn Hazard Warning

• Description:
Trained Operators and Service Personnel are warned of hot surfaces in the workholder
area and on the bond head and optics assembly.
S.13.3 Pinch Point Hazard Warning
Figure S-8 Pinch Point Warning Label

• Label: Pinch Point Hazard Label
• Description:
Trained Operators and Service Personnel are warned to keep hands and fingers clear of the
area. This applies to the front areas of the input and output magazine handlers, rear cover
area of the input and output magazine handlers, and on the front of the workholder area.

S.13.4 Electrical Hazard Warning
Figure S-9 Electrical Hazard Warning Label

• Label: Electrical Hazard Warning Label
• Description: This label alerts Trained Service Personnel to the presence of high voltage in
the area
S.13.5 General Hazard Warning
Figure S-10 General Hazard Warning Label

• Label: Warning, General Hazard Label
• Description:
This label alerts Trained Service Personnel (TSP) to the presence of danger at the
workholder area, Upper and lower console areas when covers are taken out The TSP is
required to follow-up on the related labels (next to the General Hazard Label) and read the
safety information before you try to service the equipment.
S.13.6 Disconnect Power Label
Figure S-11 Disconnect Power Before Servicing Label

• Label: Disconnect Power Before Servicing Label
• Description:
The label notifies Trained Service Personnels that the input power cord of the power
supply assembly must be disconnected before you service the equipment within the lower
console of the machine.
• Color: White on Blue Background

S.13.7 Equipment Grounding IEC
Figure S-12 Equipment Grounding IEC Label

• Label: Equipment Grounding IEC Label
• Description:
• Label: Identifies the connection point for input power ground
• Color: Black on White Background
S.13.8 Operator ESD Connection Point Label
Figure S-13 Operator ESD Connection Point Label

• Label: Operator ESD Connection Point Label
• Description:
Label identifies the connection point to attach the ESD wrist strap. This is to avoid
equipment damage from electrostatic discharge.
• Color: Black on White Background
S.13.9 Beryllium Product Warning
Figure S-14 Beryllium Product Warning Label

• Label: Beryllium Product Warning Label. “BERYLLIUM PRODUCT. HAZARDOUS
DUST PRODUCED WHEN MACHINED, FILED, OR GROUND”.
• Description:
Trained Service Personnel are directed to Manual for safety information with parts made
from Beryllium alloy, which can represent a health hazard under certain conditions.
During normal machine operations and maintenance actions, the Beryllium alloy does not
represent a hazard to machine users or service technicians. Refer to ATPremier Plus Stud
Bumper Maintenance Manual, chapter 5: bond head, for more data.

S.13.10 Hard Stop Caution
A
A Hard Stop Limit Line

Figure S-15 Hard Stop Caution
• Label: Hard Stop Caution Label. “HARD STOP CAUTION. Do not force beyond the hard
stop”.
• Description:
Trained operators and service personnel are alerted to not rotate the work light beyond the
hard stop as rotation beyond the hard stop will cause damage to the joint on the goose
neck. The hard stop location is denoted on the caution label.
• Color: Black and white text on yellow, red, and gray background

S.14 Identification Label Descriptions

The sections below give descriptions of each identification label that includes label location,
color(s) and purpose, meaning, additional instructions, etc.
S.14.1 EFO Box Ordering Notice Label
Figure S-16 EFO Box Ordering Notice Label

• Label: EFO Box Ordering Notice Label
• Description:
This label tells the trained service personnel to take note of the full part number that
includes the last two digits when ordering a new or replacement EFO Box. It also instructs
them to consult the customer service representative if required.
• Color: Black on beige card stock
S.14.2 Equipment Identification/Manufacturer’s Identification Label
Figure S-17 Equipment Identification Label

• Label: Equipment Identification/Manufacturer's Identification Label
• Description:
The label specifies the Equipment and Manufacturer's Identification Numbers (model
number, serial number, series and date manufactured), identifies the country of origin, and
indicates CE compliance. It also shows data on the AC power configuration of the system
on the date shipped and informs the customers and trained maintenance personnel of the
expected maximum power consumption of the bonder at listed nominal voltages. It also
directs trained maintenance personnel to consult the Machine Manuals before you try to
reconfigure the system.
• Color: Black on gray

S.14.3 FDA Explanatory/Certification Label
Figure S-18 FDA Explanatory/Certification Label

• Label: FDA Explanatory/Certification Label
• Description:
This label specifies that, with the use of Class 1 lasers within, the equipment is considered
a Class 1 Laser Product as classified per international standard EN/IEC 60825-1:2007. It
also specifies that the equipment complies with the US Food and Drug Administration/
Center for Devices and Radiological Health (FDA/CDRH) performance standards for
laser products except for deviations as documented in FDA/CDRH Laser Notice Number
50 published on June 24, 2007.
This label, in conjunction with the Equipment Identification Label (FDA/CDRH
Manufacturer's Identification Label), comprise the required US FDA/CDRH label
requirement for Class 1 Laser Products.
• Color: Black on white

S.15 Laser Safety

Note: The data below applies to K&S machines with serial numbers @@E@-@@XXXXX
where @ is alpha configuration information and X is numeric.
LASER SAFETY INFORMATION: Mercury & ChipEncoder

These encoders contain an infrared laser diode or diodes. Emitted invisible laser radiation levels
have been measured to be within the CDRH Class 1 range, which is not considered hazardous;
however, to minimize exposure to the diverging beam, the encoder sensor should be installed in
its operational configuration in close proximity to the encoder scale before power is applied.
• Invisible laser radiation; wavelength: 850 nm

• Max power 2.4 mC CW (4.8 mW CW for Mercury II™)
• All maintenance procedures such as cleaning must be performed with the MicroE encoder
turned off.
• Do not insert any reflective surface into the beam path when encoder is powered.
• Do not attempt to service the encoder.
MicroE Systems
125 Middlesex Turnpike, Bedford, MA 01730
Serial # XXXXX
Model # Mercury II 1900XY/ZCRS
Manufactured Date: October 2011
A. Caution - use of controls or adjustments or performance of procedures other than those spec-
ified herein may result in hazardous radiation exposure.
B. This laser product is designated as Class 1 during all procedures of operation.
• Non-accessible Laser Parameters:
• Wavelength: 850 nm
• Laser Power: <4.8 mWatts
C. The bond head Z-axis encoder and the XY table X and Y encoders contain a Class 1 laser.
While the encoders are mounted in the bonder, the laser poses no danger to the user or
maintenance technician. However, when the encoder heads are removed and machine power
is on, the laser light can cause eye damage if viewed directly on axis. Always turn off/lock-out
machine power before you remove the sensor heads from the bond head or the XY table.
D. Under normal usage, there is no user maintenance required or any scheduled maintenance
necessary to the laser encoders. The laser encoders should not be opened and no repair,
service or modification shall be done by customer. Only trained K&S service personnel or
K&S trained customer service engineers are able to service the encoders.

E. Due to the complexity and special tools required for the repair, setup and recali-
bration, in the event that the X or Y encoder becomes faulty, the repair and/or replacement is
to be done with the return of the complete X/Y table assembly to the factory. In some
instances, and subject to the fault finding results, a trained K&S service engineer may make
the repairs on-site. The repair or replacement of the Z-axis encoder can be done at a cus-
tomer site but only by a trained K&S service engineer or K&S trained customer service engi-
neer.
F. A bonder with a faulty laser encoder should be taken out of service for repair by a qualified
service engineer as mentioned above.
G. For customer performed service functions, only K&S trained customer service engineers,
supplemented by K&S supplied calibration tools and maintenance procedures contained
within the equipment's Maintenance Manual, are permitted.
Note: The data below applies to K&S machines with serial numbers @@H@-@@XXXXX
where @ is alpha configuration information and X is numeric.
H. Caution - use of controls or adjustments or performance of procedures other than those spec-
ified herein may result in hazardous radiation exposure.
I. This laser product is designated as Class 1 during all procedures of operation.
• Non-accessible Laser Parameters:
• Wavelength: 850 nm
• Laser Power: <1.5 mWatts
J. The bond head Z-axis encoder contains a class 1 laser. While the encoder is mounted in the
bonder, the laser poses no danger to the user or maintenance technician. However, when the
encoder head is removed and machine power is on, the laser light can cause eye damage if
viewed directly on axis. Always turn off/lock-out machine power before you remove the sen-
sor head from the bond head.
K. Under normal usage, there is no user maintenance required or any scheduled maintenance
necessary to the laser encoders. The laser encoders should not be opened and no repair,
service or modification shall be performed by customer. Only trained K&S service personnel
or K&S trained customer service engineers are allowed to service the encoders.
L. The repair or replacement of the Z-axis encoder can be done at a customer site but only by a
trained K&S service engineer or K&S trained customer service engineer.
M. A bonder with a faulty laser encoder should be taken out of service for repair by a qualified
service engineer as mentioned above.
N. For customer performed service functions, only K&S trained customer service engineers,
supplemented by K&S supplied calibration and maintenance procedures contained within the
equipment's Maintenance Manual, are permitted.

S.16 Declaration of Exemption

Kulicke & Soffa Pte Ltd declares that our products, i.e. ball bonders, wedge bonders, die bonders
and similar industrial equipment are exempt from the European RoHS (Restriction of Use of
Certain Hazardous Substances) and WEEE (Waste of Electrical and Electronics Equipment)
directives based on the equipment under the not applicable category of “Large-scale, stationary
industrial tools” as referenced in EU Directive 2011/65/EU (RoHS) Article 2§4(d) and Article
3§(3).
Examples of this type of equipment have previously been reviewed by third party evaluators (see
Note 1) who determined that the equipment reviewed meet the above criteria (see Note 2) and, as
such, are deemed to be outside the scope of both European Union (EU) RoHS and WEEE.
Note: 1) TUV Rheinland of North America, RoHS & WEEE – Official letter of exemption,
Kulicke & Soffa; September 26, 2005
Note: 2) TUV Rheinland of North America, WEEE and RoHS Directive Applicability to
Industrial Machinery; September 27, 2005

S.17 Shutdown and Start-up Procedures
In the event of a plant shutdown, bonders must be shut down appropriately. The machine
shutdown and start-up procedures are given below:
S.17.1 Machine Shutdown Procedure
A. Turn “OFF” all heaters (pre-heat, bond site & post-heat) from the GUI.
B. Remove all materials, units, magazines, wires, P-parts, etc from the bonder.
C. Re-initialize the workholder.
D. Save Bond Process Programs (if needed).
E. Save MDP to C:\ drive.
F. Push the machine off button to shut down the machine.
G. Disconnect clean dry air (CDA) supply line and AC power cord from the AC mains.
H. Wait for machine to cool down to room temperature. Place desiccants on the X/Y motors,
lower console (inside and outside) and heat block. Position the bond headbond head above
the heat block.
I. Place a plastic sheet over the machine to prevent dust accumulation.
J. At this juncture, inform the personnel in-charge of the site to shut down the HVAC (heating,
ventilating and air conditioning) system.
S.17.2 Machine Start-up Procedure

Note: Coordination with facilities is extremely important to make sure that there is smooth
transition of the bonders into production.
A. Wait for the production environment to stabilize to the these conditions:
• Temperature ~77°F (25°C) or below
• Relative humidity of 40-60%
• Barometric pressure of 540 to 810 mm Hg (21.2 to 31.9” Hg)
B. Remove all desiccants from the bonder.
C. Purge the CDA supply (incoming facilities) before you connect the CDA supply line to the
bonder.
D. Check the supply (incoming) voltage with a multimeter. This is dependent on the AC voltage
requirement on the machine.
E. Connect the AC power cord to the AC mains.
F. Push the machine on button to power up the machine.
G. Load Bond Process Program.
H. Install the heat block & clamp insert.
I. Do the bonder dry cycle mode with pre-heat, bond site and post-heat temperature set-points
turned “OFF”.
J. Turn “ON” pre-heat, bond site and post-heat heaters after successful completion of dry cycle.
K. Do the machine setup for production qualification based on customer’s standard procedure.


Table Of Contents
Use of This Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-1
General Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-1
Terms and Conventions used in this manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-1
Record of Changes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-2
Safety Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-1

S.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-1
S.2 Symbols and Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-1
S.2.1 Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-1
S.2.2 Caution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-1
S.2.3 Note - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-1
S.3 Equipment-Specific Warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-2
S.4 General Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-3
S.5 Trained Operators and Service Technicians - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-4
S.6 Servicing Electrical Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-4
S.6.1 Types of Electrical Hazards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-4
S.6.2 Servicing Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-5
S.6.3 Lockout/Tagout Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-5
S.7 Safe Use of Heated Material and Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-6
S.7.1 User's Responsibilities for Personal Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-6
S.8 Potential Ergonomic Hazard – Microscope Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-6
S.8.1 Servicing Heated Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-6
S.9 Fire Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-7
S.9.1 Fire Suppression - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-7
S.9.2 Flammable Maintenance Supplies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-7
S.10 Emergency Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-8
S.10.1 Emergency Off Switch Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-8
S.10.2 Test Emergency Off Switch Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-8
S.11 Cover Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-9
S.12 Machine Emissions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-9
S.12.1 Ionizing and Non-Ionizing Radiation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-9
S.12.2 Vibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-9
S.12.3 Noise - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-9
S.12.4 Gases, Vapor, Dust - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-9
S.13 Warning and Safety Labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-10
S.13.1 Emergency Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-14
S.13.2 Burn Hazard Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-14
S.13.3 Pinch Point Hazard Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-14
S.13.4 Electrical Hazard Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-15
S.13.5 General Hazard Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-15
S.13.6 Disconnect Power Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-15
S.13.7 Equipment Grounding IEC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-16
S.13.8 Operator ESD Connection Point Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-16
S.13.9 Beryllium Product Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-16
S.13.10Hard Stop Caution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-17
S.14 Identification Label Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-18
S.14.1 EFO Box Ordering Notice Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-18
S.14.2 Equipment Identification/Manufacturer’s Identification Label - - - - - - - - - - - - - - - - - - - - - - - S-18
S.14.3 FDA Explanatory/Certification Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-19
S.15 Laser Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-20
S.16 Declaration of Exemption - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-22
S.17 Shutdown and Start-up Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-23
98888-0000-JB3-01 Table Of Contents TOC-1

S.17.1 Machine Shutdown Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-23

S.17.2 Machine Start-up Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-23
Table Of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TOC-1
List of Figures- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LOF-1
List Of Tables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LOT-1
1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
1.1 General Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
1.1.1 Scope - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
1.1.2 MHS Manual Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
1.1.3 MHS Information in Other Manuals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.1.4 Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.2 Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1.2.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1.2.2 Workholder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
1.2.3 Device Indexing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
1.2.4 Magazine Handlers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
1.3 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.3.1 Carrier Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.3.1.1 J Boat Carrier Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.3.2 Magazine Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.3.3 Other Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.4 Operator Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.4.1 EMERGENCY OFF Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.4.2 Operator Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.4.3 Video Monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
1.4.4 Signal Light and Audible Alarm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
1.5 Video and Graphics Displays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-10
1.6 MHS Software Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-12
1.6.1 MHS Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
1.6.2 MHS Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
1.6.3 MHS Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
1.6.4 MHS Magazine Utilities (Without Safety Covers) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14
1.6.5 MHS Workholder Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15
1.6.6 MHS Auto Run Configuration (Indexing Type) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
1.6.7 MHS Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17
1.7 Operating Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-18
1.7.1
Initial Start–up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-18
1.7.2
Load/Unload Magazines During Bonding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-20
1.7.3
Stop Auto Bonding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-20
1.7.4
Clear Leadframes from Indexer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-20
1.7.5
Remove Magazines From Magazine Handlers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-20
1.7.6
Bonder/Workholder System Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-21
1.8 Product Conversion (Figure 1-17) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-22
1.8.1 Tools/Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-23
1.8.2 Replace Heat Block Inserts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-23
1.8.3 Load Existing Process Program - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-24
1.8.4 MHS Material Dimension/Parameter File Handling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-24
1.8.4.1 Edit Workholder Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-24
1.8.4.2 Edit Magazine Handler Parameters: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25
1.8.5 MHS Operation Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25
2 Workholder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
TOC-2 Table Of Contents 98888-0000-JB3-01
2.1 About this section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2.2 Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
2.2.1 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
2.2.2 Workholder Subsystems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
2.2.2.1 Puller Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
2.2.2.2 Front/Rear Rail Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2.2.2.3 Preheat Heat Block Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2.2.2.4 Bond Site Heat Block Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
2.2.2.5 Index/Tucker Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
2.2.2.6 J Boat MHS Pneumatic System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
2.2.2.7 Indexer Intermediate Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
2.2.3 Boat Injection Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9
2.2.4 Boat Transfer Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-11
2.2.5 Boat Indexing and Ejection Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-11
2.3 Setups and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-13
2.3.1 Set-Up Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-13
2.3.2 Puller Pin Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-15
2.3.2.1 Workholder Gauge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-15
2.3.2.2 Puller Pin Setup Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-16
2.3.3 Index Pin/Tucker Eject Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20
2.3.3.1 Index Pin Setup Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20
2.3.3.2 Tucker Eject Setup Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-22
2.3.4 Bond Site Heat Block Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-24
2.3.5 Rail Parallelism Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-27
2.3.6 Preheat Heat Block/Bond Site Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-32
2.3.7 Puller Rack Backlash Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-36
2.3.8 Heat Block Vacuum Sensor Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-38
2.4 Workholder Calibration Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-40
2.4.1 Workholder Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-40
2.4.1.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-40
2.4.1.2 Do the Workholder Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-40
2.4.2 Heat Block Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-51
2.4.2.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-51
2.4.2.2 Do the Heat Block Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-51
2.4.3 Tucker Eject Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-52
2.4.3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-52
2.4.3.2 Do the Tucker Eject Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-52
2.4.4 Workholder Calibrations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-53
2.5 Workholder Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-54
2.5.1 Boat/Device Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-55
2.5.1.1 Boat Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-55
2.5.1.2 Device Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-56
2.5.1.3 Bond Plane Offset - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-57
2.5.2 Indexing Parameters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-57
2.5.3 Indexing Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-59
2.5.4 Workholder Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-59
2.6 J Boat Indexer Assembly Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - 2-61
2.7 J Boat Slider Assembly Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-66
2.8 Preventive Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-69
2.9 Parts Replacement Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-71
2.9.1 Bond Site/Preheat Heat Block Assembly Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-71
2.9.1.1 Compression Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-71
2.9.1.2 Preheat Heater Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-73
2.9.1.3 Preheat Thermocouple Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-75
2.9.1.4 Bond Site Heater Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-76
2.9.1.5 Bond Site Thermocouple Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-78
2.9.1.6 Preheat Heat Block Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-79
2.9.1.7 Bond Site Heat Block Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-80
2.9.1.8 Preheat Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-82

2.9.1.9 Bond Site Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-85
2.9.1.10 Preheat Linear Slide Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-86
2.9.2 Puller Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-88
2.9.2.1 Puller Finger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-88
2.9.2.2 Puller Rack - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-89
2.9.2.3 Puller Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-90
2.9.2.4 Puller Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-93
2.9.3 Index/Tucker Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-95
2.9.3.1 Index Arm and Pin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-95
2.9.3.2 Tucker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-98
2.9.3.3 Tucker Soienoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-99
2.9.4 Rail Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-101
2.9.4.1 Indexer Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-101
2.9.4.2 X Axis Leadscrew Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-103
2.9.4.3 Leadscrew Bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-105
2.9.5 Sensor Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-106
2.9.5.1 X Registration Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-106
2.9.5.2 Optical Switch Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-107
2.9.5.3 J Boat Present Sensor Amplifier - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-109
2.9.6 Indexer Flex Cable Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-111
2.9.6.1 Puller Flex Cable Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-111
2.9.6.2 Gripper Flex Cable Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-113
2.9.7 Heat Block Vacuum Solenoid Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-116
3 Magazine Handlers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

3.1 About This Section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3.2 Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
3.2.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
3.2.2 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
3.2.3 Magazine Handler Positions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
3.2.3.1 Input and Output Pickup Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
3.2.3.2 Input and Output Slot Positions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3.2.3.3 Input Staging Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3.2.3.4 Deposit Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3.2.4 Optional Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3.2.4.1 Safety Covers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3.2.4.2 Bar Code Readers (Optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3.3 Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3.4 Magazine Handler Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3.4.1 Input/Output Trays Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3.4.2 Input/Output Slot Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-9
3.5 Magazine Handler Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-13
3.6 Magazine Handler Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-13
3.6.1 Set-up the Belt Tension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
3.6.2 Tray Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-15
3.7 Magazine Handler Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-15
3.7.1 Input Magazine Handler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-15
3.7.2 Output Magazine Handler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-21
3.8 Preventive Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-24
3.9 Part Replacement Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-26
3.9.1 Replace Sensor Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-26
3.9.2 Replace Cable Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-29
3.9.2.1 Magazine Gripper Assembly Motor Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-29
3.9.2.2 Y Axis Motor Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-30
3.9.2.3 Z Axis Motor Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-30
3.9.3 Replace Magazine Handler Circuit Board Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-31

3.9.4 Replace Load Tray Timing Belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-31
3.9.4.1 Replace Driven Timing Belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-31
3.9.4.2 Replace Drive Timing Belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-32
3.9.5 Replace Load Tray Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-35
3.9.6 Replace Magazine Gripper Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-36
3.9.6.1 Replace Magazine Gripper Paw/Paw Return Springs - - - - - - - - - - - - - - - - - - - - - 3-36
3.9.6.2 Replace Magazine Stop Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-40
3.9.7 Replace Brake Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-41
3.9.8 Replace Stepper Motors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-44
3.9.8.1 Z Axis Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-44
3.9.8.2 Y Axis Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-46
3.9.8.3 Magazine Gripper Assembly Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-48
4 Electronics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
4.2 Overall Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4.2.1 System Organization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4.2.2 Stepper Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
4.2.3 Sensor Handling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
4.2.4 DMHS Backplane Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
4.3 Subsystem/Board Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
4.3.1 Circuit Board Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
4.3.2 Circuit Board Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-14
4.3.2.1 DMHS Indexer/Solenoid Driver Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-14
4.3.2.2 DMHS Hex Half Stepper Driver Circuit Boards - - - - - - - - - - - - - - - - - - - - - - - - - 4-15
4.3.2.3 DMHS Stepper Controller Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17
4.3.2.4 DMHS Micro/Tri Half Stepper Driver Board - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-18
4.3.2.5 Magazine Handler Intermediate Board (08888-4116-000-xx) - - - - - - - - - - - - - - - - 4-20
4.3.2.6 Indexer Intermediate Board (08888-4226-000-xx) - - - - - - - - - - - - - - - - - - - - - - - 4-21
4.3.2.7 Magazine Handler Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-22
4.3.3 Replace DMHS Card Rack Circuit Boards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-23
4.3.4 Replacing the Input/Output Magazine Handler Intermediate Board - - - - - - - - - - - - - - - - - - - 4-24
4.3.5 Replace Indexer Intermediate Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-26
4.4 MHS Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-28
4.4.1 Sensor Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-28
4.4.2 Workholder Sensor Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-29
4.4.3 Magazine Handler Sensor Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-30
4.4.4 Reflective Sensor Amplifier Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-33
4.4.4.1 J Boat Present Sensor Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-34
4.4.5 Sensor Status Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-34
4.5 Cable Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35
5 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
5.2 Preventive Maintenance Schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
5.3 Special Tools and Gauges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-5
5.4 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-5
5.4.1 MHS Workholder and Motor Cycling Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-5
5.4.1.1 Indexer Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
5.4.1.2 Puller Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
5.4.1.3 Heat Block Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
5.4.1.4 Magazine Handler Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
5.4.2 Temperature Controller Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
5.4.2.1 System Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
5.4.2.2 Any Zone Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
5.4.2.3 Zone Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
5.4.3 Re–Initialize MHS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
5.4.4 Maintenance Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10

5.4.5 MHS Toolbar Utility Menus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14
5.4.5.1 MHS Workholder Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14
5.4.5.2 MHS Magazine Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5.4.6 MHS Manual Mode Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5.4.6.1 Index Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5.4.6.2 Heat Block Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-18
5.4.6.3 Preheat Block Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-18
5.4.6.4 Pin Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-19
5.5 MHS Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-21
5.5.1 Error Indications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-21
5.5.1.1 Error Recovery Options Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-21
5.5.1.2 Signal Lights and Audible Alarm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-21
5.5.2 Error and Status Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-22
5.5.2.1 ”Home Not Found” or ”Not Out of Home” Errors - - - - - - - - - - - - - - - - - - - - - - - 5-22
5.5.2.2 Material Condition Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-22
5.5.2.3 Status Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-23
5.5.2.4 Calibration Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-23
5.5.2.5 Magazine Handling Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-23
5.5.2.6 Injection, Indexing, and Ejection Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-26
5.5.2.7 Initialization Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-28
5.5.2.8 Program Execution Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-29
5.6 MHS–Related Bonding Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-30
5.6.1 Eye Point Find Failures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-31
5.6.2 Non–Stick on Pad (NSOP) Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-32
5.6.3 Non–Stick on Lead (NSOL) Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-33
A Glossary of Terms & Abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A-1
B IConn J Boat Wire Bonder MHS Wiring Diagrams - - - - - - - - - - - - - - - - - - - - - - - - B-1
Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INDEX-1

List of Figures
Figure S-1 Safety LED on the Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -S-5
Figure S-2 Machine Front and MHS Safety Label Tags - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-10
Figure S-3 Machine Rear Safety Label Tags - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-11
Figure S-4 Lower Console Front Safety Label Tags - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-12
Figure S-5 Bond Head, EFO, and MHS Safety Labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-13
Figure S-6 Emergency Off Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-14
Figure S-7 Burn Hazard Warning Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-14
Figure S-8 Pinch Point Warning Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-14
Figure S-9 Electrical Hazard Warning Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-15
Figure S-10 General Hazard Warning Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-15
Figure S-11 Disconnect Power Before Servicing Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-15
Figure S-12 Equipment Grounding IEC Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-16
Figure S-13 Operator ESD Connection Point Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-16
Figure S-14 Beryllium Product Warning Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-16
Figure S-15 Hard Stop Caution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-17
Figure S-16 EFO Box Ordering Notice Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-18
Figure S-17 Equipment Identification Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-18
Figure S-18 FDA Explanatory/Certification Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-19
Figure 1-1 The IConn J Boat Material Handling System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
Figure 1-2 “C” Style Magazine Handling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Figure 1-3 Operator Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7
Figure 1-4 Operator Control Panel (MMI) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
Figure 1-5 Video Monitor Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
Figure 1-6 MHS Configuration (Workholder and Magazine Handler) - - - - - - - - - - - - - - - - - - - - - 1-12
Figure 1-7 MHS Calibration Menus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
Figure 1-8 Access to MHS Utilities (Manual Mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14
Figure 1-9 Standard Mag Handler Utilities Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14
Figure 1-10 Workholder Utilities Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15
Figure 1-11 Boat Inject Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15
Figure 1-12 Clamp Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
Figure 1-13 Heat Block Vacuum Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
Figure 1-14 Access to Auto Run Configuration Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17
Figure 1-15 Access to MHS Diagnostics Menus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-18
Figure 1-16 Load Magazines on Magazine Handler (Input Magazine Handler Shown) - - - - - - - - - - 1-19
Figure 1-17 Product Conversion Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-22
Figure 2-1 Slider Assembly: Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
Figure 2-2 Indexer Assembly: Major Components (Front View) - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
Figure 2-3 Indexer Assembly: Major Components (Rear View) - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
Figure 2-4 MHS Boat Injection Sequence (Top View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10
Figure 2-5 MHS Boat Transfer Sequence (Top View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-11
Figure 2-6 MHS Boat Indexing and Ejection Sequence (Top View) - - - - - - - - - - - - - - - - - - - - - - 2-12
Figure 2-7 Workholder Setup Sequence, Sheet 1 of 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-13
Figure 2-8 Workholder Setup Sequence, Sheet 2 of 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-14
Figure 2-9 Workholder Gauge Funtionality for Puller Pin Setup - - - - - - - - - - - - - - - - - - - - - - - - - 2-15
Figure 2-10 Install the Workholder Setup and Calibration Gauge Assembly Position - - - - - - - - - - 2-17
Figure 2-11 Install the Workholder Setup and Calibration Gauge Assembly at 45o angle - - - - - - - - 2-17
Figure 2-12 Puller Pin Y axis Adjustment (Top View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-18
Figure 2-13 Puller Pin Level 1 Adjustment (Right Side View) - - - - - - - - - - - - - - - - - - - - - - - - - - 2-18
Figure 2-14 Puller Pin Level 2 and Level 3 Adjustment (Rear View) - - - - - - - - - - - - - - - - - - - - - - 2-19
Figure 2-15 Puller Pin Level 4 Adjustment (Side View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-19
Figure 2-16 Index Pin Alignment Groove - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20
Figure 2-17 Index Pin - Y axis Adjustment and Up/Down Adjustment - - - - - - - - - - - - - - - - - - - - - 2-21
Figure 2-18 Tucker Eject Alignment Surfaces - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-22
98888-0000-JB3-01 List of Figures LOF-1
Figure 2-19 Tucker “Raised Position” Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-23

Figure 2-20 Tucker Pin Lower Travel Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-23
Figure 2-21 Install the Workholder Setup Gauge Position (Right Side View) - - - - - - - - - - - - - - - - -2-24
Figure 2-22 Bond Site Heat Block Alignment (Top View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-25
Figure 2-23 Y Value At The Top Right Corner of the GUI Display - - - - - - - - - - - - - - - - - - - - - - -2-25
Figure 2-24 Rear Rail Assembly (Rear View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-28
Figure 2-25 Front Rail Assembly (Front View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-28
Figure 2-26 Install the Rail Width Gauge Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-29
Figure 2-27 Install the Rail Width Gauge and Gauge Pins - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-30
Figure 2-28 Rail Parallelism - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-31
Figure 2-29 Install the Rail Width Gauge - 3.6” Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-33
Figure 2-30 Install the Rail Width Gauge at 45o angle (Right Side View) - - - - - - - - - - - - - - - - - - -2-33
Figure 2-31 Install the Preheat Setup Gauge and the Gauge Pins - - - - - - - - - - - - - - - - - - - - - - - - -2-34
Figure 2-32 Preheat Heat Block Alignment (Top View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-35
Figure 2-33 Puller Rack Backlash - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-36
Figure 2-34 Vacuum Sensor Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-38
Figure 2-35 Workholder Calibration Menu - Remove Material - - - - - - - - - - - - - - - - - - - - - - - - - -2-41
Figure 2-36 Workholder Calibration - Install Bond Site Heat Block Gauges/Inserts - - - - - - - - - - - -2-41
Figure 2-37 Workholder Calibration - Heat Block Focus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-41
Figure 2-38 Workholder Calibration - Heat Block Crosshair Alignment (Left - Rear Corner) - - - - - -2-42
Figure 2-39 Heat Block Crosshair Alignment (Right - Front Corner) - - - - - - - - - - - - - - - - - - - - - -2-42
Figure 2-40 Workholder Calibration - Remove Heat Block Gauge/Insert - - - - - - - - - - - - - - - - - - -2-42
Figure 2-41 Workholder Calibration - Install Rail Width Gauge - - - - - - - - - - - - - - - - - - - - - - - - -2-43
Figure 2-42 Workholder Calibration - Install the Rail Width Gauge Position - - - - - - - - - - - - - - - - -2-43
Figure 2-43 Workholder Calibration - Install the Rail Width Gauge at 45o angle - - - - - - - - - - - - - -2-44
Figure 2-44 Workholder Calibration - Teach Heat Block Assembly - - - - - - - - - - - - - - - - - - - - - - -2-44
Figure 2-45 Workholder Calibration - Pin Touches Bond Site Heat Block Assembly - - - - - - - - - - -2-44
Figure 2-46 Workholder Calibration - Remove Rail Width Gauge - - - - - - - - - - - - - - - - - - - - - - - -2-45
Figure 2-47 Workholder Calibration - Install Bond Site Heat Block Gauge/Insert - - - - - - - - - - - - - -2-45
Figure 2-48 Workholder Calibration - Teach Bond Height Position - - - - - - - - - - - - - - - - - - - - - - -2-45
Figure 2-49 Workholder Calibration - Remove Heat Block Gauge/Insert - - - - - - - - - - - - - - - - - - -2-45
Figure 2-50 Workholder Calibration - Install the Workholder Setup and Calibration Gauge Assembly Position
2-46
Figure 2-51 Workholder Calibration - Install the Workholder Setup and Calibration Gauge Assembly at 45o
angle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-46
Figure 2-52 Workholder Calibration - Install the Gauge Pedestal - - - - - - - - - - - - - - - - - - - - - - - - -2-47
Figure 2-53 Workholder Calibration - Gauge Pedestal Focus - - - - - - - - - - - - - - - - - - - - - - - - - - -2-47
Figure 2-54 Workholder Calibration - Gauge Pedestal Crosshair Alignment (Right Side) - - - - - - - -2-48
Figure 2-55 Workholder Calibration - Gauge Pedestal Crosshair Alignment (Left Side) - - - - - - - - -2-48
Figure 2-56 Workholder Calibration - Remove the Gauge Pedestal - - - - - - - - - - - - - - - - - - - - - - -2-48
Figure 2-57 Workholder Calibration - Puller move into Input Magazine Handler Area - - - - - - - - - -2-49
Figure 2-58 Workholder Calibration - Remove the Workholder Setup and Calibration Gauge Assembly 2-49
Figure 2-59 Workholder Calibration - Teach Preheat Heat Block Assembly - - - - - - - - - - - - - - - - -2-49
Figure 2-60 Workholder Calibration - Pin Touches Preheat Heat Block Assembly - - - - - - - - - - - - -2-50
Figure 2-61 Workholder Calibration - Remove the Rail Width Gauge - - - - - - - - - - - - - - - - - - - - -2-50
Figure 2-62 Workholder Calibration - Remove All Calibration Gauges - - - - - - - - - - - - - - - - - - - - -2-50
Figure 2-63 Workholder Calibration - Install Heat Block Inserts - - - - - - - - - - - - - - - - - - - - - - - - -2-50
Figure 2-64 Workholder Calibration - Complete - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-50
Figure 2-65 Heat Block Calibration - Install Bond Site Heat Block Gauges/Inserts - - - - - - - - - - - - -2-51
Figure 2-66 Heat Block Calibration - Move Bond Head - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-51
Figure 2-67 Heat Block Calibration - Remove the Heat Block Gauge - - - - - - - - - - - - - - - - - - - - - -2-52
Figure 2-68 Heat Block Calibration - Complete - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-52
Figure 2-69 Tucker Eject Calibration - Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-52
Figure 2-70 Tucker Eject Calibration - Align the Tucker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-53
LOF-2 List of Figures 98888-0000-JB3-01

Figure 2-71 Tucker Eject Calibration - Tucker Tip Extends 1/16 inches - - - - - - - - - - - - - - - - - - - - 2-53
Figure 2-72 Workholder Configuration Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-54
Figure 2-73 Boat/Device Parameters Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-55
Figure 2-74 Boat Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-56
Figure 2-75 Hole On Boat End Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-56
Figure 2-76 Device Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-57
Figure 2-77 Index Parameters Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-57
Figure 2-78 Indexing Options Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-59
Figure 2-79 Workholder Configuration Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-59
Figure 2-80 Remove/Replace J Boat Indexer Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-63
Figure 2-81 Remove/Replace J Boat Indexer Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-64
Figure 2-82 Remove/Replace J Boat Slider Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-68
Figure 2-83 Compression Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-72
Figure 2-84 Preheat Heater and Thermocouple Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-74
Figure 2-85 Bond Site Heater and Thermocouple Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-77
Figure 2-86 Replace Preheat Heat Block Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-80
Figure 2-87 Replace Bond Site Heat Block Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-81
Figure 2-88 Remove Preheat Assembly (Front View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-83
Figure 2-89 Replace Preheat Motor - Exploded Rear View - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-84
Figure 2-90 Replace Bond Site Motor - Exploded Rear View - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-86
Figure 2-91 Replace Preheat Linear Slide Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-87
Figure 2-92 Puller Finger (Front Wall Assembly - Rear View) - - - - - - - - - - - - - - - - - - - - - - - - - - 2-88
Figure 2-93 Puller Rack - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-89
Figure 2-94 Puller Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-92
Figure 2-95 Puller Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-94
Figure 2-96 Index Arm and Pin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-97
Figure 2-97 Tucker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-99
Figure 2-98 Tucker Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-100
Figure 2-99 Indexer Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-102
Figure 2-100 X Axis Leadscrew Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-104
Figure 2-101 X Registration Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-107
Figure 2-102 J Boat Present Sensor Amplifier Controls/Indicators - - - - - - - - - - - - - - - - - - - - - - 2-109
Figure 2-103 Puller Flex Cable Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-112
Figure 2-104 Gripper Flex Cable Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-114
Figure 2-105 Heat Block Vacuum Solenoid Valve (XY Table Assembly - Right View) - - - - - - - - 2-116
Figure 3-1 Magazine Handlers Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
Figure 3-2 Tray Assembly (Load and Unload Trays) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
Figure 3-3 Touching Benching Buttons (Side View) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8
Figure 3-4 Magazine-Sized Gauge and Workholder Setup & Calibration Gauge - - - - - - - - - - - - - - - 3-9
Figure 3-5 Install the Workholder Setup & Calibration Gauge Assembly Position - - - - - - - - - - - - 3-10
Figure 3-6 Install the Workholder Setup & Calibration Gauge Assembly at 45o angle - - - - - - - - - - 3-11
Figure 3-7 Install the Workholder Setup & Calibration Gauge - - - - - - - - - - - - - - - - - - - - - - - - - - 3-12
Figure 3-8 Magazine Handler Configuration Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
Figure 3-9 Load Tray, Belt Tension Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-14
Figure 3-10 Remove/Install Magazine Handler (Input Magazine Handler Shown) - - - - - - - - - - - - - 3-17
Figure 3-11 Input Tray Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19
Figure 3-12 Cable Routing & Sensors (Input Magazine Handler Shown - Detail A) - - - - - - - - - - - - 3-27
Figure 3-13 Cable Routing & Sensors (Input Magazine Handler Shown - Detail B) - - - - - - - - - - - - 3-28
Figure 3-14 Load Tray Assembly (Exploded View - Bottom of Tray) - - - - - - - - - - - - - - - - - - - - - 3-34
Figure 3-15 Bottom Paw/Spring Replacement (Lower Jaw Gripper Assembly) - - - - - - - - - - - - - - - 3-37
Figure 3-16 Top Paw/Spring Replacement (Upper Jaw Magazine Gripper Assembly Shown) - - - - - 3-39
Figure 3-17 Brake Assembly Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-43
Figure 3-18 Remove/Replace Z Axis Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-45
Figure 3-19 Remove/Replace Y Axis Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-47
98888-0000-JB3-01 List of Figures LOF-3

Figure 4-1 Model 3131 Control System Organization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3

Figure 4-2 Typical Stepper Motor Control Path - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
Figure 4-3 Sensor Data Input to Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
Figure 4-4 DMHS Backplane Board P/N 08888-4000-000-xx, Major Components - - - - - - - - - - - - - 4-7
Figure 4-5 Sensor Data Input to Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
Figure 4-6 Serial Communications Path - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
Figure 4-7 Card Rack Circuit Board Assembly Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-11
Figure 4-8 MHS Interface Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-12
Figure 4-9 Power Supply Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-13
Figure 4-10 DMHS Indexer/Solenoid Driver Board, P/N 08888-4032-000-xx,
Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-14
Figure 4-11 DMHS Hex Half-Stepper Drivers, P/N 08888-4166-000-xx,
Figure 4-12 DMHS Stepper Controller Board, P/N 08888-4300-000-xx,
Figure 4-13 DMHS Micro/Tri Half Stepper Driver Board, Major Components - - - - - - - - - - - - - - -4-19
Figure 4-14 Magazine Handler Intermediate Board Layout, Major Components - - - - - - - - - - - - - - -4-20
Figure 4-15 Indexer Intermediate Board Connection Points - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-21
Figure 4-16 Input or Output Interconnect Boards, Cable and Sensor Connections - - - - - - - - - - - - - -4-22
Figure 4-17 Replace Input or Output Magazine Handler Intermediate Board (Input Side) - - - - - - - -4-25
Figure 4-18 Replace Indexer Intermediate Board (Front View of J Boat Indexer Assembly) - - - - - -4-27
Figure 4-19 Workholder Sensor Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-29
Figure 4-20 Magazine Handler Sensors - Detail A (Input Magazine Handler Shown) - - - - - - - - - - -4-30
Figure 4-21 Magazine Handler Sensors - Detail B (Input Magazine Handler Shown) - - - - - - - - - - -4-31
Figure 4-22 Tray Assembly Sensors - Detail C (Output Tray Assembly Shown) - - - - - - - - - - - - - -4-32
Figure 4-23 Reflective Sensor Amplifier Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-33
Figure 5-1 Access to Workholder and Magazine Handler Cycling Menus - - - - - - - - - - - - - - - - - - - 5-5
Figure 5-2 Indexer Motor Diagnostics Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
Figure 5-3 Puller Diagnostics Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
Figure 5-4 Heat Block Diagnostics Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
Figure 5-5 Magazine Handler Motor Diagnostics Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
Figure 5-6 Temperature Controller Diagnostics Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Figure 5-7 Maintenance Diagnostics Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-10
Figure 5-8 Sensor Diagnostics Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-11
Figure 5-9 Access to Workholder and Mag Handler Utilities (without safety cover) - - - - - - - - - - - -5-14
Figure 5-10 Boat Inject Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-15
Figure 5-11 Heat Block Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-15
Figure 5-12 Heat Block Vacuum Dialog Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-15
Figure 5-13 Access to MHS Utilities (Manual Mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-16
Figure 5-14 Index Utilities Dialog Box (Manual Mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-17
Figure 5-15 Heat Block Utilities Dialog Box (Manual Mode) - - - - - - - - - - - - - - - - - - - - - - - - - - -5-18
Figure 5-16 Preheat Block Utilities Dialog Box (Manual Mode) - - - - - - - - - - - - - - - - - - - - - - - - -5-19
Figure 5-17 Pin Utilities Dialog Box (Manual Mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-20
Figure 5-18 Error Recovery Options Dialog Boxes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-22
LOF-4 List of Figures 98888-0000-JB3-01

List Of Tables
Table 2-1 Boat Injection - Puller Pin and Boat Present Sensor Conditions - - - - - - - - - - - - - - - - - - - 2-9
Table 2-2 Workholder Preventive Maintenance Schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-69
Table 3-1 Magazine Handler Preventive Maintenance Schedule - - - - - - - - - - - - - - - - - - - - - - - - - 3-24
Table 4-1 DMHS Circuit Boards, 3U Circuit Board (Top Level) - - - - - - - - - - - - - - - - - - - - - - - - - 4-10
Table 4-2 DMHS Indexer/Solenoid Driver Board, P/N 08888-4032-000-xx - - - - - - - - - - - - - - - - - 4-14
Table 4-3 DMHS Hex Half-Stepper Drivers, P/N 08888-4166-000-xx - - - - - - - - - - - - - - - - - - - - - 4-15
Table 4-4 DMHS Stepper Controller Board, P/N 08888-4300-000-xx - - - - - - - - - - - - - - - - - - - - - 4-17
Table 4-5 DMHS Micro/Tri Half Stepper Board, P/N 08888-4214-000-xx - - - - - - - - - - - - - - - - - - 4-18
Table 4-6 Magazine Handler Intermediate Board, P/N 08888-4116-000-xx - - - - - - - - - - - - - - - - - 4-20
Table 4-7 Indexer Intermediate Board, P/N 08888-4226-000-xx - - - - - - - - - - - - - - - - - - - - - - - - - 4-21
Table 4-8 Recommended Signal values for output signal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-34
Table 4-9 MHS Cable Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35
Table 5-1 MHS Preventive Maintenance Schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
Table 5-2 Special Tools and Gauges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-5
98888-0000-JB3-01 List Of Tables LOT-1

LOT-2 List Of Tables 98888-0000-JB3-01

1 Introduction
1.1 General Information
1.1.1 Scope
This manual contains information for operation, maintenance, setup, and trouble-
shooting of the J Boat Material Handling System (MHS) used on the IConn High
Performance Wire Bonder. It is the Material Handling System Manual of the IConn
Manual Set.
1.1.2 MHS Manual Contents

The J Boat MHS manual is divided into five (5) sections:
• Section 1: Introduction
Contains descriptions of the J-Boat MHS equipment, controls/indicators used
in MHS operations, and machine software functions involved in MHS setup
and use. It also includes simple daily MHS operating procedures, and product
conversion procedures.
• Section 2: Workholder
Covers the workholder subsystem of the J-Boat MHS, which transports, heats,
and clamps leadframe or other device carriers for bonding. Contains detailed
descriptions of the workholder and provides procedures for setup, calibration,
workholder removal/installation, and parts replacement.
• Section 3: Magazine Handlers
Covers the two MHS subsystems that handle carrier storage magazines: the
input magazine handler (at workholder input end) and output magazine han-
dler (at workholder output end). Although there are some physical difference
between the subsystems, they are functionally identical. This section contains
descriptions of the magazine handlers and provides procedures for setup, cal-
ibration, magazine handler removal/installation, and parts replacement.
• Section 4: Electronics
Contains a general description of the J Boat MHS electronic control system
and more specific information concerning circuit board locations within the
machine, functions of individual circuit boards in the system, and location/iden-
tification of cables, motors, and sensors. Also includes procedures for circuit
board replacement, sensor replacement, and sensor setup.
• Section 5: Maintenance
Specifies preventive maintenance requirements for the J Boat MHS and pro-
vides error recovery/troubleshooting information. This includes coverage of
IConn software functions that may be helpful when determining the cause of
machine errors.
98888-0000-JB3-01 Introduction 1-1

1.1.3 MHS Information in Other Manuals

The IConn manual set consists of six volumes. In addition to this volume
(described in the previous paragraph), five other publications are shipped with the
machine.
• IConn Operation Manual
This volume covers machine operation, programming, and use of the many
machine software functions, including calibrations, control parameter definitions,
and programming procedures for the MHS.
• IConn Maintenance Manual
Provides maintenance information for the machine as a system and for all major
components individually with the exception of the MHS, which is covered in this
volume.
• IConn Operator’s Handbook
Provides operating, maintenance, and troubleshooting information useful to
machine operators. Printed in a smaller format than the other manuals and on
clean-room paper for use at a machine in the production area.
• IConn Installation Guide
Identifies machine operating site requirements and provides procedures for
unpacking, machine installation, and power-up tests. Also includes instructions for
repacking a IConn machine for return shipment.
1.1.4 Safety
The IConn High Performance Wire Bonder with Model 3035 J Boat MHS has
been designed and manufactured to operate safely. However, as with any produc-
tion machine, certain specific and general safety precautions should always be
observed. These are listed in the “Safety Information” section, which immediately
follows the title page of this manual. Other WARNINGS and CAUTIONS have
also been added where appropriate throughout the text of this manual and in the
other volumes of the IConn manual set.
1-2 Introduction 98888-0000-JB3-01

1.2 Descriptions
1.2.1 General
The J Boat Material Handling System (MHS) (Figure 1-1) is designed for use on
the IConn High Performance Wire Bonder. The MHS performs all functions nec-
essary to move and position carriers and their magazines (automatically or under
user control) during the wire bonding process. The MHS consists of three major
subsystems:
• Input Magazine Handler (handles input magazines)
• Workholder
• Output Magazine Handler (handles output magazines)
Input Magazine Handler Output Magazine Handler
Z Tower Assembly
Z Tower
Assembly
Input Tray
Assembly Output Tray
Assembly
MHS Electronic J Boat Workholder

Control System (behind cover)
(DMHS Backplane
Board and other
control system located
in card rack, behind door
Figure 1-1 The IConn J Boat Material Handling System

The input magazine handler stages several multi–slot magazines that contain car-
riers holding die–bonded devices. Multiple magazines are used to provide suffi-
cient storage capacity of these devices to minimize material replacement time.
Each magazine has a fixed pitch (distance) between carrier slots, but the number
of magazine pitches between adjacent carriers stored in the magazine may vary.
Magazine dimensions and slot pitches must be constant within the same process
batch or lot.
The workholder extracts a carrier from the input magazine and provides the nec-
essary incremental movement and registration into and out of the location where
wires are bonded to devices (bond site). The workholder is capable of locating
each device of the carrier at the bond site with a high degree of repeatability while
providing a high transfer rate to maintain high throughputs.
The center section of the workholder has two heated blocks capable of indepen-
dent vertical motion: one preheats the device to the temperature required for wire
bond formation; the other maintains device temperature during bonding. The heat
block lifts devices upwards away from the boat after each index operation. The
bond site heat block holds the device with vacuum during bonding. After the
device at the bond site has been bonded, the heat blocks moves downward to
return the devices to the boat, the bond site vacuum is switched off, then the heat
blocks continue to move downward to a position where they will not interfere with
the boat or its devices during the carrier index.
Independently programmable heaters are located:

• Prior to the bond site (Preheat)
• At the bond site (Bond site)
Each heater location has an independent thermocouple and temperature control-
ler circuit to program, measure, and control heater performance. The temperature
controller circuits are all part of a circuit board assembly housed in the lower con-
sole card rack.
The output magazine handler stages multiple–slot magazines for ejection of pro-
cessed carriers. Output magazines are initially empty and accept carriers into the
magazine slots as they are removed from the workholder. Multiple magazines are
used to provide sufficient storage capacity.
1.2.2 Workholder
The workholder consist of the indexer and slider assemblies that provides carrier
handling capabilities for the purpose of wire bonding. The following functions are
available for carrier handling:
• Carrier extraction from an input magazine
• Device indexing
• Device vacuum clamping and positioning functions
• Independent heat block functionality (raises and lowers the preheat or bond
site heat block without affecting the rest of the workholder)
• Multiple programmable bond plane levels
• Carrier ejection into an output magazine
• Carrier jam detection during ejection.

1.2.3 Device Indexing
Indexing operations take place whether the bonder is configured to run in an Auto
Run operation (normal operating mode where wires are bonded) or a Dry Cycle
operation (wires are not bonded). Both operations include a Normal Index (auto-
matic) mode and a Manual Index mode. Normal indexing automatically moves a
device via the boat to and from the bond site. Manual indexing requires the user
to select “Index” from the function bar or the MMI to move a device to and from
the bond site.
A Dry Cycle operation also includes a Dry Index Mode that allows the bonder
exercises all parts of the MHS without using magazines and boats.
1.2.4 Magazine Handlers

The magazine handlers provide the MHS workholder with input (raw material sup-
ply) and output (finished material storage) functions. They stage magazines of
unbonded material for carrier extraction, and magazines with empty slots for
insertion of carriers after bonding. The magazine handlers operate under machine
control with no attention required from the user other than to load unprocessed
magazines and unload processed magazines. The user can, however, initiate the
following magazine handling functions:
• Jog magazine up one slot
• Jog magazine down one slot
• Pick up magazine from load tray
• Place magazine on unload tray
• Move magazine to first slot position
• Entry of magazine handling parameters
• Magazine handler calibration
Magazines are manipulated within the magazine handlers by a method referred to

as the "C" style, which reflects the path that the magazine takes from the load tray
to the unload tray (see Figure 1-2). Note that the direction in which the magazines
travel is reversed for the output magazine handler versus the direction they travel
on the input magazine handler. At the input side, full magazines are placed on
the lower tray (load tray), and when emptied are placed on the upper tray (unload
tray). At the output side, empty magazines are placed on the upper tray (load
tray) and, when filled, are placed on the lower tray (unload tray).
Gripper Gripper
Magazine Magazine
(empty) (empty)
Unload Tray Load Tray

Process
Process
Gripper Gripper
Magazine Magazine
(contains boats with (contains boats with
unbonded devices) bonded devices)
Load Tray Unload Tray
Side View Side View

Input Mag Handler Output Mag Handler
Figure 1-2 “C” Style Magazine Handling

1.3 Specifications
1.3.1 Carrier Dimensions
1.3.1.1 J Boat Carrier Dimensions
Package J Boat
Length 215.9 to 304.8 mm (8.5 to 12 in.)
Width 78.74 to 109.22 mm (3.1 to 4.3 in.)
Thickness 9.62 mm (0.38 in.)
Device Pitch 6.4 to 152 mm ( 0.25 to 6.0 in.)
Boat Index Hole Pitch 12.7 mm to 38.1 mm (0.5 to 1.5 in)
First Hole to End Minimum: none; Maximum: 1.6 in.
1.3.2 Magazine Dimensions
Magazine Dimension
Width 83.82 mm to 119.38 mm (3.3 in to 4.7 in)
Length 215.9 mm to 305 mm (8.5 in to 12.0 in)
Height 50 mm to 178mm (2.00 in to 7.00 in)
Slot Pitch5 Minimum 10.16 mm (0.4 in)

Maximum Magazine Maximum 5.5 kg (12.1254 Ibs) loaded
1.3.3 Other Specifications

For other machine/MHS specifications, refer to IConn Operation Manual and
IConn Maintenance Manual.
1.4 Operator Controls

1.4.1 EMERGENCY OFF Switch
Emergency OFF switch (Figure 1-3) is located on the front face of the upper con-
sole assembly (red mushroom switch). The switch removes all power from the
bonder and MHS when pressed (electrically identical to the Main Power switch on
the front of the computer console). However, if latched down it will prevent opera-
tion of the main power switch.
1.4.2 Operator Control Panel

NOTE: The operator control panel is sometimes referred to as the ’Man–
Machine Interface’ or ’MMI’ in IConn manuals.
The Operator Control Panel (Figure 1-4) is the primary operator interface for both
teaching and operating the machine. The three-button mouse and various key
switches have multiple functions depending on mode, current procedure, machine
status, etc.

Signal Light Tower

(Hidden)
Main Power Switch

Video Monitor
EMERGENCY OFF
(EOFF) Switch
Control Panel
Mouse
Figure 1-3 Operator Controls

• Three–Button Mouse
Moves table in the X and Y axes. Also moves screen cursor to select items on the
graphics display. Three push button switches (part of the mouse) have functions
defined in the graphics display (identified as B1, B2, and B3 in display).
• [MOTOR STOP]
Disables all servo motors and stepper motors when activated by simultaneously
pressing both of the two (2) switch actuators. Stops machine and workholder
operation. The bonder will drop out of the current mode and enter Standby Mode
when this control is latched. The [MOTOR STOP] button does not remove power
from the PC boards or power supply.
• [SHIFT]
Used in conjunction with other keys to provide additional functions.
• [INDEX]
This momentary button commands the MHS to perform one index cycle. The
function is valid under conditions determined by the bonder status.

Wire Feed Mouse Buttons

Air Guide Control/
Indicator Control/Indicator B1, B2, B3
Function Keys
Motor Stop
Run/Stop
Index Mouse
Auto Index
Alpha Keypad
Numeric Keypad (with Shift Tensioner Control/Indicator

Enter, Escape, and Arrow keys)
Figure 1-4 Operator Control Panel (MMI)

• [AUTO INDEX]
When pressed, commands the MHS to index after bonding of every device. Key
lamp lights when auto index has been selected. Active in Auto mode only.
• [ENTER]
A momentary push button pressed to enter reference points, bond positions, and
other program information into memory.
• [ESCAPE]
A momentary button pressed to exit the menu displayed on screen and return to
the previous menu.
• [RUN/STOP]
Pressed to start bonding in auto mode. Key lamp is ON while the machine is
bonding. When key lamp is lit, pressing key stops Auto mode operation and
enables Sequence Stop mode. Sequence Stop mode provides many of the same
operator options as Manual mode. Active in Auto mode only.
• [ARROW KEYS]
Press to move an axis of motion or screen feature (cursor, PRS box sides, etc.)
Active only during some calibrations or teaching procedures, as defined on the
graphics display.
• Function Keys ([F1] - [F10])
The function keys are referenced to the virtual buttons displayed at the bottom of
the monitor display. Functions change with machine status. Pressing [SHIFT] while
pressing a function key selects the tool bar function immediately above the virtual
button that defines that function key.
• Alpha Keys (A through Z)
Used to enter alpha characters (for program file name entry, etc.)
• Air Guide Control/ Indicator
Pressing button turns air pressure to air guide ON and OFF. LED lights when air
guide is ON.
• Wire Feed Control
Wire spool rotates to feed wire when button is pressed.
• Tensioner Control/ Indicator
Pressing button turns vacuum to wire tensioner ON and OFF. LED lights when
vacuum to wire tensioner is ON.

1.4.3 Video Monitor
The video monitor provides a magnified view of various areas of the device in the
display video window and displays messages, option menus and other program
information. A second window shows a graphical representation of the taught
device, that indicates the locations of reference points, bond pads, leads, wires,
and other device characteristics. Device images are acquired by a solid–state
camera head mounted on the optics housing. Lenses and a system of mirrors
complete the optical system (standard configuration).
Electronic crosshairs in the video window and graphics window on the monitor
screen are used to teach or target reference points and bond positions.
1.4.4 Signal Light and Audible Alarm

This unit can be programmed to indicate various operating conditions. Two–,
three–, or four–light units may be fitted depending on machine specification.
Green, red, and yellow lights (standard implementation) will light under the follow-
ing conditions if signal light programming has not been performed:
• GREEN:
Normal operation in Auto mode.
• RED:
• [MOTOR STOP] active
• Critical system error (logic–activated emergency off)
• YELLOW:
• PRS eye point or VLL lead non–recognition
• Missing ball detected
• BITS error
• No magazine in elevator
• MHS or elevator jam
• Machine motion error
• RAM parity error
• Logic–activated emergency off condition
• Heat block temperature alarm
An audible alarm is part of the signal light assembly. The alarm can be pro-
grammed to sound and alert the operator under some or all of the conditions
listed above. Several sounds are available to indicate different events. Refer to
IConn Operation Manual for information concerning signal light and alarm pro-
gramming.

1.5 Video and Graphics Displays

The monitor display (Figure 1-5) is the primary source of machine and program
information. Display content varies depending on mode, current operation and
machine status.
Figure 1-5 Video Monitor Screen

Unless specific operating routines have been initiated, the information on the
screen will be organized as follows:
• MODE
Current mode is highlighted on the bar at the top of the screen. Modes are Auto,
Manual, Program, Configure, Calibration, Utilities, Diagnostic, and Sys(tem)
Admin(istration).
• LIVE VIDEO AND DEVICE GRAPHIC WINDOWS
Two views of the device are present on the monitor screen. One shows video
from the bond site, either live or digitized by the PRS. The other is a graphic rep-
resentation of the taught device which shows the lead and die reference systems,
wires, operator points, and eyepoints. The views may be exchanged between the
larger and smaller windows in the display by pressing the [F1] key.
• MENUS AND DIALOG BOXES
Provide most optional operations when teaching and operating the bonder. Click
on desired functions within menu to begin them. Dialog boxes appear during
operations to allow the user to set parameters, select operating conditions, and
perform specific actions.

• CROSSHAIR
The crosshair is an electronic image in both the live video window and device
graphics window that has two purposes. It is used to target reference points to
positively locate reference systems and, secondly, it is used to target bond loca-
tions. In the second function the crosshair represents the position of the bond tool
over the device. Since the objective lens and the capillary are not in line above
the device, the distance between them (Crosshair Offset) must be taught to
achieve this alignment.
• AXIS POSITION INDICATORS
At the top–right of the screen, X, Y and Z indicators give the position of the X-Y
table (X and Y axes) and bond head capillary (Z axis) from their ‘zero’ points
(established during machine initialization). The distances are expressed in mils or
millimeters, depending upon the unit of measure selected by the user during
machine configuration.
• PRS BOX
Active in the live video window when eye points are being taught and during PRS
calibration, the PRS box is a green, outline box centered on the crosshair. The
area enclosed by the box is the scene which the PRS learns so that it can locate
the eye point during operation. The eye point itself is at the geometrical center of
the eye point scene. The size of the box can be changed to suit the scene.
• OPERATING INFORMATION
Several types of operating information are present in the display. The name of the
current process program is above the larger device image window. Operator
prompts and instructions appear below the process program name. Temperatures
of the three workholder heat zones are below the window.
• TOOL BAR AND FUNCTION KEYS
The tool bar is the upper of two rows of virtual buttons in the lower part of the dis-
play. Function keys ([F1] - [F10]) are defined in the lower of the two rows of virtual
buttons. These keys will have different functions depending upon the machine
operating mode.
Selecting a tool bar button will display a menu, enable a function, or start a proce-
dure. The purpose of the tool bar is to provide easy access to functions that are
performed often during machine operation (bond–site illumination adjustment,
MHS operations, relearn bond height, etc.) The tool bar buttons are active during
most machine functions. Tool bar functions can also be selected by holding down
the [SHIFT] key on the control panel and pressing the function key designated by
the virtual button directly below the tool bar button.
To initiate function key options, the user can either press the indicated control
panel function key or select the appropriate virtual button in the display to activate
the desired function.
• ERROR MESSAGES
When operating, error detection will generate an appropriate message on the
monitor that describes the nature of the problem, and may provide access to soft-
ware options that will help when correcting the error. Error messages may
describe an MHS malfunction, a defect in the program or device (such as PRS/
VLL teach or find failure), the entry of unacceptable information, a missing wire,
missing ball, or other machine malfunction.

1.6 MHS Software Functions

The following MHS functions are programmed or can be accessed through
machine software, using the control panel and graphics displays presented on the
monitor.
1.6.1 MHS Configuration

Dimensions and settings related to the carriers, devices, and magazines used
during the bonding operation are entered through the MHS configuration menus.
Workholder configuration can be accessed by making the following selections:
CONFIGURE and [6] WORKHOLDER (See Figure 1-6.) Magazine handler configura-
tion can be accessed by selecting CONFIGURE and [7] MAG HANDLER.
Refer to IConn Operation Manual, Section 5, for descriptions of workholder and
magazine handler configuration menus, dialog boxes, and parameters.
Select #7 Select #6
Press
ESCAPE
(or click on
menu title)
Figure 1-6 MHS Configuration (Workholder and Magazine Handler)

1.6.2 MHS Calibration
The MHS Workholder Calibration functions can be found in the CALIBRATION
mode > [4] WORKHOLDER (See Figure 1-7.) The following is a brief description of
each function.
• WORKHOLDER: This function contains several workholder calibrations: pedes-
tal insert focus height calibration, bond height calibration, location of the diago-
nal center of the bonding area, rail calibration, preheat block height calibration.
• HEAT BLOCK: Teaches the pedestal bond height position. This calibration is
also part of the Workholder Calibration function. It has been made available as
a separate function so that the user can avoid running the entire workholder
calibration after replacing the pedestal insert.
• TUCKER EJECT: Determines the distance from the index gripper home position
to the index gripper position where the working end of the tucker is aligned
with the outer surface of the output magazine handler side wall.

Select #5 Select #4
Press [DONE]
Figure 1-7 MHS Calibration Menus

• WORKHOLDER CALIBRATION: Displays a dialog box containing the results of all
the workholder calibrations. All of the items in the dialog box are for viewing
purposes only and cannot be changed by the user.
The MHS Magazine Handler Calibration functions can be found in the CALIBRA-
TION mode > (5) MAG HANDLER (See Figure 1-7.) These functions are:
• INPUT TRAYS: Establishes locations of the input side magazine trays.
• OUTPUT TRAYS: Establishes locations of the output side magazine trays.
• INPUT SLOT: Establishes location of the workholder rails in the Y and Z axes
with regard to the input magazine handler gripper.
• OUTPUT SLOT: Establishes location of the workholder rails in the Y and Z axes
with regard to the output magazine handler gripper.
• CALIBRATION RESULTS: Displays a dialog box containing the results of all the
magazine handler calibrations. All of the items in the dialog box are for viewing
purposes only and cannot be changed by the user.
See Section 2: Workholder, for more information concerning workholder calibra-
tions. See Section 3: Magazine Handlers, for information concerning magazine
handler calibrations.
1.6.3 MHS Utilities

The MHS Utilities are accessed by selecting MANUAL and then [3] MHS UTILITIES.
(See Figure 1-8.) These utilities allow manual control of MHS subsystems. Refer
to Section 5 for more information. Utilities available are:
• INDEX UTILITIES
Allow the operator to adjust the number of index cycles, reset the index count,
verify correction, inhibit strip injection, select or stop an indexing mode, park the
index gripper at a safe location, and home the index gripper.
• HEAT BLOCK UTILITIES
Allow the operator to position the bond site heat block at an entered offset value
from its raised position and to raise the heat block to bond plane height, lower the
heat block to carrier clearance height, or home the heat block.
• PREHEAT BLOCK UTILITIES
Allow the operator to move the preheat block at its raised position, carrier clear-
nace position, or home position

• PIN UTILITIES
Allow the operator to raise /lower/home the puller pin, raise or lower the indexer
pin, and raise or lower the tucker.
Select #3
Press [DONE]
Figure 1-8 Access to MHS Utilities (Manual Mode)

1.6.4 MHS Magazine Utilities (Without Safety Covers)
The standard Mag Handler Utilities dialog box appears when MAG OPER is
selected from the upper function bar (see Figure 1-9). The functions listed in this
dialog box allow the user to send a command to either magazine handler to per-
form a single action.
Select #8
Figure 1-9 Standard Mag Handler Utilities Dialog Box

NOTE: If the magazine handlers are enclosed within safety covers, the Mag
Handler Utilities dialog box contains ‘Latch’ and ‘Unlatch’ commands in
addition to those shown in Figure 1-9. These commands are used to
manipulate the locks on the input and output magazine handler access
doors. Safety covers are optional equipment and will not be present on
all IConn machines.
The Mag Handler Utilities dialog box selections and their function are defined as
follows:
• [1] JOG INPUT/ OUTPUT MAG Causes the supply magazine to step to the next
slot.
• [2] REVERSE JOG INPUT/ OUTPUT MAG Causes the supply magazine to step
backward to the previous slot.
• [3] EJECT INPUT/ OUTPUT MAG Causes the supply magazine currently in use
to be placed on the Unload tray.
• [8] MAG SELECTION Toggles INPUT mode or OUTPUT mode.

1.6.5 MHS Workholder Utilities
The Workholder Utilities menu appears when W/H OPER is selected from the tool
bar. (See Figure 1-10) The functions listed in this menu allow the operator to send
a command to the workholder to perform a single action or call up a dialog box
listing additional commands.
Select DONE to exit dialog
Figure 1-10 Workholder Utilities Dialog Box

The workholder utilities are defined as follows:
• [1] STOP INDEXING: Halts the indexing of carriers through the workholder.
• [2] PULL BOAT IN: Causes the workholder to pull a carrier from the input (left–
side) magazine.
• [3] EJECT BOAT: Causes the workholder to push a carrier into the output
(right–side) magazine.
• [4] CLEAR WORKHOLDER: Causes the workholder to remove all carriers.
• [5] BOAT INJECT: Opens another dialog box. That dialog box, shown in Fig-
ure 1-11, allows the operator to set the ON or OFF status of the puller for pull-
ing carriers from the input (supply) magazine into the workholder. Once the
desired setting is made, the user selects DONE which causes the Workholder
Utilities dialog box to appear.
• [1] BOAT INJECT OFF: Halts carrier injection. No additional carriers are
pulled into the workholder. Those carriers already in the workholder are
processed normally (unless Stop Indexing is activated) and then ejected
into the output magazine.
• [2] BOAT INJECT ON: Restores normal operation.
Figure 1-11 Boat Inject Dialog Box

• [6] HEAT BLOCK: Allows the user to perform heat block related functions.
Pressing [6] causes the Heat Block dialog box to appear as shown in Figure 1-
12 . Once the desired setting is made, the user selects DONE which causes the
Workholder Utilities dialog box to appear.
• [1] LOWER HEAT BLOCK: Causes the heat block to be lowered to the index-
ing height (i.e., the position below the boat, so as to clear the boat during
the indexing of a device).
• [2] RAISE HEAT BLOCK: Causes the heat block to be raised to the bonding
height.

• [3] HOME HEAT BLOCK: Causes the heat block to be lowered to the home
position.
Figure 1-12 Clamp Dialog Box

• [7] HEAT BLOCK VACUUM: Opens the dialog box shown in Figure 1-13. The
user may then set the vacuum to On or Off. Once the desired setting is made,
the user selects DONE which causes the Workholder Utilities dialog box to
appear.
• [1] HEAT BLOCK VACUUM ON: Applies heat block vacuum.
• [2] HEAT BLOCK VACUUM OFF: Removes heat block vacuum.
Figure 1-13 Heat Block Vacuum Dialog Box

1.6.6 MHS Auto Run Configuration (Indexing Type)
The type of MHS indexing to be used while the bonder is operating in Auto mode
is selected in the AUTO RUN CONFIGURATION dialog box. This dialog box is
accessed by selecting the AUTO mode key, (6) CONFIGURE AUTO, and (2) AUTO
RUN. (See Figure 1-14) The (6) INDEXING option is selected to change indexing
type. NORMAL Indexing should be selected for normal production operations.
Refer to IConn Operation Manual for more information concerning Auto Run con-
figuration.

Select #6 Select #2
Select Done Select Done
Figure 1-14 Access to Auto Run Configuration Dialog Box

1.6.7 MHS Diagnostics
Diagnostic routines related to the material handling system may be accessed in
Diagnostic mode. (See Figure 1-15) Refer to Section 5 for more information con-
cerning diagnostic routines.
• WORKHOLDER CYCLING: Allows the operator to verify workholder motor opera-
tions.
• MAG HANDLER CYCLING: Allows the operator to verify magazine handler motor
operations.
• TEMPERATURE CONTROLLER: Diagnostic display for workholder temperature
control system. Useful when diagnosing problems with preheat, bond site, and
post–heat heaters.
• RE-INITIALIZE MHS: Starts an MHS initialization sequence in which all axes of
motion of the workholder and magazine handlers are moved to home posi-
tions.
• MAINTENANCE DIAGNOSTICS: Diagnostic display that shows status of sensors.
Useful when diagnosing problems with workholder or magazine
handler sensors.
• BAR CODE DIAGNOSTICS: Diagnostic display that allows the user to test opera-
tion of bar code reader (optional) that may be mounted on the input and output
magazine handlers. This option is active only if bar code reader are present on
the machine.

SelectSelect
#1 #1
Select
Select #2#2
Select#3
Select #3
Select #5
Select #5
Select #1
Select #1
Sensor Diagnostics
(See Section 5)
Sensor Diagnostics
(See Section 5)
Figure 1-15 Access to MHS Diagnostics Menus

1.7 Operating Procedures
The following procedures are those commonly performed when bonding with the
J Boat MHS Model 3035 MHS and IConn Bonder.
1.7.1 Initial Start–up

NOTE: This procedure assumes that the machine has been previously set up
and calibrated, and that a process program is avaliable on the hard disk
drive or on a floppy disk for the device and carrier that will be processed.
It is also assumed that the correct P–parts (bond site heat block insert
and preheat heat block insert) for the carrier and device being pro-
cessed have been installed. If necessary, install the heat blocks follow-
ing instructions in paragraph 1.8.4. Refer to the appropriate kit
installation instruction if it is necessary to install equipment for a different
type of carrier.
CAUTION: Remove all P-parts when prompt to avoid damaging the rails.
A. Perform bonder power–up sequence (refer to IConn Operation Manual).

B. Make sure all system pneumatic gauges indicate adequate pressure. (Refer to
IConn Maintenance Manual for pneumatic settings.)
C. Make sure wire feed system is correctly configured.

D. Load desired process program. The input magazine handler,
workholder, and output magazine handler are automatically converted to cor-
rect positions for selected carrier, device, and magazine. Temperature control-
ler states (on or off) and set points will be loaded as part of the program. Allow
at least 30 minutes for the workholder heaters to stabilize at set–point tem-
peratures.
E. Enter “H.B. (heat block) Operator Point”. Follow instructions in the display.
F. Select AUTO at top of graphics display.
G. Place magazines containing carriers with unbonded devices onto the load tray
of the input magazine handler. Place empty magazines onto the load tray of
the output magazine handler. Make sure that the magazines are correctly ori-
ented to feed carriers into or receive carriers from the workholder and that they
are benched against the magazine handler side plate. (See Figure 1-16).
H. Make sure correct process program name is displayed. (See Figure 1-5 for
location.)
I. Verify master bond parameters.
Z Tower Assembly Note:

Input Tray When placing magazine on load tray,
make sure magazine is parallel to
front edge of motorised tray and
Unload Tray benched against input side plate
Input Magazines Wall
Magazines
Magazine guide should be set Place magazine on load tray

approximately 1/1 in. (1.5mm) belts. Belts move magazine to
from end of magazine Load Tray pickup position.
Figure 1-16 Load Magazines on Magazine Handler (Input Magazine Handler Shown)
NOTE: If Bond Position was not previously taught, the machine will require that
the user teach the position before it will perform an index. Refer to Sec-
tion 2 for information concerning MHS Teach.
J. Press [INDEX] to initiate carrier indexing. The input magazine handler picks up
a magazine from the load tray and align the first boat in that magazine with the
workholder. The boat is then pulled from the magazine onto the workholder
rails and indexed to where the bond site heat block raises the first device to
bond height.

K. Press [RUN/STOP] key on control panel to start automatic bonding. Press
[AUTO INDEX] for automatic indexing (if desired).
1.7.2 Load/Unload Magazines During Bonding

NOTE: If Safety Covers are installed on the magazine handlers, the magazine
handler access doors must be unlatched and opened in order to load/
unload magazines. The door latches are controlled through options on
the Mag Handler Operations menu that can be called up by a tool bar
button.
A. Select MAG OPER.

B. Load additional magazines of carriers onto the load tray of the input magazine
handler and empty magazines onto the load tray of the output magazine han-
dler, as finished magazines are placed on the unload trays (See Figure 1-16).
C. Do not allow the magazine handler load trays to become empty or operation
will be halted.
D. Remove magazines from unload trays. Do not allow the unload trays to remain
full or operation will be halted.
1.7.3 Stop Auto Bonding

NOTE: This procedure assumes that the operator wishes to halt the auto bond-
ing operation before all carriers in the input magazines are bonded.
A. Select W/H OPER button on tool bar (see Figure 1-10).

B. Set [5] BOAT INJECT. The Boat Inject dialog box appears (see Figure 1-11).
C. Select [1] BOAT INJECT OFF . Select DONE to exit the Boat Inject dialog box.
Select DONE to exit the Workholder Utilities dialog box.
D. Bonding will continue until all remaining carriers in the workholder are bonded
and ejected into an output magazine. No new carrier will be pulled into the
workholder from the input magazine.
1.7.4 Clear Leadframes from Indexer

NOTE: Use the procedure that follows if bonding has been halted with carriers
in the workholder, and bonding will not be continued.
A. Select W/H OPER button on the tool bar (see Figure 1-10).
B. Select [3] EJECT BOAT from Workholder Utilities dialog box. Carriers in work-
holder are moved into the output magazine.
C. Select DONE to exit the Workholder Utilities dialog box.
1.7.5 Remove Magazines From Magazine Handlers

NOTE: This procedure assumes that bonding is halted and that there are maga-
zines in the magazine handler grippers.
A. Select MAG OPER button on the tool bar (see Figure 1-9).
B. Select [3] EJECT INPUT MAG. and [7] EJECT OUTPUT MAG. from the Mag Handler
Utilities dialog box.

NOTE: If Safety Covers are installed on the magazine handlers, the magazine
handler access doors must be unlatched and opened in order to load/
unload magazines. The door latches are controlled through options on
the Mag Handler Operations menu that can be called up by a tool bar
button.
C. Remove magazines from the load tray and unload tray of the input magazine
handler.
D. Remove magazines from the load tray and unload tray of the output magazine
handler.
E. Select DONE to exit the Mag Handler Utilities dialog box.
1.7.6 Bonder/Workholder System Shutdown

NOTE: This procedure secures the bonder/workholder at the end of a shift/day.
A. On wire feed system, press the [AIR GUIDE] and [TENSIONER] buttons on the
MMI to turn off air pressure. (AIR GUIDE and TENSIONER LED indicators OFF.)
B. Make sure carriers are removed from workholder.
C. Make sure magazines are removed from magazine handlers.
NOTE: The [MOTOR STOP] key has two (2) actuators, and is comprised of two (2)
key switches. Both actuators must be pressed at the same time to acti-
vate the Motor Stop function. This arrangement prevents accidental acti-
vation of Motor Stop.
D. Press [MOTOR STOP] (key lamp in [MOTOR STOP] key goes ON.) The bonder
enters Standby Mode.
E. Machine power may be turned off at the Main Power circuit breaker if desired.

1.8 Product Conversion (Figure 1-17)
START
Heat block inserts NO Install new heat block inserts.

right type for
boat?*
Perform heat block calibration.

YES
Load process program from disk.
NOTE: If process program has

not been taught, refer to IConn
Operation Manual.
Enter boat/device/magazine
MHS Configuration NO dimensions and parameters as
file for boat on disk? needed.
YES
Check MHS operation.
Check/edit MHS parame- NO

ters and dimensions. MHS operation OK?
YES
DONE
Figure 1-17 Product Conversion Sequence

1.8.1 Tools/Parts
• Preheat Block Insert
• Bond Site Heat Block Insert
• M4 x 1 1/2” Socket Head Cap Screw (SHCS)
1.8.2 Replace Heat Block Inserts

The following steps show the replacement of the preheat block insert and bond
site heat block insert. This procedure assumes that the workholder has been
cleared of all material, the temperature controllers are on, and the workholder
heating zones are at their operating temperature
WARNING: DO NOT TOUCH THE HEAT BLOCK, THE INSERT OR OTHER PARTS
WITHIN THE WORKHOLDER RAILS IF THE TEMPERATURE CON-
TROLLERS ARE ON. THESE ITEMS ARE EXTREMELY HOT AND WILL
INSTANTLY BURN UNPROTECTED SKIN.
NOTE: In the following procedure, it is assumed that the temperature controllers

are on and the workholder heating zones are at operating temperatures.
A. Turn the temperature controllers off:

1. Select [4] CONFIGURE from the mode bar.
2. Select [4] TEMPERATURE from the Configure mode menu.
3. Select the TURN ALL ZONES OFF button in the Temperature Set Points dia-
log box. While the heat block cools, observe its temperature reported in the
temperature status display on the monitor (see IConn Operation Manual for
location).
WARNING: DO NOT CONTINUE WITH THIS PROCEDURE OR ATTEMPT TO

TOUCH EITHER HEAT BLOCK OR ITS INSERT UNTIL THEY HAVE
COOLED.
B. Remove the heat block inserts on the preheat and/or bond site.
1. Install a M4 x 38 mm screw into the tapped hole at the rear edge of the
insert.
2. Use a small amount of pressure to pull the insert to the front rail. This
action lift up the rear edge of the insert out of the heat block.
3. Remove the insert from the heat block.
C. Install the heat block insert on the preheat and/or bond site.
1. Hold the insert at 45 degrees angle, with the front side points down.
2. Install the insert to the heat block until the notch at its front-bottom edge
engage to the pin on the heat block.
3. Use a small amount of pressure to push the insert down until it moves
quickly into the heat block.
D. Remove the screw from the insert.
E. Refer to section 2 to calibrate the workholder.

1.8.3 Load Existing Process Program

A. Click on PROGRAM at the mode bar. Select [1] LOAD/SAVE/CLEAR from the Pro-
gram Mode menu to clear the current process program.
B. Click on [3] LOAD PROCESS PROGRAM. A dialog box appears listing the avail-
able process programs.
C. Scroll through the list on the display to find the process program file for the
device that will be processed. Click on the process program file name. Click on
LOAD to load the program.
D. A message appears in the displaying stating that the setup procedure must be
performed. Click on OK, then perform setup. Refer to Section 2 of this manual
for Teach Bond Position procedure.
E. Press [ESCAPE] key as needed to exit Program Mode.
1.8.4 MHS Material Dimension/Parameter File Handling

When performing product conversion, the user can change MHS configuration to
fit the new product by either using the K&S prepackaged software supplied with
the machine or by editing configuration parameters in Configuration mode.
The prepackaged software eliminates the task of entering each parameter and
dimension separately via the GUI software. It can only be used when the process
program uses a 3.1 inch to 4.3 inch wide boat.
If the prepackaged MHS software does not conform with the boat that will be
used, the user must manually enter MHS dimensions and parameters through
Configure mode. The following paragraphs overview the procedures required to
do this. The dimensions and parameters that reside under the Workholder config-
uration menu are defined in Section 2 and those that reside under the Mag Han-
dler configuration menu are defined in Section 3.
1.8.4.1 Edit Workholder Configuration

To edit the configuration of the workholder (see Section 2.5, Figure 2-72):
A. Select [4] CONFIGURE from the mode bar.

B. Select [5] WORKHOLDER from the Configure mode menu .
C. Do the following from the Workholder menu:
1. Select [1] DEVICE PARAMETERS. Enter the boat/device dimensions and, as
required, set the index hole at the end of the boat to TRUE or FALSE.
Select APPLY, and then DONE after all changes have been made.
2. Select [2] INDEXING PARAMETERS. Enter the index parameter values. Select
DONE after all changes have been made.
3. Select [3] INDEXING OPTIONS. As required, set the indexing options to yes
or no. Select DONE after all changes have been made.
4. Select [4] WORKHOLDER CONFIGURATION. As required, set CHECK
DEVICE OVERHEAT and CHECK HEAT BLOCK VACUUM to ON or OFF.
Enter the workholder configuration parameters. Select APPLY, and then
DONE after all changes have been made..
NOTE: All parameters accessed through the Workholder menu selection [5]
RESERVED PARAMETERS cannot be configured by the user.
5. Press [ESCAPE] as needed to exit the Configure mode.

1.8.4.2 Edit Magazine Handler Parameters:
To edit the configuration of the magazine handler (see Figure 1-6).
2. Select [7] MAG HANDLER from the menu.
3. Select [1] MAGAZINE PARAMETERS from the Mag Handler configuration
menu. In the dialog box, select INPUT to enter dimensions for the input
magazines only, OUTPUT for output magazines only, or BOTH for both mag-
azines. Enter values for the magazine dimensions. Select DONE after all
changes have been made to the dialog box.
4. If INPUT or OUTPUT was selected in step 1, open the Magazine Dimensions
dialog box again and select the remaining magazine type (Input or Output).
Enter dimensions for that magazine, then select DONE.
5. Select [2] MAG INDEX PARAMETERS. Enter magazine index parameter val-
ues. Select DONE after all changes have been made to dialog box.
6. Select [3] MAGAZINE SLOT ORDER. Select and define a sequential slot order,
or enter a user–defined slot order, for input and/or output magazines.
7. Select [4] MAGAZINE ALIGNMENT. Enter magazine alignment parameter val-
8. Select [5] MAG CONFIGURATION. Enter magazine index parameter values.
Select DONE after all changes have been made to dialog box.
9. Select [6] MAGAZINE EJECT OPTIONS. Enter magazine index parameter val-
10.Select [7] TEACH INPUT MAG SLOT. Enter magazine index parameter values.
Select DONE after all changes have been made to dialog box.
11. Select [8] TEACH OUTPUT MAG SLOT. Enter magazine index parameter val-
12.Press [ESCAPE] as needed to dismiss all menus.
13.Select SAVE BND button from the tool bar to save the MHS information as
part of the current process program.
1.8.5 MHS Operation Check

A. Place a magazine filled with sample carriers (same type that will be used in
production) on the input magazine handler load tray.
B. Place an empty magazine on the output magazine handler load tray.
C. Make sure there is no material in the workholder. If there is, click on the W/H
OPER button on the tool bar. Select [3] EJECT LEADFRAME. The carrier will be
ejected from the workholder output. Select DONE to remove dialog box from
display.
D. Select MANUAL mode. Select [4] MHS UTILITIES from the Manual mode menu.
Select [1] INDEX UTILITIES.
E. Select NORMAL INDEX CONTINUOUSLY. Select APPLY. MHS operations begin:
1. The input magazine handler will grasp the magazine on the load platform
and position the first slot level with the workholder. The output magazine
handler grasps the empty magazine on the load platform and positions its
first slot to receive a carrier from the workholder.
2. The leadframe in the first slot is pulled by the puller into the workholder and
moved to a position where it can be picked up by the index gripper.
3. The index gripper moves the first device on the carrier to the bondsite
where it is aligned, positioned, and clamped. The device is unclamped and
the next device is moved to and clamped at the bond site. This continues
until all devices of the carrier have been clamped.

4. After the last device is unclamped the tucker on the index gripper pushes
the carrier into a slot in the magazine held by the output magazine handler
gripper.
5. The indexing cycle continues until stopped by the user or until the input
magazine runs out of carriers.
F. Observe the magazine handlers and workholder as they operate. If an error is
indicated, note the information given in the error dialog box on screen, then
click on CONTINUE. If the MHS will not continue to operate and the error dialog
box is displayed again, click on ABORT, then refer to the troubleshooting infor-
mation in Section 5 of this manual.
G. When satisfied that the MHS is operating properly or that all operational prob-
lems have been identified, select the WH OPER button on the GUI tool bar.
Select [1] STOP INDEXING from the Workholder Utilities menu. Click on CANCEL
to exit the menu. Select DONE to exit the menu.
H. Select MAG OPER from the tool bar (see Figure 1-10 ). Select [3] EJECT INPUT
MAG and [7] EJECT OUTPUT MAG to eject the input and output magazines.
Select DONE to exit the Mag Handler Utilities menu. Select W/H OPER from the
tool bar and select [4] CLEAR WORKHOLDER. Use tweezers to remove lead-
frames from the workholder. Select DONE to exit the Workholder Utilities menu.
I. Adjust magazine dimensions, leadframe dimensions, and MHS parameters as
needed to correct problems noted while the MHS was operating. Save MHS
configuration when done. Refer to Section 2 for more information.

2 Workholder
2.1 About this section
Here is what you will find in this section:
• Section 2.2, Description, gives an overview of the J boat workholder and how
it functions with the IConn High Perfromance Wire Bonder. There is also a
brief description of all the major components of the J boat workholder.
• Each section from Section 2.3 through 2.9 details the calibration, operating
instructions and maintenance procedures for the workholder:
• Section 2.3, Setups and Adjustments, details the initial hardware setup of
the workholder.
• Section 2.4, Workholder Calibration Procedures.
• Section 2.5, Workholder configuration.
• Section 2.6, Workholder Removal and Installation
• Section 2.7, J Boat Slider Assembly Removal and Installation
• Section 2.8, Preventive Maintenance.
• Section 2.9, Parts Installation Procedures.
98888-0000-JB3-01 Workholder 2-1

2.2 Description
The J boat workholder contains the mechanisms and assemblies to index boats
from the input magazine handler, to the bond site, then onto the Output Magazine
Handler. It also supplies heat to the device, lifts the device from the boat for bond-
ing, and holds the device during bonding at the bond site.
2.2.1 Major Components

The major components of the workholder are:
• Slider Assembly
This assembly contains the heat block assembly that holds and heat up each
device on the carrier during bonding operation.
• Bond Site Assembly
The bond site assembly contains heat block that heats the device to the
temperature necessary for bonding. It lifts up the device to the bond height
and hold down the device during the bonding operation.
Bond Site Heat Block Assembly

Bond Site Heat Block Motor
Bond Site Assembly
Figure 2-1 Slider Assembly: Major Components
2-2 Workholder 98888-0000-JB3-01

• Indexer Assembly
The indexer assembly contains the mechanisms to move the carrier for
extraction, indexing and ejection.
• Puller Assembly
The puller pin pulls a boat within the input magazine and pulls it into the
workholder.
• X Registration Sensor
Finds the leading edge of the boat when is injected into the workholder.
• Front and Rear Rails
Support the boat as it is indexed through the workholder in the X axis direc-
tion and in the Y axis direction to the correct boat width.
• Preheat Assembly
The preheat assembly contains heat block that increases the temperature
of the device before bonding that is necessary for bond formation (hot pro-
cesses).
• Index/Tucker Assembly
Indexes the boat through the workholder in the X axis for device bonding
and, once all devices have been bonded, tucks (pushes) the boat into the
output magazine.
• Air Manifold
Distributes air pressure from the bonder main manifold to pneumatic
devices on the workholder.
• Motor Assemblies.
Move the workholder assemblies (i.e, puller, heat blocks and index/tucker)
via leadscrew or rack and pinion drive.
98888-0000-JB3-01 Workholder 2-3

J Boat Present X Registration Sensor

Sensor (Input)
Preheat Heat Block Assembly
Puller Assembly
Index/Tucker Assembly Rear Rail
J Boat Present
Puller Motor Sensor (Output)
Indexer Motor
Front Rail
Rail Height Spacer
X Axis Leadscrew
Assembly
PCB Cover
Indexer Intermediate Board
(Hidden)
Rail Height Spacer
Figure 2-2 Indexer Assembly: Major Components (Front View)
2-4 Workholder 98888-0000-JB3-01

Index/Tucker Assembly
Boat Present Sensor Rear Rail
Amplifier (Output)
Front Rail Boat Present Sensor Puller Assembly
Amplifier (Input)
Preheat Assembly
Preheat Motor
Figure 2-3 Indexer Assembly: Major Components (Rear View)

Refer to Section 4 of this volume for information concerning the stepper motor
control system.
2.2.2 Workholder Subsystems

The position and the function of each workholder subsystem are specified in this
section. The subsystems are:
• Puller Assembly
• Front/Rear Rail Assemblies
• Preheat Heat Block Assembly
• Bond Site Heat Block Assembly
• Index/Tucker Assembly
• J Boat MHS Pneumatic System
• Indexer Intemediate Board
2.2.2.1 Puller Assembly
During the operation, when a boat is sensed by the sensor at the input magazine,
the motor operates the rack and pinion to move the puller assembly in the X axis
direction to the pick-up position in the magazine. At this point, the puller solenoid
de-energizes and the puller pin moves to the up position. The puller assembly
pulls a boat from the input magazine to the preheat site of the indexer assembly
for indexing.
98888-0000-JB3-01 Workholder 2-5

It contains the following parts:
• Puller Finger
Operates in three positions: pin up, pin down and pin trigger position. (The pin
is at up position when pulling a boat from the magazine).
• Puller Solenoid
Controls the pin up/down position of the puller pin. (The solenoid is de-ener-
gized when the puller pin moves up.)
• Puller Pin Sensor and Figer Flag
Used to determine the sensor triggering position of the puller pin.
• Motor
Moves the puller assembly along the indexer assembly in the X axis direction
by the rack and pinion drive.
• Home Sensor
Detects the home positioin of the puller assembly on the indexer assembly.
2.2.2.2 Front/Rear Rail Assemblies
The front/rear rail assemblies support and guide the boat as it moves through the
indexer assembly. The width of the front/rear rail is set manually according to the
width of the boat. Each contains the following subassemblies:
• Front and Rear Rails
Support and guide the boat as it moves through the indexer assembly in the X
axis direction movement.
2.2.2.3 Preheat Heat Block Assembly
The preheat block assembly increases the temperature of the device before it is
at the bond site position. During operation, the preheat motor operates the pre-
heat block in the vertical movement along the linear slider. Before the boat is
indexed, the preheat block is lowered. When a device is at the preheat site, the
preheat block moves up to the "pick up" position to move the device up above the
top surface of the boat for heating. After the device is heated, the preheat block is
lowered and the device is placed on the top surface of the boat. The preheat
block then moved to the home position as detected by the home sensor, and the
device is indexed to the bond site.
Each contains the following subassemblies:
• Preheat Heat Block Motor
Moves the preheat block vertically.
• Linear Sliders
Allows the heat block to move smoothly in the vertical (V) axis based on the
programmed boat and device dimensions.
• Base Block
Supports the heat block.
• Heater Cartridge
Heats the heat block site to the temperature set during configuration. (Heat is
provided by a 250 watt element fitted inside the cartridge that operates under
control of a temperature controller circuit.)
• Thermocouple
Monitors the temperature of the heater cartridge. (The thermocouple is seated
inside the cartridge.)
• Home Sensor
Detects the home position of the preheat heat block.
2-6 Workholder 98888-0000-JB3-01

2.2.2.4 Bond Site Heat Block Assembly
At the bond site, the bond site motor transfers drive to the heat block via the lead-
screw allowing it to move vertically along the linear slider. Before the boat is
indexed , the heat block is lowered. Once a device reaches the bond site, the heat
block is raised to heat the device and to lift it to bond height. While the device is
out of the boat, vacuum secures it to the heat block for bonding. Once the device
is bonded, the heat block to the heat block to move to its lower position via the lin-
ear slider; vacuum is turned OFF releasing the device onto the boat; and heat
block is moved to the home position as detected by the home sensor.
2.2.2.5 Index/Tucker Assembly
In operation, the indexer/tucker assembly is positioned in relation to the boat so
that the indexer pin is above an index hole. The air cylinder then activates caus-
ing the indexer pin to move, via the cross roller way slider, to its down position
and pin the boat. Once pinned, the indexer motor provides drive via the leadscrew
to move the indexer along the X axis linear slide. In this way the boat is moved
from left to right until the all devices are bonded. After the last device is bonded,
the tucker solenoid energizes and the tucker moves to its down position. As the
indexer/tucker assembly moves to the right, the tucker pushes the boat into the
output magazine. If greater than normal resistance to boat motion is detected
during boat indexing or ejection, the index overload sensor will stop the operation.
At this point, the user will be instructed to clear the jam and restart the operation.
• Indexer Motor
Transfers drive to the indexer/tucker assembly via the leadscrew.
• Linear Sliders
X Axis - allows the index/tucker assembly to move in the X axis.
Cross Roller Way - allows the index pin to move in the Y axis.
• Coupling
Couples the indexer motor to the leadscrew. Reduces any misalignment
between the motor and the leadscrew while minimizing backlash.
• Index Pin
Holds the boat during indexing.
• Index Pin Position Sensors and Flag
Two sensors detect the current vertical position of the pin: raised position, low-
ered position with pin engaged in a boat indexing hole, or lowered position
with no boat under the index arm.
• Index Overload Sensor
Detects greater than normal resistance to boat motion during boat indexing
and ejection operations. Too much resistance to boat motion indicates the
boat is jammed.
• Air Cylinder
Causes the indexer pin to move to its down position and pin the boat.
• Tucker Solenoid (12 volt)
Controls the up and down position of the tucker.
• Tucker
Pushes the boat into the output magazine once the last device on the boat is
bonded.
98888-0000-JB3-01 Workholder 2-7

2.2.2.6 J Boat MHS Pneumatic System
The J Boat MHS pneumatic system supply vacuum to the bond site heat block
and supply air pressure to the air cylinder of the index/tucker assembly. Its com-
ponents are on the workholder and at other position on the machine. Components
of the system are:
• 3-Way Vacuum Solenoid Valve
Controls the air pressure supply to the air cylinder that moves the index pin to
its up or down position. It is at the rear of the front wall assembly of the indexer
assembly.
• Vacuum Valve Assembly
Controls the vacuum that holds the device to the bond site heat block. It is on
the right side of the XY table assembly..
• Vacuum Generator
Supply the vacuum used at the bond site from an air pressure input. It is on the
upper console assembly.
• Air Regulator
Regulates the air pressure input to the J Boat MHS pneumatic system compo-
nents. It is on the upper console assembly.
• Heat Block Vacuum Sensor
Monitors the vacuum that holds the devices at the bond site heat block. If no
vacuum or low vacuum is sensed after a device is positioned for bonding, an
error is indicated and machine auto operation is stopped. It is on the interface
panel.
2.2.2.7 Indexer Intermediate Board
The indexer intermediate board has the following functions:
• An interface between the IConn card rack and the Workholder electrical com-
ponents.
• Supplies operating voltages to the motors, solenoids and sensors.
The indexer intermediate board is at the front right side of the indexer assembly to
minimize cable routing within the workholder (see Section 4).
2-8 Workholder 98888-0000-JB3-01

2.2.3 Boat Injection Sequence
During the boat injection sequence, the workholder extracts a boat from the input
magazine and delivers it to the preheat zone through combined motions of the
puller assembly and the input magazine handler. The puller engages a boat within
the input magazine, pulls it out of its slot, and presents it to the X registration sen-
sor. The puller then moves the boat and position the first device in the boat at the
hand-off location (preheat block)(see Figure 2-4).
Depending on the conditions of the puller pin and boat present sensors, certain
types of boat injection results can occur from the boat injection sequence. Such
results are defined in Table 2-1.
Table 2-1 Boat Injection - Puller Pin and Boat Present Sensor Conditions
Puller Pin Sensor Puller Pin Sensor Boat Present Sensor Boat Injection Result
Condition Condition
Boat Detected Pin Up Blocked Move boat to X Registration Sensor
Boat Detected Pin Not Up Blocked Stop or retry the same slot
Boat Detected Pin Not Up Unblocked Stop or retry the same slot
Boat Not Detected Pin Always Up Unblocked Move to the next slot or stop and report
error (Optional)
98888-0000-JB3-01 Workholder 2-9

Boat Present
Sensor
Magazine Boat Rear Rail
X Registration
Sensor
1. The boat is ready for injection
Puller Preheat Block
2. The puller motor moves the puller fin-

ger into the magazine. The puller
solenoid deactivates and the puller
pin moves to the up position.
3. The puller assembly moves to the

workholder. The pin engages one of
the hole in the boat. As the puller
pulls the boat from the magazine, the
boat present sensor detects the boat.
4. The puller moves to the right to the X

registration sensor. This cycle is
repeated until the sensor is blocked
or the software is in the time out
mode. Registration finds the leading
edge of the boat.
5. The puller moves the boat to the pre-

heat block. The pin stays in the up
position until control is transferred to
the index. The preheat block lift up
the device.
Figure 2-4 MHS Boat Injection Sequence (Top View)
2-10 Workholder 98888-0000-JB3-01

2.2.4 Boat Transfer Sequence
During the boat transfer sequence, control of the boat on the workholder rails is
transferred from the puller assembly to the indexer assembly (see Figure 2-5).
Bond Site
Heat Block Index/Tucker
1. The workholder prepares to begin the

transfer sequence.
2. The puller solenoid activates and

puller pin moves to the down posi-
tion. The puller moves left to make
room for the index.
3. The index moves left and then pins

the boat at the preheat block.
Figure 2-5 MHS Boat Transfer Sequence (Top View)

2.2.5 Boat Indexing and Ejection Sequence
During the indexing sequence, the boat is positioned in the workholder where the
first device can be picked up from the boat and lifted to bond height by the bond
site heat block. At the same time, the temperature of the next device in the boat
is raised by the preheat block at the same time). Once the bonding
operation is complete for the first device, the boat indexes to the right and
presents the next device for bonding. This sequence continues, and when the
last device on the boat is bonded, the boat is ejected into the output magazine
(see Figure 2-6).
The bonder will stop the indexing or ejection operation if the index overload sen-
sor detects a greater than normal resistance to boat motion. The software, which
translates this action to be a boat jam at the workholder output, will display an
error dialog box on the monitor. If this occurs, the user should clear the jam and
restart the operation
98888-0000-JB3-01 Workholder 2-11

FIRST DEVICE First Device

1. With the boat held by the index
assembly at the end of the Transfer
Sequence, the heat blocks are low-
ered. The indexer moves the first
device on the boat to the bond site.
The heat blocks lift up the devices.
NEXT DEVICE ON BOAT
Next Device
1. When the first device has been
bonded, the heat blocks are low-
ered. The index assembly moves
the next device on the boat to the
bond site. The heat blocks moves
up to lift up the devices.
2. The index assembly moves its pin
out of the boat index hole. The index
assembly moves to the left to the
next index position and holds the
boat. This position is at the bond
site unless there is no hole to hold.
NEXT BOAT Preheat Block Bond Site
Heat Block
1.The index assembly moves the com-
pleted boat to the right, away from
the bond site.
2.The index assembly lifts up its pin,

moves to the transfer position, and
do the transfer sequence.
3.The index assembly moves the next First Device

boat to the bond site position and do
the sequence for "First Device".
4.The index assembly lifts up its pin,

releases the boat at the bond site.
The index assembly moves to the
right and lowers the tucker. The
tucker ejects the boat into the output
magazine. The tucker moves up
and the index assembly moves to
the left to the bond site and holds
the boat. The process continues
with the "Next Device on Boat".
Figure 2-6 MHS Boat Indexing and Ejection Sequence (Top View)
2-12 Workholder 98888-0000-JB3-01

2.3 Setups and Adjustments
2.3.1 Set-Up Sequence
The flowchart in Figure 2-7 and Figure 2-8 shows a suggested set–up sequence
for the workholder that should be followed after the machine is first installed. Note
that the area within the dash–line box contains operations that should be per-
formed whenever the type of carrier or device used in production is changed. The
rest of the operations on the flowchart should only be necessary after disassem-
ble/assemble the workholder or after the machine is moved to a different location.
START
Puller Pin NO Do the Puller Pin setup.

engage
See paragraph 2.3.2
correctly?
YES
Index Pin NO Do the Index Pin setup.

engage
See paragraph 2.3.3.1
correctly?
YES
Teach Tucker Eject Position.

See paragraph 2.3.3.2.
Bond
NO Do the Bond Site Heat
Site Heat Block
Block Alignment.
aligned with optical
See paragraph 2.3.4
crosshair?
YES
Is Do the Rail Parallelism

NO
the Rails Adjustment.
parallel? See paragraph 2.3.5
YES
Figure 2-7 Workholder Setup Sequence, Sheet 1 of 2
98888-0000-JB3-01 Workholder 2-13

Preheat Do the Preheat Heat Block/ Bond

Heat Block aligned NO Site Alignment.
with Rails and Bond See paragraph 2.3.6
Site?
YES
Do the Workholder Calibra-

tions. See paragraph 2.4.
Correct NO Install new Heat Block

Heat Block Inserts Inserts.
installed?
YES
Enter MHS configuration

Carrier/Device Specific
parameter values and select
repeat each time carrier or
MHS options.
device type is changed.
See paragraph 2.5
Teach carrier bonding

position.
DONE
Figure 2-8 Workholder Setup Sequence, Sheet 2 of 2
2-14 Workholder 98888-0000-JB3-01

2.3.2 Puller Pin Setup
2.3.2.1 Workholder Gauge
The puller pin setup procedure uses the workholder setup and calibration gauge
assembly K&S P/N: 03035-0501-000-XX. The part of the gauge used to set up
the puller pin is divided into four levels. Each level is individually referenced
during this procedure as to where the top surface of the puller pin must be on that
level. The holes in the gauge are used to engage the tip of the puller pin as it trav-
els through the slot in the gauge. Figure 2-9 shows the part of the gauge used and
identifies its four levels.
Rear Rail
Workholder Gauge
(Top View)
Puller Pin
(Beneath Gauge in Slot)
Front Rail
Top View
Level 1 Level 2 Level 3 Level 4

Puller Pin Up Puller Pin Puller Pin Puller Pin Down
Sensior ON Sensor OFF
Level 1
Puller Pin Up Level 3
Puller Pin
Sensor OFF
Level 2 Level 4
Puller Pin Puller Pin Down
Sensior ON
Figure 2-9 Workholder Gauge Funtionality for Puller Pin Setup
98888-0000-JB3-01 Workholder 2-15

2.3.2.2 Puller Pin Setup Sequence
The purpose of this adjustment is to make sure that the puller pin is engaged to
the correct hole in the gauge. The adjustment is necessary, only when the
machine is first installed or if the puller pin is disassembled. It is not necessary to
do this adjustment at any other time.
Tools/ Materials/ Parts

• Workholder setup and calibration gauge assembly (P/N: 03035-0501-000-XX)
• Hand Tools
Procedure
A. Turn temperature controllers OFF:
3. Select the TURN ALL ZONES OFF button from the "Temperature Set Points"
dialog box. While the heat blocks cool down, observe their temperature at
the temperature status display on the monitor.
4. Select DONE when the heat blocks cool down to close the dialog box.
5. Push the [ESCAPE] button to exit the Configure mode.
WARNING: TO PREVENT ACCIDENTAL BURNING OF THE SKIN, DO NOT CON-

TINUE WITH THIS PROCEDURE UNTIL BOTH HEAT BLOCKS HAVE
COOLED DOWN.
B. Move the puller to home position:

1. Select [2] MANUAL from the mode bar.
2. Select [3] MHS UTILITIES from the Manual menu.
3. Select [4] PIN UTILITIES from the MHS Utilities menu.
4. Select HOME PULLER from the Pin Utilities menu.
5. Select APPLY to move the puller to home position.
6. Select DONE to close the dialog box.
C. Display the sensor panel:
1. Select [7] DIAGNOSTIC from the mode bar.
2. Select [5] MAINTENANCE DIAGNOSTICS from the Diagnostic mode menu.
3. Select [1] SENSOR from the Maintenance Diagnostics menu.
4. Monitor the PULLER PIN sensor on the Sensor Diagnostics panel while
doing the puller pin adjustments.
D. Put workholder setup and calibration gauge assembly between the rails (see
Figure 2-10 and Figure 2-12).
WARNING: DO NOT DAMAGE THE REAR RAIL BOAT BIAS SPRING WHEN YOU
PUT THE WORKHOLDER SETUP AND CALIBRATION GAUGE
ASSEMBLY BETWEEN THE RAILS.
1. Make sure that the index slot of the gauge is on the right side, point
towards the Output Magazine Handler Assembly (see Figure 2-10).
2-16 Workholder 98888-0000-JB3-01

Rear Rail
Output Magazine
Handler Assembly
Front Rail
Index slot on the

right side.
Figure 2-10 Install the Workholder Setup and Calibration Gauge Assembly Position
2. Hold the gauge at 45o angle (rear edge down) and put the rear edge of the
gauge on the rear rail (see Figure 2-11).
3. Without moving the gauge forward, slowly lower the gauge until it is on the
front rail (see Figure 2-11).
4. Make sure that the gauge can move along the rails with small resistance.
Gauge at 45o angle
Front Rail
Rear Rail
Figure 2-11 Install the Workholder Setup and Calibration Gauge Assembly at 45o angle
E. Move the gauge to the left and let the puller pin move in the oval slot on the left
front side of the gauge. As the puller pin moves in the slot, make sure that it is
in center position. If not:
1. Loosen the two M2 screws at the left side of the puller solenoid (see Figure
2-12).
2. Adjust the puller pin in the Y-axis direction (front and back) until the pin is in
the center position when it moves in the slot of the gauge.
3. Tighten the screws.
98888-0000-JB3-01 Workholder 2-17

.
Puller Pin 2x M2 Screws
Puller Pin Solenoid
Figure 2-12 Puller Pin Y axis Adjustment (Top View)

F. Disconnect the puller pin solenoid cable at connector J2 on the puller assem-
bly circuit board.
NOTE: If necessary, refer to Figure 2-9 while doing the following “LEVEL”
adjustments.
G. Do the LEVEL 1 (Puller Pin UP) adjustment (see Figure 2-13).

1. Set the position of the puller pin tip below level 1 of the gauge.
2. Turn the M3 set screw above the puller pin solenoid to adjust the tip of the
puller pin until it touches level 1.
M3 Set Screw
Puller Pin Solenoid
Figure 2-13 Puller Pin Level 1 Adjustment (Right Side View)
2-18 Workholder 98888-0000-JB3-01

H. Do the LEVEL 2 (Puller Pin Sensor ON) adjustment (see Figure 2-
14).
1. Move the gauge until the tip of the puller pin touches level 2.
2. Look for the PULLER PIN sensor display on the Sensor Diagnostic dialog
box, loosen the sensor flag mounting screw and adjust the puller pin sen-
sor flag until the sensor turns ON.
3. Tighten the sensor flag mounting screw.
Puller Pin Sensor Flag
Puller Pin Sensor

Sensor Flag Mounting Screw
Figure 2-14 Puller Pin Level 2 and Level 3 Adjustment (Rear View)
I. Do the LEVEL 3 (Puller Pin Sensor OFF) adjustment (see Figure 2-14).
2. Manually push the puller pin down to get into this position.
3. Make sure that the PULLER PIN sensor display in the Sensor Diagnostic dia-
log box is OFF. If not, adjust the sensor flag until the sensor turns OFF.
4. Do a check for Level 2 (step H.) and Level 3 (step I.) adjustments. Make
sure that the adjustments are adjusted correctly.
5. Connect the puller soleniod cable to connector J2 on the puller assembly
circuit board.
J. Do the LEVEL 4 (Puller Pin DOWN) adjustment (see Figure 2-15).
2. Look for the PULLER PIN sensor display in the Sensor Diagnostic dialog
box, turn the top M3 set screw on the flag mounting arm to adjust the tip of
the puller pin until it touches level 4.
M3 Set Screw
Figure 2-15 Puller Pin Level 4 Adjustment (Side View)

98888-0000-JB3-01 Workholder 2-19
K. Select DONE to exit the Sensor Diagnostic dialog box.
L. Select DONE to exit the Maintenance Diagnostics menu.
M. Push the [ESCAPE] button if necessary to exit the Diagnostics mode.
N. Remove the workholder setup and calibration gauge assembly.
2.3.3 Index Pin/Tucker Eject Setup

2.3.3.1 Index Pin Setup Sequence
The purpose of this adjustment is to make sure that the index pin is engaged to
the correct groove in the gauge. The adjustment is necessary, only when the
machine is first installed or if the index pin is disassembled. It is not necessary to
do this adjustment at any other time.

• Hand Tools
Procedure

COOLED DOWN.
B. Put workholder setup and calibration gauge assembly between the rails (see
section 2.3.2.2, step D.
C. Disconnect the tubing from the fitting in the index mount. This tubing supplies
air to the index pin air cylinder.
D. Manually lift the index pin and move the gauge under it.
E. Set the pin position until it moves smoothly to the lower shelf of the groove at
the right front portion of the gauge (see Figure 2-16).
Upper Shelf
Lower Shelf
Groove
Figure 2-16 Index Pin Alignment Groove
2-20 Workholder 98888-0000-JB3-01

F. Make sure that the pin aligns correctly in the groove. If not:
1. Loosen the two M3 screws that attach the pin to the assembly
(see Figure 2-17).
2. Adjust the pin until it is aligned directly on the groove.
2x M3 Screws
Sensor Flag Mounting Screw
Indexer Pin
Sensor Flag
Figure 2-17 Index Pin - Y axis Adjustment and Up/Down Adjustment

G. Display the sensor panel:
1. Select [7] DIAGNOSTIC from the mode bar.
2. Select [5] MAINTENANCE DIAGNOSTICS from the Diagnostic mode menu.
3. Select [1] SENSOR from the Maintenance Diagnostics menu.
4. Monitor the sensors on the Sensor Diagnostics panel while doing the index
pin UP and pin DOWN adjustments.
NOTE: Before doing the following steps, make sure that there is no interference
between the work light and the operation of the index sensor.
H. Put the index pin in the lower shelf of the groove on the gauge and do a index
pin DOWN position check.
I. Look for the INDEXER PIN RIGHT and INDEXER PIN LEFT sensors display in the
Sensor Diagnostic dialog box. Make sure that the INDEXER PIN RIGHT sensor is
ON and INDEXER PIN LEFT sensor is OFF. If not (see Figure 2-17):
1. Loosen the sensor flag mounting screw.
2. Adjust the sensor flag until the INDEXER PIN RIGHT sensor is ON and
INDEXER PIN LEFT sensor is OFF.
J. Put the index pin in the upper shelf of the groove on the gauge and do a index
pin UP position check.
K. Make sure that the INDEXER PIN RIGHT sensor and INDEXER PIN LEFT sensor
are OFF. If not:
1. Loosen the sensor flag mounting screw.
98888-0000-JB3-01 Workholder 2-21

2. Adjust the sensor flag until the INDEXER PIN RIGHT sensor and INDEXER PIN
LEFT sensor are OFF.
L. Select DONE to exit the Sensor Diagnostic panel.
M. Select DONE to exit the Maintenance Diagnostic menu.
N. Push the [ESCAPE] button if necessary to exit the Diagnostics mode.
O. Remove the workholder setup and calibration gauge assembly.
P. Connect the tubing that supplies air to the index pin air cylinder.
2.3.3.2 Tucker Eject Setup Sequence
The purpose of this setup is to make sure the tucker eject is positioned correctly.
This is done to avoid interference between the tucker tip and other indexer parts
during carrier ejection.

• Hand Tools
Procedure

COOLED DOWN.
B. Put workholder setup and calibration gauge assembly between the rails (see
section 2.3.2.2, step D..
C. Move the gauge to the right and put the tucker tip over the upper shelf at the
front, right side of the gauge (see Figure 2-18).
Upper Shelf
Lower Shelf
Figure 2-18 Tucker Eject Alignment Surfaces

D. Make sure that the tucker tip touches the upper shelf. If not (see Figure 2-19):
1. Find the set screw below the tucker solenoid and loosen it.
2. Adjust the set screw until the tucker top touches the upper shelf.
2-22 Workholder 98888-0000-JB3-01

3. Tighten the set screw..
Tucker Solenoid
Set Screw
Figure 2-19 Tucker “Raised Position” Adjustment

E. Move the gauge to the right until the tucker tip is above the lower shelf at the
front, right side of the gauge.
F. Move the tucker down to the lower shelf of the guage:
3. Select [4] PIN UTILITIES from the MHS Utilities menu.
4. Select the LOWER TUCKER option from the Pin Utilities dialog box.
5. Select APPLY.
G. Make sure that the tucker tip touches the lower shelf. If not (see ):
1. Loosen the M3 set screw at the left side of the tucker solenoid
(see Figure 2-20).
2. Use a wrench tool to turn the M3 hex screw until the tucker tip touches the
lower shelf on the gauge.
3. Tighten the M3 set screw.
4. Select the LIFT TUCKER option from the Pin Utilities dialog box.
5. Select APPLY.
6. Press the [ESCAPE] button if necessary to exit the Manual mode.
Tucker Solenoid
M3 Set Screw
M3 Hex Screw
Figure 2-20 Tucker Pin Lower Travel Adjustment

H. Remove the workholder setup and calibration gauge assembly.
98888-0000-JB3-01 Workholder 2-23
2.3.4 Bond Site Heat Block Alignment

The purpose of this adjustment is to align the heat block with the X axis of the
Bond Head. The adjustment is necessary, only when the machine is first installed
or if the bond site heat block assembly is disassembled. It is not necessary to do
this alignment frequently.
Specification
• Y value is +/- 0.0254 mm (1 mil).
• Workholder Setup Gauge (P/N: 03035-0908-001-XX)
• Torque Wrench, 13 lb.in. (1.47 Nm)
• Hand Tools
Procedure
5. Press [ESCAPE] to exit the Configure mode.

COOLED DOWN.
B. Install the workholder setup gauge on the bond site heat block assembly.
When you install the gauge, make sure that (see Figure 2-21):
1. The engrave part number on the top surface of the gauge points to you.
2. The notch at the front edge of the gauge engages to the pin on the bond
site heat block assembly.
Engraved Part Number Workholder Setup Gauge
Notch
Notch engages to the pin
Figure 2-21 Install the Workholder Setup Gauge Position (Right Side View)
2-24 Workholder 98888-0000-JB3-01

C. Align the horizontal line of the crosshair to the left rear edge of
the gauge (see Figure 2-22). If necessary, select the F10 button on the func-
tion bar to adjust the illumination until the edge can see clearly.
Align the crosshair horizontal line to the M3 Screws Align the crosshair horizontal line to the
rear edge to the left side as shown. rear edge to the right side as shown.
03035-0908-001
Workholder Setup Gauge
Figure 2-22 Bond Site Heat Block Alignment (Top View)

D. Make a note of the Y value at the top right corner of the graphical user inter-
face (GUI) display for left rear edge position of the gauge (see Figure 2-23). At
the same time, take note of the X value.
Align the crosshair horizontal

line to the rear edge to the Y Value
left side as shown.
Figure 2-23 Y Value At The Top Right Corner of the GUI Display
E. Chess the horizontal line of the crosshair to the right rear edge of the gauge.
F. Make a note of the Y value for this position. At the same time, take note of the
X value
G. Compare the measured Y position values for the right and left edges. The dif-
ference must be 0.0254 mm (1 mi). If not, go to step H.
98888-0000-JB3-01 Workholder 2-25

H. If the value is greater than 0.0254 mm (1 mil), do the bond site heat block
alignment (see Figure 2-22):
1. Hold the heat block assembly, then loosen the four M3 screws that attach
the heat block to the heat block slider assembly slowly to 1/4 turn.
2. Rotate the heat block assembly and chess the horizontal line of the cross-
hair to the rear edge of the heat block gauge.
3. Chess the horizontal line of the crosshair from left to right edges (the
approximate X values in step D. and F.) of the gauge.
4. Make sure that the rear edge of the gauge is straight. Use the Y value on
the display to do the check (refer to step G.).
5. Tighten each of the four M3 screws on the bond site heat block assembly
with a 1/4 turn in diagonal sequence, to set the assembly position.
6. Use a torque wrench to apply a torque of 13 lb.in. (1.47 Nm) to the four M3
screws in diagonal sequence.
7. Make sure that the heat block assembly does not move when the screws
are tightened.
I. Do a check on the bond site heat block alignment.
1. Align the horizontal line of the crosshair to the left rear edge, then to right
rear edge of the gauge.
2. Make note of the Y value on the display and compare.
3. Do the alignment again (see step H.) if the value is greater than 0.0254
mm.
J. Remove the workholder gauge.
K. Continue the rail parallelism adjustment (see paragraph 2.3.5).
2-26 Workholder 98888-0000-JB3-01

2.3.5 Rail Parallelism Adjustment
The purpose of this adjustment is to adjust the the front and rear workholder rails
until the rails are parallel to each other and the heat block is parallel to the rails.
This adjustment will continue after the bond site heat block alignment is done (see
paragraph 2.3.4).
NOTE: Do the bond site head block alignment first before you do the rail
parallelism adjustment.
Specification
• Parallelism between the front and rear rail is +/- 0.1 mm over the length of the
rails.
• Gauge Pin (P/N: 03035-0908-005-XX)
• Rails Width Gauge (Example: 3.6” (standard), P/N: 03035-0908-003-XX)
• Hand Tools
Procedure

COOLED DOWN.
B. Make sure that the heat block is at the home position. If not, move the heat
block to its home position:
3. Select [2] HEAT BLOCK UTILITIES from the MHS utilities menu.
4. Select [4] HOME HEAT BLOCK. The bond site heat block moves to its home
position.
5. Select DONE.
C. Loosen the four M5 screws at the two ends of the rear rail assembly, that
attach the rear rail to the input and output base supports (see Figure 2-24).
D. Manually move the rear rail a small distance to the back
98888-0000-JB3-01 Workholder 2-27

.
Front Rail Assembly
Rear Rail
Assembly
M5 Screw
M5 Screws
M5 Screws
(one screw is not shown)
Figure 2-24 Rear Rail Assembly (Rear View)
E. Loosen the four M5 screws at the two ends of the front rail assembly, that
attach the front rail to the input and output base supports (see Figure 2-24 and
Figure 2-25).
F. Manually move the front rail a small distance to the front.
M5 Screw
Front Rail Assembly
M5 Screw
(not shown)
Figure 2-25 Front Rail Assembly (Front View)

2-28 Workholder 98888-0000-JB3-01
G. Install the workholder setup gauge on the bond site heat block
assembly. When you install the gauge, make sure that (see Figure 2-21):
1. The engrave part number on the top surface of the gauge points to you.
2. The groove at the front edge of the gauge touches the pin on the bond site
heat block assembly.
H. Install the rail width gauge on the workholder setup gauge.
PUT THE RAIL WIDTH GAUGE BETWEEN THE RAILS.
1. Make sure that the cut-out of the gauge is on the right side, point towards
the Output Magazine Handler Assembly (see Figure 2-26).
Output Magazine
Handler Assembly
Cut-out on the right side

Figure 2-26 Install the Rail Width Gauge Position
2. Put the rail width gauge on the workholder gauge.
I. Install the gauge pins (see Figure 2-27):
1. Align the first hole of the rail width gauge with the first hole of the work-
holder setup gauge.
2. Continue to align the remaining holes in the gauges.
3. Install the gauge pins through the holes in the rail width gauge.
NOTE: If the gauge pins cannot install, do not use force. Do the hole alignment
on the workholder gauge with rail width gauge until the pins can be
install.
4. Make sure that the gauge pins install through the holes in the gauges.
98888-0000-JB3-01 Workholder 2-29

Gauge Pins First Hole of the Rail Width Gauge
Rail Width Gauge
Figure 2-27 Install the Rail Width Gauge and Gauge Pins
J. Do the rail parallelism (see Figure 2-28):
1. Manually push the front rail to the front surface of the rail width gauge.
2. Make sure that the bottom surface at the front edge of the rail width gauge
is on the front rail. If not,
a. Lift up the rail width gauge until the edges of the gauge are aligned to
the front surface.
b. Hold the gauge and manually move the front rail a small distance to the
rear until the front, bottom surface of the gauge is on the front rail.
3. Tighten the four M5 screws at the two ends of the front rail assembly, that
attach the front rail assembly to the base supports (see Figure 2-24 and
Figure 2-25).
4. Manually push the rear rail to the rear surface of the rail width gauge.
5. Make sure the bottom surface at the rear edge of the rail width gauge is on
the rear rail. If not,
a. Lift up the rail width gauge until the edges of the gauge are aligned to
the rear rail surface.
b. Hold the gauge and manually move the rear rail a small distance to the
front until the rear, bottom surface of the gauge is on the rear rail.
6. Tighten the four M5 screws at the two ends of the rear rail assembly, that
attach the rear rail assembly to the base supports (see Figure 2-24 and
Figure 2-25).
2-30 Workholder 98888-0000-JB3-01

Push the rear rail
Rail Width Gauge

Push the front rail
Bottom surface of the Rail

Width Gauge on the
Rear Rail
Bottom surface of the Rail
Width Gauge on the
Front Rail
Lift up the Rail Width Gauge

to align with the rails surface.
Figure 2-28 Rail Parallelism
K. Remove the gauge pins.
L. Move the rail width gauge across the rails. Make sure that the gauge can
moves smoothly and you can feel the guage with small friction.
M. Remove the the rail width gauge and the workholder gauge from the Work-
holder.
N. Continue the preheat heat block alignment (see paragraph 2.3.6).
98888-0000-JB3-01 Workholder 2-31

2.3.6 Preheat Heat Block/Bond Site Alignment

The purpose of this adjustment is to align the preheat heat block with the rails and
sets the distance between the preheat and bond site. This is to make sure that the
carrier is correctly index. The adjustment is necessary, only when the machine is
first installed, or if the preheat or bond site heat block assembly is disassembled.
It is not necessary to do this alignment frequently. This adjustment will continue
after the rail parallelism adjustment is done (see paragraph 2.3.5).
NOTE: Do the rail parallelism adjustment before you do the preheat heat block/
bond site alignment.

• Gauge Pin (P/N: 03035-0908-005-XX)
• Rails Width Gauge
• Preheat Setup Gauge Assembly (P/N: 03035-0502-000-XX)
• Hand Tools
Procedure

COOLED DOWN.
B. Make sure that the preheat heat block is at the home position. If not, move the
heat block to its home position:
3. Select [3] PREHEAT HEAT BLOCK UTILITIES from the MHS utilities menu.
4. Select HOME PREHEAT BLOCK. The preheat heat block moves to its home
position.
5. Select APPLY then DONE.
C. Do a check on the preheat heat block alignment with the rail and the distance
between the preheat and bond site.
1. Install the workholder setup gauge on the preheat heat block assembly.
2. Install the rail width gauge between the rails, above the preheat heat block
assembly.
PUT THE RAIL WIDTH GAUGE ASSEMBLY BETWEEN THE RAILS.
a. Make sure that the cut-out of the gauge is on the right side, point
2-32 Workholder 98888-0000-JB3-01
Output Magazine
Handler Assembly

Figure 2-29 Install the Rail Width Gauge - 3.6” Position
b. Hold the gauge at 45o angle (rear edge down) and put the rear edge of
the gauge on the rear rail (see Figure 2-30).
c. Without moving the gauge forward, slowly lower the gauge until the
front edge is on the front rail.
d. Move the rail width gauge across the rails. Make sure that the gauge
can moves smoothly and you can feel the guage with small friction.
Gauge at 45o angle
Rear Edge of the Gauge
Front Edge of the Gauge

Rear Rail
Front Rail
Figure 2-30 Install the Rail Width Gauge at 45o angle (Right Side View)
3. Install the preheat setup gauge assembly in front of the first hole on the rail
width gauge (see Figure 2-31 ).
98888-0000-JB3-01 Workholder 2-33

a. Do a check if the pin on the preheat setup gauge touches the left side of
the bond site heat block assembly (see Figure 2-31 ). If not, do the pre-
heat/bond site alignment in step D.
Rail Width Gauge Gauge Pins

Preheat Setup Gauge
Pin touches the left side

of the bond site heat block assembly
First Hole of the Rail Width Gauge
NOTE: The position of the preheat setup gauge pin shown in this figure is
possibly different in its position for the other types of applications.
Set the pin position to the correct type of application used.
Figure 2-31 Install the Preheat Setup Gauge and the Gauge Pins
4. Install the gauge pins (see Figure 2-31):
a. Align the first hole of the rail width gauge to the first hole of the work-
holder setup gauge.
b. Continue to align the remaining holes in the gauges.
c. Install the gauge pins through the holes in the rail width gauge.
NOTE: If the gauge pins cannot install, do not use force. Do the hole alignment
on the workholder gauge with rail width gauge until the pins can be
install.
d. Do a check if the gauge pins is installed through the holes in the

gauges. If not, do the preheat block alignment in step D..
D. Do the preheat heat block alignment (see Figure 2-32):
1. Remove the gauge pins from the gauges on the preheat assembly.
2. Do not remove the preheat setup gauge.
3. Get access to the preheat heat block assembly at the left side of the pre-
4. Hold the preheat heat block assembly, then loosen the four M3 screws that
attach the heat block to the preheat top plate slowly to 1/4 turn.
2-34 Workholder 98888-0000-JB3-01

.
Rail Width Gauge M4 Screws Preheat Setup Gauge
Get access to the

preheat heat block
assembly
M4 Screws
Figure 2-32 Preheat Heat Block Alignment (Top View)
5. Manually turn the preheat heat block assembly until the first hole of the rail
width gauge is aligned to the first hole of the workholder setup gauge.
6. Manually turn the preheat heat block assembly until:
a. The first hole of the rail width gauge is aligned to the first hole of the
workholder setup gauge.
b. All the holes on the rail width gauge are aligned to all the holes on the
workholder setup gauge.
c. The pin on the preheat setup gauge touches the left side of the bond
site heat block assembly.
7. Install the gauge pins through the holes in the rail width gauge (see Figure
2-31).
8. Make sure that the gauge pins is installed through the holes in the work-
holder setup gauge.
9. Tighten each of the four M3 screws on the preheat heat block assembly
with a 1/4 turn in diagonal sequence, to set the assembly position.
10.Use a torque wrench to apply a torque of 13 lb.in. (1.47 Nm) to the four M3
screws in diagonal sequence.
11. Make sure that the preheat heat block assembly does not move when the
screws are tightened.
E. Remove the gauge pins, preheat setup gauge, rail width gauge and work-
holder setup gauge on the rails and preheat assembly.
98888-0000-JB3-01 Workholder 2-35

2.3.7 Puller Rack Backlash Adjustment

Specification
• Backlash of 0.0015 +/- 0.0010 in. (Range = 0.0005 - 0.0025 in.)
• Dial Indicator with Maganetic Stand
• Hand Tools
Procedure
A. Remove the lubricant from the puller rack.
B. Measure the backlash at the center, left, and right positions of the rack (see
Figure 2-33):
1. Move the puller assembly to the center of the rack until the left edge is
aligned to the notch on the front wall.
2. Put the dial indicator on the linear slider so that its tip touches the lowest
point on the puller mount.
3. Measure the backlash at the center position.
4. Move the puller assembly to the left side limit, and then back to the right
approximately 3 mm (1/8 inch).
5. Measure the backlash at the left side position.
6. Move the puller assembly until the right edge is aligned to the right edge of
the rack.
7. Measure the backlash at the right side position.
8. Reposition the dial indicator and measure the backlash at the right-side
position.
9. Go to step "C." if one of the measured position are out of the specification
of 0.0005 to 0.0025 in.
NOTE: If the measurements at all positions are within specification,it is not nec-
essary to continue with this procedure.
Slide Block
(Puller Assembly) X Axis Linear Slide Assembly
Slide Block
(Index Assembly)
Set Screw Front Wall Notch
Puller Rack Set Screw
Figure 2-33 Puller Rack Backlash

2-36 Workholder 98888-0000-JB3-01
C. Move the puller assembly to the output side of the indexer assem-
bly until it is off of the rack.
D. Loosen the two M3 screws that attach the rack, then torque the screws to
5 in lbs.
E. Move the puller assembly to the center of the rack until the left edge is aligned
to the notch on the front wall.
F. Put the dial indicator on the linear slider until its tip touches the lowest point on
the puller mount.
G. Measure the backlash at the center position (see Figure 2-33).
1. If the backlash is less than 0.0005 in., turn the set screws at the two ends
of the rack to the right (in). to move the rack to the rear of the indexer
assembly.
2. If the backlash is greater than 0.0025 in., turn the sets crews at the two
ends of the rack to the left (out) to move the rack to the front of the indexer
assembly.
3. Repeat step 1 to 2 until the backlash is within the specification of 0.0005 to
0.0025 in.
H. Move the puller assembly to the left side limit, and then to the right side
approximately 1/8 in (3 mm).
I. Put the dial indicator on the left side and measure the left backlash specifica-
tion. If it is not within the specification of 0.0005 to 0.0025 in.:
1. Move the puller assembly to the far right side of the rack.
2. Turn the left-side set screw.
a. If it is less than 0.0005 in., turn it to the right to move the rack to the
rear of the indexer assembly.
b. If it is greater than 0.0025 in., turn it to the left to move the rack to the
front of the indexer assembly.
3. Do the step 2 procedure until the backlash is within the specification of
0.0005 to 0.0025 in.
J. Move the puller assembly until its right edge is aligned to the right edge of the
rack.
K. Put the dial indicator on the right side and measure the right backlash specifi-
cation. If it is not within the specification of 0.0005 to 0.0025 in.:
1. Move the puller assembly to the left side limit.
2. Turn the right-side set screw.
a. If it is less than 0.005 in., turn it to the right to move the rack to the rear
of the indexer assembly.
b. If it is greater than 0.0025 in., turn it to the left to move the rack to the
front of the indexer assembly.
3. Do the step 2 procedure until the backlash is within the specification of
0.0005 to 0.0025 in.
L. Remove the dial indicator, and move the puller assembly away from the rack
to the output side of the indexer assembly.
M. Torque the screws to 8 in. lbs. (0.9 Nm)
N. Do the step "B." again.
O. Torque the screws to 14 in. lbs. (1.6 Nm).
P. Apply a small quatity of lubricate to the the rack (refer to Section 5: Mainte-
nance).
98888-0000-JB3-01 Workholder 2-37

2.3.8 Heat Block Vacuum Sensor Setup

The purpose of this procedure is to make sure that the heat block vacuum sensor
controller is setup to detect if a device is properly held down on the heat block.
This procedure also set up the conditions under which the low vaccum sensor
operates. All references to ’buttons’ in the steps that follow refer to the control but-
tons located on the vacuum sensor controller operator panel (see Figure 2-34)
and not to keys on the machine operator control panel (MMI).
Figure 2-34 Vacuum Sensor Controller

NOTE: Make sure that the necessary workholder calibrations, configura-
tions and adjustments, for the correct type of carrier and device
used, are done before setting up the vacuum sensor. If not, do the
necessary workholder calibration, configurations and adjustments,
refer to Section 5 of IConn Operation Manual.
• None.
Procedure
A. Find the vacuum sensor/controller at the front of the interface panel.
B. Unlock Vacuum Sensor:
1. Press SET button and hold for 4 seconds or longer to display the [LOC] set-
ting.
2. Press the UP or DOWN arrow button until [UNL] appears on the digital dis-
play screen.
3. Press SET button.
C. Unit Measurement Setting
1. Press and hold the SET button for 2 seconds or longer.
2. Press the UP or DOWN arrow button to set the unit of measurement to [INH].
3. Press SET button to set the unit. Proceed to color setting in step D.
D. Color Setting
1. Press the UP or DOWN arrow button and select the display color to
[ ] (red).
2. Press SET button to set the colour. Proceed to operating mode setting in
step E.
E. Set Operating Mode
1. Press the UP or DOWN arrow button to display [HYS] (Hysteresis).
2. Press SET button to set the operating mode. Proceed to output type setting
in step F.
2-38 Workholder 98888-0000-JB3-01
F. Set Output Type
1. Press the DOWN arrow button and select [NC] (normally closed).
2. Press SET button to set the output type. Proceed to response time setting
in step G.
G. Response Time Setting
1. Press the UP or DOWN arrow button and select [2.5] (2.5 ms).
2. Press SET button to set the response time. Proceed to auto preset setting
in step H.
H. Auto Preset Setting
1. Press the UP or DOWN arrow button and select [ ] (manual).

2. Press SET button to set the auto preset type. Proceed to vacuum setting in
step I.
I. Vaccum Setting
1. Press SET button to display the set value. [N_1] (normally closed) and cur-
rent set value e.g. [.330] will appear on the digital display screen and blink
alternately.
2. Press SET button to display the next set value (if available).
3. Set the current value to [-15.0].
a. Press the UP or DOWN arrow button. The first digit, right-most digit on
the LCD display will blink. Press the UP or DOWN arrow button and set
the first digit value to ‘0’.
NOTE: If any of the button has not been pressed for more than 10 seconds, the
current value will be automatically set and the function will return to the
set value display mode.
b. Press SET button to move to the second digit in left direction. The sec-
ond digit blinks. Press the UP or DOWN arrow button and set the second
digit value to ‘.’ .
c. Press SET button to move to the third digit. Press the UP or DOWN arrow
button and set the third digit value to ‘5’.
d. Press SET button to move to the fourth digit. Press the UP or DOWN
arrow button and set the fourth digit value to ‘1’.
e. Press SET button to move to the fifth digit. Press the UP or DOWN arrow
button and set the fifth digit value to ‘-’.
f. Press and hold the SET button for 3 second or longer to save the vac-
uum value for [N_1].
4. Press and hold the SET button for 4 seconds or longer to return to the nor-
mal measuring mode to perform the switch operations.
J. Set the Hysteresis (H) value to the zero (if necessary).
1. Press SET button once to display current H value.
2. Press and hold the UP and DOWN arrow buttons simultaneously to reset the
value to zero [0.0].
3. Press and hold the SET button for 3 seconds to save the H value.
K. Lock Out
1. Press and hold the SET button for 4 seconds or longer to display the current
[UNL] setting.
2. Press the UP or DOWN arrow button until [LOC] appears on the digital dis-
play screen. Press SET button.
98888-0000-JB3-01 Workholder 2-39

2.4 Workholder Calibration Procedures

WARNING: WORKHOLDER CALIBRATIONS SHOULD BE PERFORMED WITH
WORKHOLDER HEATERS AT OPERATING TEMPERATURE FOR
MOST ACCURATE RESULTS. IF THE WORKHOLDER IS HEATED,
AVOID TOUCHING HEATED PARTS WHEN REMOVING PARTS OR
MATERIAL (CARRIERS, HEAT BLOCK INSERT, CLAMP INSERT) OR
WHEN PERFORMING OTHER OPERATIONS.
NOTE: The following calibration procedures are designed to provide parame-

ters which allow for the alignment of the workholder so as to ensure cor-
rect centerlines of bond.
NOTE: Calibrations should be performed with no material in the workholder or

magazine handlers.
NOTE: It is assumed that the die cavity of the heat block targeted during work-
holder calibrations is on the workholder X axis and Y axis centerlines.
NOTE: MHS calibration should not be done unless the X, Y, and Z servo motion
axes have been tuned, bond plane height has been established, and
crosshair offset has been calibrated.
2.4.1 Workholder Calibration

2.4.1.1 Introduction
The Workholder calibration contains a group of routines used to calibrate certain
areas of the workholder. Each routine displays a series of dialog boxes in the
proper sequence to complete the calibration. Each dialog box contains instruc-
tions on how to perform that specific step in the calibration. All instructions should
read and understood before select ok to proceed. All workholder calibrations
should be performed when the heat blocks are at the operating temperature to
produce the most accurate results.
2.4.1.2 Do the Workholder Calibration

WARNING: DO NOT TOUCH THE HEAT BLOCK OR INSERTS WITH UNPRO-
TECTED HANDS IF THE WORKHOLDER HEATERS ARE AT OPERAT-
ING TEMPERATURE. WHEN REMOVING THE HEAT BLOCKS OR
INSERTS, INSTALL A SCREW AT THE REAR EDGE OF THE HEAT
BLOCK/INSERT AND GRASP THE SCREW WITH PLIERS. THERE IS
ONE M4 TAPPED HOLE IN THE HEAT BLOCK/INSERT FOR THIS PUR-
POSE.
• Workholder Setup Gauge (P/N: 03035-0908-001-XX) (Heat Block Gauge)
• Heat Block Inserts (P-part)
• Rails Width Gauge - 3.6” (P/N: 03035-0908-003-XX)
Procedure
A. Select [5] CALIBRATION from the mode bar.
B. Select [4] WORKHOLDER from the Calibration menu.
C. Select [1] WORKHOLDER from the Workholder menu.
D. Remove all material from the Workholder.
2-40 Workholder 98888-0000-JB3-01
Figure 2-35 Workholder Calibration Menu - Remove Material

E. Make sure that the correct heat block gauge/insert is installed on the bond site
heat block assembly, then select OK (see Figure 2-36).
Figure 2-36 Workholder Calibration - Install Bond Site Heat Block Gauges/Inserts
F. Do the heat block focus (see Figure 2-37)
1. Use the mouse and [B2] (center button on the mouse) to move the bond
head until the heat block gauge/insert on the bond site appears on the
screen.
2. If necessary, adjust the illumination using the F10 button on the function
bar.
3. Do the heat block focus by pushing the Up or Down arrow buttons on the
MMI until the heat block gauge/insert can be seen clearly on the screen.
4. Select OK.
.
Figure 2-37 Workholder Calibration - Heat Block Focus

G. Position the crosshair on the heat block.
1. Use the mouse and [B2] to position the crosshair on the left rear corner of
the heat block (see Figure 2-38).
bar.
98888-0000-JB3-01 Workholder 2-41

3. Select OK.
Crosshair
Figure 2-38 Workholder Calibration - Heat Block Crosshair Alignment (Left - Rear Corner)
4. Use the mouse and [B2] to position the crosshair on the right front corner of
the heat block (see Figure 2-39).
bar.
6. Select OK.
Crosshair
Figure 2-39 Heat Block Crosshair Alignment (Right - Front Corner)

H. Remove the heat block gauge/insert from the bond site, then select OK (see
Figure 2-40).
Figure 2-40 Workholder Calibration - Remove Heat Block Gauge/Insert
2-42 Workholder 98888-0000-JB3-01

I. Install the rail width gauge between the rails (see Figure 2-41).
PUT THE RAIL WIDTH GAUGE BETWEEN THE RAILS.
Figure 2-41 Workholder Calibration - Install Rail Width Gauge

1. Make sure that the cut-out of the gauge is on the right side, point towards
the Output Magazine Handler Assembly (see Figure 2-42).
Output Magazine
Handler Assembly

Figure 2-42 Workholder Calibration - Install the Rail Width Gauge Position
2. Hold the gauge at 45o angle (rear edge down) and put the rear edge of the
gauge on the rear rail (see Figure 2-43).
3. Without moving the gauge forward, slowly lower the gauge until the front
edge is on the front rail.
4. Make sure that the gauge can move along the rails with small resistance.
5. Select OK.
98888-0000-JB3-01 Workholder 2-43

Gauge at 45o angle
Rear Edge of the Gauge
Front Edge of the Gauge Rear Rail
Front Rail
Figure 2-43 Workholder Calibration - Install the Rail Width Gauge at 45o angle
J. Teach the bond site heat block assembly at rail level (see Figure 2-44):
Figure 2-44 Workholder Calibration - Teach Heat Block Assembly

1. Move the rail width gauge and position it until the bottom surface of the pin,
at the left side of the gauge, is directly above the heat block assembly of
bond site (see Figure 2-45).
2. Use the Up and Down arrow button on the MMI to move the heat block
assembly up until the top surface touches the pin of the rail width gauge.
3. Select OK (see Figure 2-44).
Rail Width Gauge

Pin touches the top surface
of the bond site heat block assembly
Figure 2-45 Workholder Calibration - Pin Touches Bond Site Heat Block Assembly
2-44 Workholder 98888-0000-JB3-01
K. Remove the rail width gauge from the rails, then select OK (see
Figure 2-46).
Figure 2-46 Workholder Calibration - Remove Rail Width Gauge

L. Install the heat block gauge/insert on the bond site heat block assembly, then
select OK (see Figure 2-47).
Figure 2-47 Workholder Calibration - Install Bond Site Heat Block Gauge/Insert
M. Teach the bond height position (see Figure 2-48).
1. Use the mouse to move the bond head position directly above the heat
block gauge/insert at the bond site.
2. Make sure that the capillary is above the solid portion of the heat block
gauge/insert surface shown on the screen.
3. Select OK. The capillary will moves up and down on the heat block gauge/
insert surface.
Figure 2-48 Workholder Calibration - Teach Bond Height Position

N. Remove the heat block gauge/insert from the bond site, then select OK (see
Figure 2-49).
Figure 2-49 Workholder Calibration - Remove Heat Block Gauge/Insert

O. Teach the bond center position:
1. Put workholder setup and calibration gauge assembly between the rails
(see Figure 2-51).
PUT THE WORKHOLDER SETUP AND CALIBRATION GAUGE
ASSEMBLY BETWEEN THE RAILS.
98888-0000-JB3-01 Workholder 2-45

a. Make sure that the index slot of the gauge is on the right side, point
Output Magazine
Handler Assembly
Index slot on the right side.

Figure 2-50 Workholder Calibration - Install the Workholder Setup and Calibration Gauge
Assembly Position
c. Without moving the gauge forward, slowly lower the gauge until it is on
the front rail (see Figure 2-51).
d. Make sure that the gauge moves smoothly along the rails.
Gauge at 45o angle
Front Rail
Rear Rail
Figure 2-51 Workholder Calibration - Install the Workholder Setup and Calibration Gauge
Assembly at 45o angle
2. Move the workholder setup and calibration gauge to the bond site.
3. Make sure the index slot is aligned to the bond center.
4. Install the gauge pedestal on the workholder setup and calibration gauge
(see Figure 2-52).
a. Make sure that the engrave words, “FOCUS BK”, on the gauge pedestal
points to you.
2-46 Workholder 98888-0000-JB3-01

b. Install the gauge pedestal on the right side of the work-
holder setup and calibration gauge.
Workholder Setup and Calibration

Gauge Assembly
Gauge Pedestal
Figure 2-52 Workholder Calibration - Install the Gauge Pedestal

5. Select OK.
6. Do the gauge pedestal focus (see Figure 2-53)
a. Do the gauge pedestal focus by pushing the Up or Down arrow buttons
on the MMI until the gauge pedestal can be seen clearly on the screen.
b. If necessary, adjust the illumination using the F10 button on the function
bar.
c. Select OK..
Figure 2-53 Workholder Calibration - Gauge Pedestal Focus

7. Position the crosshair on the gauge pedestal.
a. Use the mouse and [B2] to position the crosshair on the right side of the
gauge pedestal (see Figure 2-54).
b. Make sure that the crosshair is aligned on the edge of the gauge pedes-
tal top shelf.
c. If necessary, adjust the illumination using the F10 button on the function
bar.
98888-0000-JB3-01 Workholder 2-47

d. Select OK.
Crosshair
Align the crosshair on the edge of the top

shelf at the right side of the gauge pedestal.
Gauge
Pedestal
Figure 2-54 Workholder Calibration - Gauge Pedestal Crosshair Alignment (Right Side)
e. Use the mouse and [B2] to position the crosshair on the right side of the
gauge pedestal (see Figure 2-55).
f. Make sure that the crosshair is aligned on the edge of the gauge pedes-
tal top shelf.
g. If necessary, adjust the illumination using the F10 button on the function
bar.
h. Select OK.
Crosshair
Align the crosshair on the edge of the top

shelf at the right side of the gauge pedestal.
Gauge
Pedestal
Figure 2-55 Workholder Calibration - Gauge Pedestal Crosshair Alignment (Left Side)
P. Remove the gauge pedestal from the workholder calibration and setup gauge,
then select OK (see Figure 2-56).
Figure 2-56 Workholder Calibration - Remove the Gauge Pedestal
2-48 Workholder 98888-0000-JB3-01

Q. Make sure that the input magzine handler area is clear for the
puller to move into.
R. Select OK (see Figure 2-57). The index gripper will move the workholder setup
and calibration gauge assembly to the X sensor, then to bond site center posi-
tion.
Figure 2-57 Workholder Calibration - Puller move into Input Magazine Handler Area
S. Remove the workholder setup and calibration gauge assembly from the bond
site, then select OK (see Figure 2-58).
Figure 2-58 Workholder Calibration - Remove the Workholder Setup and Calibration Gauge
Assembly
T. Teach the preheat heat block assembly at rail level (see Figure 2-59):
Figure 2-59 Workholder Calibration - Teach Preheat Heat Block Assembly

1. Install the rail width gauge between the rails (see step I.).
2. Move the rail width gauge and position it until the bottom surface of the pin,
at the left side of the gauge, is directly above the preheat heat block
assembly of preheat assembly (see Figure 2-60).
3. Use the Up and Down arrow button on the MMI to move the heat block
assembly up until the top surface touches the pin of the rail width gauge.
98888-0000-JB3-01 Workholder 2-49

4. Select OK (see Figure 2-59).
Pin touches the top surface

of the preheat heat block assembly
Rail Width Gauge
Preheat Heat Block Assembly
Figure 2-60 Workholder Calibration - Pin Touches Preheat Heat Block Assembly
U. Remove the rail width gauge from the preheat assembly, then select OK (see
Figure 2-61).
Figure 2-61 Workholder Calibration - Remove the Rail Width Gauge

V. Make sure that all calibration gauge removed from the workholder, then select
OK (see Figure 2-62).
Figure 2-62 Workholder Calibration - Remove All Calibration Gauges

W. Install the heat block inserts on the bond site and preheat heat block assem-
bly, if necessary, then select OK (see Figure 2-63).
Figure 2-63 Workholder Calibration - Install Heat Block Inserts

X. Workholder Calibration completes, then select OK (see Figure 2-64).
Figure 2-64 Workholder Calibration - Complete
2-50 Workholder 98888-0000-JB3-01

2.4.2 Heat Block Calibration
The function of this calibration is to teach the bond height position. Bond height is
the vertical position of the bond site heat block gauge/insert when the device
focus is set.
2.4.2.2 Do the Heat Block Calibration
• Workholder Setup Gauge (P/N: 03035-0908-001-XX) (Heat Block Gauge)
• Heat Block Inserts (P-part)
Procedure
WARNING: DO NOT TOUCH THE HEAT BLOCK OR INSERTS WITH UNPRO-

TECTED HANDS IF THE WORKHOLDER HEATERS ARE AT OPERAT-
ING TEMPERATURE. WHEN REMOVING THE HEAT BLOCKS OR
INSERTS, INSTALL A SCREW AT THE REAR EDGE OF THE HEAT
BLOCK/INSERT AND GRASP THE SCREW WITH PLIERS. THERE IS
ONE M4 TAPPED HOLE IN THE HEAT BLOCK/INSERT FOR THIS PUR-
POSE.

C. Select [2] HEAT BLOCK from the Workholder menu.
D. Make sure that the correct heat block gauge/insert is installed on the bond site
heat block assembly, then select OK (see Figure 2-65).
Figure 2-65 Heat Block Calibration - Install Bond Site Heat Block Gauges/Inserts
E. Use the mouse and [B2] to move the bond head until the heat block gauge/
insert on the bond site appears on the screen.
F. If necessary, adjust the illumination using the F10 button on the function bar.
G. Continue to move the bond head until the bond tool is above a solid portion of
the heat block gauge/insert (see Figure 2-66).
H. Select OK. The head block assembly moves up and the bond tool (capillary)
touches the heat block gauge/insert.
Figure 2-66 Heat Block Calibration - Move Bond Head
98888-0000-JB3-01 Workholder 2-51

I. Remove the heat block gauge from the bond site (see Figure 2-67).
Figure 2-67 Heat Block Calibration - Remove the Heat Block Gauge
J. Heat block calibration completes, then select OK (see Figure 2-68).
Figure 2-68 Heat Block Calibration - Complete

2.4.3 Tucker Eject Calibration
The tucker eject calibration calculates the distance from the indexer/tucker home
position to the position where the end of the tucker pin is aligned with the outer
surface of the Output Magazine Handler side wall. This calibration is necessary
only when the tucker is replaced.
2.4.3.2 Do the Tucker Eject Calibration

• Ruler
Procedure
C. Select [3] TUCKER EJECT from the Workholder menu.
WARNING: THE OUTPUT MAGAZINE MAY BE EJECTED AS PART OF THE

TUCKER CALIBRATION. KEEP HANDS AWAY FROM THE OUTPUT
MAGAZINE HANDLER.
D. Keep hands away from the Output Magazine Handler. The output magazine (if
the gripper holds the magazine) will eject before the calibration start, then
select OK (see Figure 2-69).
Figure 2-69 Tucker Eject Calibration - Warning
2-52 Workholder 98888-0000-JB3-01

E. Do the calibration (see Figure 2-70):
Figure 2-70 Tucker Eject Calibration - Align the Tucker

1. Use the Left and Right arrow key on the MMI to move the tucker until the tip
extends 1/16 inches through the opening of the Output Magazine Handler
wall (see Figure 2-71).
2. Select OK. The tucker moves to home position.
Output Magazine Handler Wall Tip extends 1/16 inches through the
opening of wall
Tucker
Figure 2-71 Tucker Eject Calibration - Tucker Tip Extends 1/16 inches
2.4.4 Workholder Calibrations
Selecting [4] WORKHOLDER CALIBRATIONS from the ‘Workholder’ menu displays a
dialog box containing the results of all the workholder calibrations. All of the items
in the dialog box are for viewing purposes only and cannot be changed by the
user.
98888-0000-JB3-01 Workholder 2-53

2.5 Workholder Configuration

The workholder is configured in the Workholder Configuration menu. Each item in
the menu displays a dialog box that contains parameters related to the opera-
tional characteristics of the workholder components.
To access the Workholder Configuration menu (see Figure 2-72), select [4]CON-
FIGURE from the mode bar then select [5] WORKHOLDER from the Configure mode
menu. The dialog box for each item is opened when the item is selected from the
menu by the mouse or the number of the specified item is selected on the key-
board. When the specified dimensions, parameters, or options have been config-
ured, the user can select APPLY, DONE, or CANCEL.
• Select APPLY to write the settings to the software and the dialog box remains
open.
• Select DONE to write the settings to the software and close the dialog box.
• Select CANCEL to close the dialog box and ignore the changes made.
To close the Workholder Configuration menu, push the [ESC] button on the key-
board when necessary.
Boat/device dimensions and indexing parameters are specified in the paragraphs
that follow. For information on magazine dimensions and parameters refer to Sec-
tion 3 of this manual.
Figure 2-72 Workholder Configuration Menu
2-54 Workholder 98888-0000-JB3-01

2.5.1 Boat/Device Dimensions
Select [1] DEVICE PARAMETERS from the Workholder Configuration menu (see
Figure 2-73). The "Boat/Device Dimensions" dialog box appears. It contains the
boat dimensions, device dimension and bond plane offset adjustment parame-
ters.
Enter the boat and device dimensions to prepare a bond program for a new type
of boat and to adjust the bond plane offset.
Figure 2-73 Boat/Device Parameters Dialog Box

2.5.1.1 Boat Dimensions
The boat dimension parameters in the ‘Boat/Device Parameters’ dialog box are
given below (see Figure 2-74):
• DEVICE PITCH
Device Pitch is the measurement from the center of one device (center of the
index hole marking) to the center of the next device (center of the next index
hole marking) to be indexed. It is the distance the index assembly moves
during each index cycle. The J Boat MHS supports a device pitch from 0.25
inch (6.4 mm) to 6.0 inches (152.4 mm).
• BOAT WIDTH
Boat Width is the measurement from the front edge of the boat to the rear
edge of the boat. The J Boat MHS supports boat widths from 3.1 inches (78.7
mm) to 4.3 inches (109.2 mm).
• INDEXES PER BOAT
Indexes per Boat is the total number of the index operations necessary to
move the boat through the bond site.
• RIGHT CENTER OFFSET
Right Center Offset is the distance measured from the right edge of the boat to
the center of the first right-most device.
• LEFT CENTER OFFSET
Left Center Offset is the distance measured from the left edge of the boat to
the center of the first left-most device.
• Y FRONT CENTER OFFSET
Y Front Center Offset is the distance from the front edge of the boat to the cen-
ter of a device.
98888-0000-JB3-01 Workholder 2-55

• HOLE PITCH
Hole Pitch is the distance measured between the centers of two adjacent
index holes. IConn Ball Bonder software supports an index hole pitch of 0.5,
0.6, 0.75, 1.0, and 1.5 inches (12.7, 15.2, 19, 25.4, and 38.1 mm).
LEFT RIGHT
CENTER CENTER
OFFSET OFFSET
BOAT
WIDTH DEVICE DEVICE DEVICE DEVICE
Y FRONT
CENTER
OFFSET
DEVICE PITCH HOLE

PITCH
Figure 2-74 Boat Dimensions

• CAVITY DOWN SET
Cavity Down Set is the distance measured from the top surface of the boat to
the surface of the boat on which the device is on the edge of the boat. (see
Figure 2-76).
• HOLE ON BOAT END
• Hole On Boat End is the index hole at the end of the boat. It should be set to
‘True’ if it is machined to represent part of the size of the index hole. For condi-
tions other than this, the parameter must be set to "False" (see Figure 2-75).
TRUE CONDITION FALSE CONDITION
Figure 2-75 Hole On Boat End Conditions

2.5.1.2 Device Dimensions
The device dimension parameters in the ‘Boat/Device Parameters’ dialog box are
given below (see Figure 2-76):
• BOND PLANE HEIGHT
Bond Plane Height is the distance measured from the center bond plane of the
device to the heat surface of the device.
• VACUUM HEIGHT
Vacuum Height is the distance measured from the surface of the device that is
on the boat to the heat surface of the device.
• LOWER EXTENSION
Lower Extension is the distance measured from the heat surface of the device
to the bottom of the device.
• DEVICES PER INDEX
"Device Per Index" specified the number of devices that are moved up by the
heat block for bonding during each index cycle.
2-56 Workholder 98888-0000-JB3-01

BOND PLANE HEIGHT

BOAT CAVITY DEVICE
DOWN SET
VACUUM HEIGHT
HEAT SURFACE
BOAT LOWER EXTENSION
Figure 2-76 Device Dimensions

2.5.1.3 Bond Plane Offset
The Bond Plane Offset adjustment sets the heat block height. It is the value
entered in this parameter, which is offset (+/- 50 mils) from the calibrated height of
the heat block. This offset is added to the heat block default value set under ‘Heat
Block Utilities’.
2.5.2 Indexing Parameters

Select [2] INDEXING PARAMETERS from the Workholder Configuration menu (see
Figure 2-77). The "Indexing Parameters" dialog box appears. It allows the user to
enter the parameters that is related to the indexing operation.
Figure 2-77 Index Parameters Dialog Box

The indexing parameters are given below:
• MAXIMUM SLOT COUNT
Maximum Slot Count keeps the count of empty slots that have been detected
in the input magazine. It should be set to the maximum number of consecutive
empty boat slots allowed for the input magazine during the process program.
For process programs, a fully occupied input magazine is required, it should
be set to zero. This will cause the machine to stop as soon as an empty input
slot is encountered.
98888-0000-JB3-01 Workholder 2-57

• MAXIMUM NO VAC COUNT
Maximum No Vac Count determines the maximum number of devices that are
allowed to be skipped as a recovery action for a missing vacuum before an
error is indicated. If no vacuum is detected at the bond site heat block, a "Miss-
ing Vacuum Recovery" dialog box is displayed. This dialog box gives the user
several options, including the option to skip the present device at the bond
site and resume the process.
• BOAT 1ST INDEX DELAY
User-specified delay to allow for device thermal expansion prior to bonding
alignment. Sets the delay time between securing the material at the bond site
and the subsequent align/bond cycle. The delay is applied to the first index of
every boat no matter what type of index used (i.e., Index key, Auto index, dry
cycle index).
• BOAT 2ND+ INDEX DELAY
Same as the Boat 1st Index Delay parameter except that this delay is applied
to subsequent indexes of every boat (i.e., all indexes of the boat after the first
index of that boat).
• MIN PREHEAT TIME
Min Preheat Time is the minimum amount of time the device is to remain over
the preheat block before being indexed to the bond site heat block.
• MAX PREHEAT TIME
Max Preheat Time is the maximum amount of time the device is to remain
over the preheat block before being indexed to the bond site heat block. This-
parameter works in conjunction with the Check Device Overheat parameter in
the "Workholder Configuration" dialog box.
• PREHEAT LIFT
Preheat Lift defines how high the preheat block raises a device above the
boat surface on which it rests. This parameter must be set to a value to have
the device lifted high enough so that it is not touching the boat. However,
since the preheat block does not incorporate a device holding mechanism
(vacuum), this parameter should not be set to a height that would cause the
device to slip out of its nest on the boat. Therefore, it is boat dependent.
• PREHEAT THICKNESS
Set the vertical distance between the top and bottom surfaces of the preheat
heat block insert.
• HEAT BLOCK THICKNESS
Set the vertical distance between the top and bottom surfaces of the bond site
heat block insert.
• RAIL HEIGHT
Set the rail height relative to the preheat and bond site heat block height for
the different type of carrier that will be processed. The applicable spacers are
installed to the indexer assembly to adjust the rail height.
• PREHEAT DELAY TIME
The Preheat Delay Time prevents the device from over-heated before bond-
ing. Sets the delay time before the puller starts to inject the next device to the
bond site.
2-58 Workholder 98888-0000-JB3-01

2.5.3 Indexing Options
Indexing Options allow the user to enable or disable the "Count Empty Slot"
parameter. The "Index Options" dialog box is displayed by selecting [3] INDEXING
OPTIONS from the Workholder Configuration menu (see Figure 2-78).
Figure 2-78 Indexing Options Dialog Box

The indexing options parameters are given below:
• COUNT EMPTY INPUT SLOT
Count Empty Input Slot stops the machine if it is enabled and if an input maga-
zine slot is empty. If slots are to be skipped in the input magazine, the Slots/
Step parameter from the "Input Magazine Slot Order" and the "Output Maga-
zine Slot Order" dialog boxes should be used in order to keep the bonder exe-
cuting the process program (refer to Section 3).
• COUNT NO VAC SLOT
This parameter, when set to "Yes", works in conjunction with the "Check Heat
Block Vacuum" setting in the Workholder Configuration dialog and the "Maxi-
mum No Vacuum Count" setting in the Index Parameters dialog. For example,
if "Check Heat Block Vacuum" is set to "On" and "Maximum No Vacuum
Count" is set for three (3) indexes, the bonder will stop indexing after the third
"skip index" during a "vacuum not present" condition at the heat block as long
as "Count No Vacuum Slot" is set to "Yes".
2.5.4 Workholder Configuration

Workholder Configuration allows the user to set parameters that control the
default cycle times used when carried out the diagnostics on the workholder. It
also allows the user to check for device overheating at the preheat block and a
vacuum-present condition at the bond site heat block.
The Workholder Configuration dialog box is displayed by selecting [3] WORK-
HOLDER CONFIGURATION from the Workholder Configuration menu (see Figure 2-
79.).
Figure 2-79 Workholder Configuration Dialog Box
98888-0000-JB3-01 Workholder 2-59

The Workholder Configuration parameters are given below:
• CHECK DEVICE OVERHEAT
Check Device Overheat can be set to ON or OFF, but should be set to ON
when running a hot process. If running a cold process, it should be set to OFF.
When set to ON, the amount of time that the device is heated at the preheat
block is compared with the Max Preheat Time parameter in the "Index Param-
eters" dialog box. If the device is on the preheat block for a time period longer
than the one specified by "Max Preheat Time" parameter, an alert recovery
dialog box is displayed giving the operator the following options:
• Skip Device (skips device on the preheat block and resume process).
• Ignore Overheat (ignores overheat alert and resumes process).
• Skip Boat (skips boat at preheat block and resumes process with next
boat).
• Abort (re-initializes and removes material)
• CHECK HEAT BLOCK VACUUM
Check Heat Block Vacuum can be set to ON or OFF, but should be set to ON
when running a process program. When set to ON, the presence of vacuum is
verified whenever a device is at the bond site pedestal or heat block. If no
vacuum is detected, a "Missing Vacuum Recovery" dialog box is displayed giv-
ing the operator the following options.
• Skip Device (skips device at bond site heat block and resumes process).
• Check Vacuum Sensor Again (performs a retry using same device).
• Skip Boat (skips boat at heat block and resumes process with next boat).
• Abort (re-initializes and remove material)
• CYCLE DELAYS
Cycle Delays relate directly to the Cycle Period parameters in the dialog boxes
that are used to run component diagnostics under the Diagnostic mode (refer
to IConn Operation Manual). There are cycle delays for puller, indexer, and
heat block diagnostics. When set by the user, each parameter defines the
default value for how much time (pause) there is to be between each cycle
during the execution of that component's diagnostic.
2-60 Workholder 98888-0000-JB3-01

2.6 J Boat Indexer Assembly Removal and Installation
Purpose
• Remove the J boat indexer assembly from the machine. When necessary, use
the following procedure to remove the J boat indexer assembly from the
machine for maintenance.
WARNING: INJURY HAZARD. INCORRECT MAINTENANCE COULD CAUSE

INJURY. DO NOT DO MAINTENANCE UNLESS YOU HAVE COM-
PLETED THE APPROVED MAINTENANCE TRAINING COURSE. READ
THE DATA IN THE SAFETY CHAPTER.
CAUTION: Injury Hazard. The J Boat Indexer Assembly weight approximately 44

pounds (20 Kilograms) . To prevent injury, use approved equipment or
two persons to lift and move the assembly.

• J Boat Indexer Assembly, P/N 03035-0010-000-xx
• Hand Tools
Procedure
A. Remove all material from the workholder.
B. Press [MOTOR STOP] and turn off machine power.

COOLED DOWN.
C. Remove the preheat heat block assembly and bond site heat block assembly.
D. Open the lower console front door.
E. Remove MMI assembly from the machine.
1. Make sure that the electrical cables to the MMI assembly are correctly
identified. If not, make a note of the connection.
2. Remove all the cable ties and open the cable clamps if necessary to
release the cables. Make a note of the cable routing and cable clamps
positions.
3. Disconnect the following cables connectors at the rear of the MMI assem-
bly:
• USB1 cable from the matrox box
• USB2 cable from the matrox box
• MMI cable from wire feed/ bits board
4. Remove two (2) x M4 shoulder screws with flat nylon washers and wave
washers at the bottom of the lower console top plate that attach the MMI
onto the lower console top plate.
5. Lift up the MMI Assembly and remove it from the machine.
F. Remove the microscope assembly:
1. Loosen the M6 screw on the left side of the indexer base that holds the
microscope stand.
2. Remove the microscope with the stand from the J boat indexer assembly.
G. Loosen the two captive screws that attach the PCB cover to the indexer base.
H. Remove the PCB cover to access the indexer intermediate board.
98888-0000-JB3-01 Workholder 2-61

I. Remove the input tray assembly:
CAUTION: Injury Hazard. The Input Tray Assembly weight approximately 17.64
pounds (8 Kilograms). To prevent injury, use approved equipment or
one to two persons to lift and move the assembly.
1. Make sure that the electrical cables to the input tray assembly are correctly
positions.
3. Disconnect the in/out tray cable connector from the connector J14 of the
indexer intermediate board.
4. Loosen the four (4) M6 captive screws that attach the input tray assembly
to the input base plate and machine top plate.
5. Remove the input tray assembly from the machine.
J. Remove the output tray assembly:
CAUTION: Injury Hazard. The Output Tray Assembly weight approximately 17.64
1. Make sure that the electrical cables to the output tray assembly are cor-
rectly identified. If not, make a note of the connection.
positions.
3. Disconnect the in/out tray cable connector from the connector J15 of the
to the input base plate and machine top plate.
5. Remove the output tray assembly from the machine.
K. Remove the three (3) M4 screws and washers that attach the indexer cover
assembly to the J boat indexer assembly.
L. Remove the indexer cover assembly.
M. Remove the J boat indexer assembly from the machine (see Figure 2-80 and
Figure 2-81).
1. Make sure that the electrical cables to the indexer assembly are correctly
positions.
3. Remove the input and output present sensor brackets:
a. Loosen the M3 set screw in the present sensor bracket that attach the
present sensor.
b. Remove the present sensor from the bracket.
c. Remove the M3 screw each at the two ends of the rear rail assembly
that attach the present sensor bracket.
d. Remove the present sensor brackets.
2-62 Workholder 98888-0000-JB3-01

4. Disconnect the following cables from the indexer intermediate
board. Refer to Appendix B on the MHS cable routing for details.:
• MHS Sensor Bus Cable P/N 08888-1082-000-17 to board connector J2
• Indexer DMHS Cable P/N 08888-1250-000-xx to board connector J1
• Solenoid Cable P/N 08888-1251-000-xx to board connector J6
5. Disconnect the following cables from the interface panel at the right side of
the XY table assembly, attach to the Upper Console. Refer to Appendix B
on the MHS cable routing for details.:
• Preheat Heater Assembly P/N 03118-0333-000-00
• Preheat Thermocouple Assembly P/N 03118-1004-000-19
release the preheat heater and thermocouple cables on the slider assem-
bly. Make a note of the cable routing and cable clamps positions.
7. Use the T-handle wrench supplied in the tool kit (P/N: 08888-0901-000-xx)
to remove the four (4) M6 screws and washers from the indexer base.
8. Hold the left and right side of the front wall and lift up the J boat indexer
assembly from the lower console top plate (see CAUTION).
Input Tray Assembly ‘C’ Plates
Present Sensor Brackets

(see Figure 2-81) Output Magazine Handler
(Not shown here)
4x M6 Screws
and Washers
Integrated Table
Lifting
Support
Handler
J Boat Lifting Support

Indexer J Boat
Handler
Assembly Slider Assembly
Figure 2-80 Remove/Replace J Boat Indexer Assembly

98888-0000-JB3-01 Workholder 2-63
M3 Screw M3 Set Screw

M3 Set Screw M3 Screw Input Present Sensor
Input Present
Sensor Bracket
Input Present Sensor
Rear Rail Assembly

Output Present
Sensor Bracket
Notch on J boat slider

base for indexer pin
4x Threaded holes
Indexer pin engages to the notch
on the slider base
Figure 2-81 Remove/Replace J Boat Indexer Assembly
N. Install the J boat indexer assembly (see Figure 2-80 and Figure 2-81).
1. You must have the aid of at least two persons to hold the J boat indexer
assembly at the left and right side of the front wall, and put on the machine
top plate. (See CAUTION.)

2. Make sure that the rear of the J boat indexer assembly points to the front of
the slider assembly.
3. Move the rear of J boat indexer assembly to the front of the slider assembly
until the benching pin is engaged to the notch on the slider base.
4. Install the J boat indexer assembly to the lower console top plate with the
screws and washers removed before with the T-handle wrench.
5. Torque the screws to 70 in.lb (7.9 Nm).
6. Install the input and output present sensor brackets to the two ends of the
rear rail assembly with the screw removed before.
7. Install the present sensors to the sensor brackets and tighten the set-
screws.
2-64 Workholder 98888-0000-JB3-01

8. Connect the electrical cables to the indexer intermediate
board. Refer to your notes.
9. Connect the preheat heater cable and thermocouple cables connectors to
the interface panel. Refer to your notes.
10.Attach the electrical cables with cable ties and cable clamps to the J boat
indexer assembly and slider assembly. Refer to your notes.
11. Attach the indexer cover assembly to the J boat indexer assembly with the
screws and washers removed before.
12.Install the microscope assembly to the left side of the indexer base and
tighten the screw loosen before.
O. Install the input tray assembly (see CAUTION).
1. Put the input tray assembly on the front edge of the input base plate.
2. Attach the input tray assembly to the input base plate with the captive
screws removed before.
3. Make sure the ‘C’ plates on the input wall and the input fixed wall interlock
each other.
4. Connect the in/out tray cable connecor to the connector J14 of the indexer
intermediate board. Refer to your notes.
5. Attach the electrical cables with cable ties and cable clamps to the input
tray assembly and indexer assembly. Refer to your notes.
P. Install the output tray assembly (see CAUTION).
1. Put the output tray assembly on the front edge of the output base plate.
2. Attach the output tray assembly to the output base plate with the captive
3. Make sure the ‘C’ plates on the output wall and the output fixed wall inter-
lock each other.
4. Connect the in/out tray cable connecor to the connector J15 of the indexer
intermediate board. Refer to your notes.
Q. Install the PCB cover to the indexer base and tighten the two captive screws.
R. Install the MMI Assembly on the machine.
1. Put the MMI assembly on the front edge of the lower console top plate.
2. Pull the electrical cables for the MMI assembly below and through the
opening on the lower console top plate. Refer to your notes.
3. Connect the cables to the MMI assembly. Refer to your notes.
4. Install, but do not tighten the two (2) shoulders screws with flat washers
and wave washers below the lower console top plate to attach the MMI
assembly.
5. Move the MMI assembly to the front of the J boat indexer assembly.
6. Tighten the screws to attach the MMI assembly to the lower console top
plate.
S. Close the lower console front door.
T. Install the preheat heat block assembly to the preheat assembly.
U. Install the bond site heat block assembly to the slider assembly.
98888-0000-JB3-01 Workholder 2-65

2.7 J Boat Slider Assembly Removal and Installation

Purpose
• Remove the J boat slider assembly from the machine. When necessary, use
the following procedure to remove the J boat slider assembly from the
machine for maintenance.
WARNING: INJURY HAZARD. INCORRECT MAINTENANCE COULD CAUSE

INJURY. DO NOT DO MAINTENANCE UNLESS YOU HAVE COM-
PLETED THE APPROVED MAINTENANCE TRAINING COURSE. READ
THE DATA IN THE SAFETY CHAPTER.
CAUTION: Injury Hazard. The J Boat Slider Assembly weight approximately 22


• J Boat Slider Assembly, P/N 03035-0040-000-xx
• Hand Tools
Procedure

COOLED DOWN.
C. Remove the input tray assembly from the machine. Refer to paragraph 2.6,
step I..
D. Remove the output tray assembly from the machine. Refer to paragraph 2.6,
step J..
CAUTION: Injury Hazard. The Output Tray Assembly weight approximately 17.64
E. Remove the J boat indexer assembly from the machine. Refer to paragraph
2.6.

F. Remove the J boat slider assembly from the machine. (See Figure 2-82).
1. Make sure that the electrical cables to the J boat slider assembly are cor-
positions.
2-66 Workholder 98888-0000-JB3-01

3. Disconnect the following cables connectors and vacuum tubing
from the interface panel. Refer to Appendix B on the MHS cable routing for
details.
• Heat Block Sensor P/N 03411-1031-001-17
• Heat Block Motor Assembly P/N 08888-1101-000-xx
• Heat Block Heater Assembly P/N 03118-0333-000-01
• Heat Block Thermocouple Assembly P/N 03118-1004-000-20
• Clamp Ground Wire Cable P/N 08888-1064-000-xx
• Vacuum Tubing
4. Remove the cables and vacuum hose from the slider routing bracket attach
to the integrated table assembly.
5. Disconnect the vacuum valve hose from the fitting on the rear right edge of
the J boat slider assembly.
6. Remove the two (2) M6 screws and washers on the left and right side of
the J boat slider assembly that attach the assembly to the integrated table
assembly.
7. Use the T-handle wrench supplied in the tool kit (P/N: 08888-0901-000-xx)
to remove the four (4) M6 screws and washers at the front and rear of the
slider base.
8. Hold the left and right side of the slider base and lift up the J boat slider
assembly from the machine top plate. (See CAUTION.) .
CAUTION: Injury Hazard. The J Boat Slider Assembly weight approximately 22

G. Install the J boat slider assembly (See Figure 2-82)

1. You must have the aid of at least two persons to hold the J boat slider
assembly at the left and right side of the slider base, and put on the
machine top plate. (See CAUTION.)
2. Make sure that the rear of the J boat slider assembly points to the front of
the integrated table assembly.
3. Move the rear of J boat slider assembly to the front of the integrated table
assembly.
4. Make sure that the three surfaces on the slider base touches the surfaces
at the front of the integrated table base.
5. Install the J boat slider assembly to the machine top plate and front of inte-
grated table assembly with the screws and washers removed before with
the T-handle wrench.
6. Torque the screws to 70 in.lb (7.9 Nm).
7. Connect the electrical cables and vacuum tubing to the interface panel.
Refer to your notes.
8. Attach the electrical cables with cable ties and cable clamps to the J boat
slider assembly. Refer to your notes.
9. Put the electrical cables and tubing through the slider routing bracket.
10.At the rear right edge of the J boat slider assembly, connect the vacuum
valve tubing to the elbow fitting.
H. Install the J boat indexer assembly to the machine. Refer to paragraph 2.6.
98888-0000-JB3-01 Workholder 2-67


I. Install the input tray assembly (see paragraph 2.6, step O.).
J. Install the output tray assembly (see paragraph 2.6, step P.)
4x M6 Screws and Washers Benching Surfaces
See detail below Integrated Table
Slider Assembly
Lifting Support
2x M6 Screws
and Washers Lifting Support
Surfaces on the Integrated table base touch

the surfaces on the Slider Base
Left Threaded holes Right Threaded holes
Surfaces on the Slider base touch

the surfaces on the Integrated Table Base 4x Threaded holes
Figure 2-82 Remove/Replace J Boat Slider Assembly
2-68 Workholder 98888-0000-JB3-01
2.8 Preventive Maintenance
A preventive maintenance schedule for the workholder subsystem is provided in
Table 2-2.
WARNING: REMOVE POWER FROM THE MACHINE BEFORE CHECKING THE

SECURITY AND INTEGRITY OF THE WORKHOLDER ELECTRICAL
CONNECTIONS. MAKE SURE ALL HEATING SURFACES HAVE
COOLED BEFORE PROCEEDING.

TIGHTNESS OF THE WORKHOLDER ATTACHING HARDWARE AND
INSPECTING THE PNEUMATIC LINES. MAKE SURE ALL HEATING
SURFACES HAVE COOLED BEFORE PROCEEDING.
Table 2-2 Workholder Preventive Maintenance Schedule

Action Period Tools Procedure
Clean heat block 8 hours Vacuum Hose Remove any dirt or contaminates from
the preheat and bond site heat block
area.
Clean workholder and 40 hours Vacuum Hose Remove any dirt or contaminates from
magazine handlers exposed and moving parts of the work-
holder.
Lubricate puller drive 1000 hours Lubriplate #630-2 P/N: Apply thin coat of Lubriplate to rack
rack on workholder 39086-6004-000 teeth, making sure that all teeth are com-
pletely filled. Remove excess lubricant
from top of rack and around rack when
done.
Replace heat block vac- 1000 hours 1. Hand tools 1. Replace the vacuum hose between
uum hose 2. Silicone Tubing, 9” the rear of the heat block and the heat
long, P/N sink.
82719-3000-000 2. Make sure that there are no leaks or
kinks in the hose before resuming pro-
duction.
Check hardware tight- 1000 hours Hand Tools Make sure all attaching hardware
ness (screws, washers, nuts, etc.) are
securely installed.
Inspect electrical 1000 hours — Check for security and integrity of all
connections electrical connections on the workholder.
Refer to Section 4 for connector loca-
tions.
Inspect pneumatic lines 1000 hours — Check for cracks, cuts, leaks, pinching or
kinks. Also check for loose fittings or
signs of stretching or wear. Correct as
required. See Section 4 for connections.
98888-0000-JB3-01 Workholder 2-69

Lubricate X-slide 3 months to 6 1. Lubricant (10 ml, in 1. Push the [Motor Stop] button.
bearing on the indexer months syringe), P/N: 2. Remove the indexer assembly front
assembly 27790-5020-000 cover.
2. Lint-Free Cloth 3. Move the gripper assembly to the left
3. Hand gloves or right side manually when necces-
4. Cotton buds sary.
5. Hex Wrench Set
4. Clean the v-grooves of the X-slide
bearing on the front wall using the lint-
free cloth.
5. Apply about 0.1 ml to 0.2 ml of the
lubricant to the top and bottom of the
v-grooves of the X slide bearings.
6. Move the puller assembly and index
assembly along the X-slide bearing
manually for 10 times.
7. Do steps 5 to 6 again for four times.
8. Remove the unwanted lubricant from
the X-slide bearing with the lint-free
cloth.
2-70 Workholder 98888-0000-JB3-01

2.9 Parts Replacement Procedures
2.9.1 Bond Site/Preheat Heat Block Assembly Parts
2.9.1.1 Compression Spring
Purpose
• Replace the compression spring on the bond site or preheat heat block
assembly.
• Compression Spring, P/N: 63543-1229-036
• Hand Tool
Procedure
WARNING: IF THE WORKHOLDER IS HEATED, AVOID TOUCHING HEATED
PARTS WHEN REMOVING PARTS OR MATERIAL (CARRIERS AND
HEAT BLOCK INSERTS OR WHEN PERFORMING OTHER OPERA-
TIONS. WAIT FOR HEATERS TO COOL.

B. Press [MOTOR STOP]. Turn off machine power.
C. Remove the heat block gauge or inserts (see section 1).
D. Remove the heat block assembly:
1. Make sure that the electrical cables to the heat block assembly are cor-
2. Disconnect the heater and thermocouple cable connectors from the inter-
face panel.
positions.
4. Remove the applicable ground strap/wire on the bond site (see step a.) or
preheat (see b.) heat block assembly:
a. At the left side of the bond site heat block assembly, loosen the M2.5
screw and pull out the metal jacket of the ground strap.
b. At the front of the preheat heat block assembly, remove the M2.5 screw
then remove the ground wire terminal.
5. Remove the four (4) M3 screws and washers that attach the heat block
assembly to the preheat or bond site assembly.
6. Remove the heat block assembly and put it on a work bench.
E. Remove the compression spring (see Figure 2-83):
1. Hold the lock pin and latch bar that are attach to the heat block assembly.
2. Remove the two (2) M3 flat head screws.
3. Remove the lock pin, the latch bar and the compression spring.
4. Discard the compression spring.
F. Install the replacement compression spring (see Figure 2-83):
1. Install the spring into the hole at the front of the heat block assembly.
2. Install the latch bar to the front of the heat block assembly. Make sure that
the ledge is at the top and points to the rear of the heat block assembly.
3. Hold the latch bar in position against the front of the heat block assembly.
Make sure that the ledge is on the pin on the top of the heat block assem-
bly.
98888-0000-JB3-01 Workholder 2-71

4. Align the front surface of the latch bar with the front surface of the heat
block assembly, while the spring is compressed.
5. Position the center of the lock pin to the groove in the latch bar.
6. Torque the flat screws removed before to 6 in.Ibs (0.68 Nm).
Heat Block Assembly
Compression Spring
Lock Pin
Latch Bar
2x M3 Flat Head Screws
Figure 2-83 Compression Spring

G. Install the heat block assembly:
1. Put the heat block assembly on the preheat or bond site.
2. Install the heat block assembly to the preheat or bond site with the screws
and washers removed before. Tighten the screws.
3. Connect the electrical cables to the interface panel. Refer to your notes.
4. Attach the electrical cables with cable ties and cable clamps to the work-
holder. Refer to your notes.
5. Install the ground strap/wire to the applicable preheat or bond site heat
block assembly with the screw removed before .
H. Install the heat block gauge or inserts removed before to the heat block
assembly (see section 1).
I. Push the green machine ON switch.
J. Select OK to start initialization.
K. Do the setup and calibration procedures (see paragragphs 2.3 and 2.4).
2-72 Workholder 98888-0000-JB3-01

2.9.1.2 Preheat Heater Assembly
Purpose
• Replace the heater assembly in the preheat heat block assembly. This assem-
bly contains a heating element that heats the preheat area up to a temperature
set during configuration.
• Heater Assembly, 03118-0333-000-00
• Hand Tool
Procedure
HEAT BLOCK INSERTS) OR WHEN PERFORMING OTHER OPERA-

D. Remove the preheat heat block assembly:
2. Disconnect the preheat heater and thermocouple cable connectors from
the interface panel.
positions.
4. At the front of the preheat heat block assembly, remove the M2.5 screw
5. Remove the four (4) M3 screws and washers that attach the preheat heat
block assembly to the preheat assembly.
6. Remove the preheat heat block assembly and put it on a work bench.
E. Remove the heater element assembly (see Figure 2-84):
1. Loosen the heater element set screws at the top rear surface of the heat
block assembly.
2. At the front of the heat block assembly, pull out the heater element assem-
bly and discard.
F. Install the replacement heater element assembly (see Figure 2-84):
1. Install the new heater element assembly into the bore at the front of the
98888-0000-JB3-01 Workholder 2-73

2. At the top rear surface of the heat block assembly, carefully tighten the
heater element set screws until it is engaged to the heater elements.
Thermocouple
Heater Element Set Screw Set Screw
Preheat Heat Block Assembly Preheat Thermocouple
Preheat Heater Assembly

Heater Element
Set Screw
Figure 2-84 Preheat Heater and Thermocouple Assemblies

G. Install the preheat heat block assembly:
1. Put the heat block assembly on the preheat assembly.
2. Install the heat block assembly to the preheat assembly with the screws
5. Install the ground wire to the front of the preheat heat block assembly with
the screw removed before.
H. Install the heat block gauge or inserts removed before to the preheat heat
block assembly (see section 1).
2-74 Workholder 98888-0000-JB3-01

2.9.1.3 Preheat Thermocouple Assembly
Purpose
• Replace the thermocouple assembly in the preheat heat block assembly. This
assembly monitors the temperature of the heater cartridge.
• Thermocouple Assembly, P/N: 03118-1004-000-19
• Hand Tool
Procedure

D. Remove the preheat heat block assembly (see paragraph 2.9.1.2, step D.).
E. Remove the thermocouple assembly (see Figure 2-84):
1. Loosen the thermocouple set screw at the top rear surface of the heat
block assembly.
2. At the rear of the heat block assembly, pull the thermocouple assembly
rearward and discard.
F. Install the replacement thermocouple assembly (see Figure 2-84):
1. Install the new thermocouple assembly into the bore at the rear of the heat
block assembly.
2. At the top rear surface of the heat block assembly, carefully tighten the
thermocouple set screw until it is engaged to the thermocouple.
G. Install the preheat heat block assembly (see paragraph 2.9.1.2, step G.).
H. Install the heat block gauge or inserts removed before to the preheat heat
98888-0000-JB3-01 Workholder 2-75

2.9.1.4 Bond Site Heater Assembly
Purpose
• Replace the heater assembly in the bond site heat block assembly. This
assembly contains a heating element that heats the bond site area up to a
temperature set during configuration.
• Heater Assembly, 03118-0333-000-01
• Hand Tool
Procedure

D. Remove the bond site heat block assembly:
2. Disconnect the bond site heater and thermocouple cable connectors from
positions.
4. At the left rear side of the bond site heat block assembly, loosen the M2.5
5. Remove four M3 screws and washers that attach the bond site heat block
assembly to the bond site heat block assembly.
6. Remove the bond site heat block assembly and put it on a work bench.
E. Remove the heater element assembly (see Figure 2-85):
1. Remove the two M2.5 screws at the bottom rear of the heat block.
2. Remove the cable shield that attach to the rear of the heat block assembly.
3. Loosen the heater element set screws at the front top surface of the heat
block assembly.
4. At the rear of the heat block assembly, pull the heater element assembly
F. Install the replacement heater element assembly (see Figure 2-85):
1. Install the new heater element assembly into the bore at the rear of the
2. At the front top surface of the heat block assembly, carefully tighten the
heater element set screws until it is engaged to the heater elements.
2-76 Workholder 98888-0000-JB3-01

3. Install the cable shield to the rear of the heat block with the
Cable Shield
Bond Site Heater Assembly
Thermocouple Set Screw

2x M2.5 Screws
Bond Site Thermocouple
Heater Element Set Screw

Figure 2-85 Bond Site Heater and Thermocouple Assemblies
G. Install the bond site heat block assembly:
1. Put the heat block assembly on the bond site assembly.
2. Install the heat block assembly to the bond site assembly with the screws
5. Install the ground strap to the left rear side of the bond site heat block
assembly with the screw removed before.
H. Install the heat block gauge or inserts removed before to the bond site heat
98888-0000-JB3-01 Workholder 2-77

2.9.1.5 Bond Site Thermocouple Assembly
Purpose
• Replace the thermocouple assembly in the bond site heat block assembly.
This assembly monitors the temperature of the heater cartridge.
• Thermocouple Assembly, P/N: 03118-1004-000-20
• Hand Tool
Procedure

D. Remove the bond site heat block assembly (see paragraph 2.9.1.4, step D.).
E. Remove the thermocouple assembly (see Figure 2-85):
1. Remove the two M2.5 screws at the rear bottom of the heat block.
2. Remove the cable shield that attach to the rear of the heat block assembly.
3. Loosen the thermocouple set screw at the rear top surface of the heat
block assembly.
4. At the rear of the heat block assembly, pull the thermocouple assembly
F. Install the replacement thermocouple assembly (see Figure 2-85):
1. Install the new thermocouple assembly into the bore at the rear of the heat
block assembly.
2. At the rear top surface of the heat block assembly, carefully tighten the
thermocouple set screw until it is engaged to the thermocouple assembly.
3. Install the cable shield to the rear of the heat block with the screws
removed before.
G. Install the bond site heat block assembly (see paragraph 2.9.1.4, step G.).
H. Install the heat block gauge or inserts removed before to the bond site heat
2-78 Workholder 98888-0000-JB3-01

2.9.1.6 Preheat Heat Block Assembly
Purpose
• Replace the preheat heat block assembly. This assembly increases the tem-
perature of the device before it is at the bond position. It contains the heat
block and the heat block insulator, which are replaced as a set.
• Preheat Heat Block Assembly, P/N: 03035-0063-000-XX
• Hand Tools
Procedure

D. Remove the preheat heat block assembly (see Figure 2-86):
2. Disconnect the preheat heater and thermocouple cable connectors from
positions.
4. At the front of the preheat heat block assembly, remove the M2.5 screw
5. Remove four M3 screws and washers that attach the preheat heat block
assembly to the preheat assembly.
6. Remove the preheat heat block assembly and put it on a work bench.
7. Remove the heater assembly from the preheat heat block assembly (see
paragraph 2.9.1.2).
8. Remove the thermocouple assembly from the preheat heat block assembly
(see paragraph 2.9.1.3).
9. Discard the preheat heat block assembly.
E. Install the replacement preheat heat block assembly (see Figure 2-86):
1. Install the heater assembly to the preheat heat block assembly removed
before.
2. Install the thermocouple assembly to the preheat heat block assembly
removed before.
3. Put the preheat heat block assembly on the preheat assembly.
4. Install the preheat heat block assembly to the preheat assembly with the
screws and washers removed before. Tighten the screws.
7. Install the ground wire to the front of the preheat heat block assembly with
the screw removed before.
F. Install the heat block gauge or inserts removed before to the preheat heat
98888-0000-JB3-01 Workholder 2-79
G. Push the green machine ON switch.
H. Select OK to start initialization.
I. Do the setup and calibration procedures (see paragragphs 2.3 and 2.4).
4x M3 Screws
M3 Washers
Heater Element Set Screw

Thermocouple Set Screw
Heater Element
Set Screw
M2.5 Screws Preheat Thermocouple
Preheat Heat
Preheat Heater Assembly Block Assembly
Ground Wire Terminal

(not shown)
Preheat Assembly
Figure 2-86 Replace Preheat Heat Block Assembly

2.9.1.7 Bond Site Heat Block Assembly
Purpose
Replace the bond site heat block assembly. This assembly heats the devices
while at bond site to the temperature required for bonding. It contains the heat
block, heater assembly, thermocouple assembly, and the heat block insulator.
These parts are replaced as a set but the heater assembly or thermocouple
assembly can be replaced as a single part.

• Bond Site Heat Block Assembly, P/N:03035-0061-000-XX
• Hand Tools
Procedure

D. Remove the bond site heat heat block assembly (see Figure 2-87):
2-80 Workholder 98888-0000-JB3-01

2. Disconnect the bond site heater and thermocouple cable con-
nectors from the interface panel.
positions.
4. At the left rear side of the bond site heat block assembly, loosen the M2.5
5. Remove four M3 screws and washers that attach the bond site heat block
assembly to the bond site heat block assembly.
6. Remove the bond site heat block assembly from the bond site and discard
it.
E. Install the replacement bond site heat block assembly (see Figure 2-87):
1. Put the heat block assembly on the slider assembly.
2. Install the heat block assembly to the slider assembly with the screws and
washers removed before. Tighten the screws.
5. Install the ground strap to the left rear side of the bond site heat block
assembly with the screw removed before.
F. Install the heat block gauge or inserts removed before to the bond site heat
4x M3 Screws
4x Washers
Ground Strap Bond Site Heat Block Assembly
Silder Assembly
Figure 2-87 Replace Bond Site Heat Block Assembly
98888-0000-JB3-01 Workholder 2-81

2.9.1.8 Preheat Motor
Purpose
• Replace the preheat motor that moves the preheat assembly in vertical direc-
tion.
• Preheat Motor, P/N 13565-6043-001
• Hand tools
Procedure

D. Remove the indexer assembly (see paragraph 2.6).
E. Remove the preheat assembly (see Figure 2-88):
1. Make sure that the electrical cables to the preheat assembly are correctly
2. Loosen two captive screws that attach the PCB cover to the indexer base.
3. Remove the PCB cover to access the indexer intermediate board.
4. Disconnect the preheat motor home sensor connector J10 from the indexer
board.
5. At the rear of the preheat assembly, disconnect the preheat motor cable
from the motor. Make a note of the connection.
positions.
7. Remove two M5 screws that attach the preheat base to the front of the
indexer base.
8. Remove the preheat assembly from the rear of the workholder.
9. Put the preheat assembly on the work bench.
2-82 Workholder 98888-0000-JB3-01

Preheat Assembly
Preheat Base
2x M5 Screws
PCB Cover
Indexer Base
2x Captive Screws
Figure 2-88 Remove Preheat Assembly (Front View)

F. Remove the preheat motor (see Figure 2-89):
1. Get access to the preheat motor from the rear side of the preheat assem-
bly.
2. Remove the four M4 screws that attach the motor to the rear of the preheat
base.
3. Remove the motor with the cam and preheat home sensor.
4. Loosen two set screws that attach the cam to the motor shaft.
5. Remove the motor and discard.
G. Install the replacement preheat motor (see Figure 2-89):
1. Install the cam to the preheat motor with the set screws removed before.
2. Install the preheat motor with the cam and preheat home sensor to the pre-
heat base with the screws removed before.
3. Take note of the preheat home sensor when you install the motor. Make
sure that the home sensor is correctly installed at the bottom right of the
preheat base.
H. Install the preheat assembly (see Figure 2-88):
1. Position the preheat assembly on the left side of the indexer base.
2. Install the preheat assembly to the indexer base with the screws removed
before.
3. Connect the preheat home sensor cable to the connector J10 on the
indexer intermediate board. Refer to your notes.
4. Connect the prehest motor cable connector to the preheat motor. Refer to
your notes.
98888-0000-JB3-01 Workholder 2-83

5. Attach the cables with cable ties and cable clamps to the workholder. Refer
to your notes.
I. Install the indexer assembly to the machine (see paragraph 2.6).
J. Install the heat block gauge or inserts removed before to the preheat heat
K. Push the green machine ON switch.
L. Select OK to start initialization.
M. Do the setup and calibration procedures (see paragragphs 2.3 and 2.4).
2x Set Screws
Preheat Motor
Preheat Base
4x M4 Screws
Preheat Home Sensor Cam
Figure 2-89 Replace Preheat Motor - Exploded Rear View
2-84 Workholder 98888-0000-JB3-01

2.9.1.9 Bond Site Motor
Purpose
• Replace the bond site motor that moves the heat block assembly vertically.
• Hand tools
• Heat Block Motor Assembly, P/N 08888-1101-000-xx
Procedure (Figure 2-90).
TIONS.

E. Remove the slider assembly (see paragraph 2.7).
F. Remove the bond site motor from the slider assembly (see Figure 2-90):
1. Get access to the bond site motor from the rear side of the slider assembly.
2. Hold the motor and remove the four M4 screws with flat washers that
attach the motor to the rear of the slider assembly.
3. Remove the motor with motor coupling from the slider assembly.
4. Loosen the two set screws that attach the motor coupling to the motor
shaft.
5. Remove the motor coupling from the motor shaft.
G. Install the replacement bond site motor (see Figure 2-90):
1. Install the motor coupling to the motor shaft:
a. Make sure the motor coupling end is flush with the motor shaft end.
b. Make sure that the set screws are on the flat cutouts of the motor shaft.
c. Tighten the two (2) setscrews in the motor coupling.
2. Position the motor with the motor cable connector points downward.
3. Make sure the pins on the motor coupling are aligned to the holes on the
heat block coupling.
98888-0000-JB3-01 Workholder 2-85

4. Install the motor with coupling to the slider assembly with the screws and
flat washers removed before.
2x Set Screws
Bond Site Motor
4x Washers
4x M4 Screws
Motor Coupling
Figure 2-90 Replace Bond Site Motor - Exploded Rear View

H. Install the slider assembly back to the machine. Refer to paragraph 2.7, steps
G..
I. Install the indexer assembly to the machine (see paragraph 2.6).
J. Install the heat block gauge or inserts removed before to the preheat heat
K. Push the green machine ON switch.
L. Select OK to start initialization.
M. Do the setup and calibration procedures (see paragragphs 2.3 and 2.4).
2.9.1.10 Preheat Linear Slide Assembly

Procedure
Replace the preheat linear slide assembly. This assembly moves the preheat heat
block assembly in the vertical direction through the preheat motor.

• Preheat Linear Bearing, P/N: 03035-0043-004-xx
• Hand Tools
Procedure
E. Remove the preheat assembly (see paragraph 2.9.1.8, step E.).
F. If the preheat heat block assembly is on the preheat assembly, remove the
four M3 screws and washers, then remove the assembly.
2-86 Workholder 98888-0000-JB3-01

G. Remove the preheat slide assembly (see Figure 2-91):
1. Disengage the two springs at the front of the preheat assembly.
2. Remove the four M3 screws at the front of the preheat assembly.
3. Remove the preheat slide assembly from the preheat assembly.
H. Remove the preheat linear slide assembly (see Figure 2-91):
NOTE: Hold the linear slide in its position when you remove the screws on the
linear slide.
CAUTION: Do not move the preheat linear slide block out from the rail. The ball
bearings will fall out.
1. Remove the two M4 screws that attach the preheat linear slide assembly to
the preheat assembly.
2. Remove the preheat linear slide assembly and discard it.
I. Install the replacement preheat linear slide assembly (see Figure 2-91):
1. Put the preheat linear slide assembly to the mounting position of the pre-
heat assembly.
2. Install the screws removed before to attach the preheat linear slide assem-
bly to the preheat assembly.
J. Install the preheat slide assembly (see Figure 2-91):
1. Put and hold the preheat slide assembly against the preheat linear slide
block.
2. Make sure that the holes in the rear of the slide assembly is aligned to the
holes in the linear slide block.
3. Install the preheat slide assembly with the screws removed before.
K. Install the preheat assembly to the indexer assembly (see paragraph 2.9.1.8,
step H.).
L. Install the indexer assembly to the machine (see paragraph 2.7).
M. Install the heat block gauge or inserts removed before to the preheat heat
N. Push the green machine ON switch.
O. Select OK to start initialization.
P. Do the setup and calibration procedures (see paragragphs 2.3 and 2.4).
Preheat Linear Slide Assembly
2x M4 Screws
Preheat Slide Assembly
4x M3 Screws
2x Springs
Figure 2-91 Replace Preheat Linear Slide Assembly

98888-0000-JB3-01 Workholder 2-87
2.9.2 Puller Parts

2.9.2.1 Puller Finger
Purpose
• Replace the puller finger. The puller finger hook the carrier to pull it out of the
input magazine.
• Puller Finger, P/N 03201-0113-004-xx
• Hand tools
Procedure

COOLED DOWN.
C. Remove the puller finger (see Figure 2-92):

1. Remove the two M2 screws that attach the puller finger to the puller mount.
2. Move the puller finger out from the rear of the front rail slot.
3. Discard the puller finger.
D. Install the replacement puller finger (see Figure 2-92):
1. Hold the puller finger along the rear of the front rail slot.
2. Make sure that the puller finger is parallel to the front rail, and the pin points
up at the left side of the indexer assembly.
3. Hold the puller finger on the puller finger mount.
4. Install two screws removed before to attach the puller finger to the puller
finger mount.
5. Torque the screws to 7 in. lbs. (0.8 Nm).
E. Push the green machine ON switch.
F. Select OK to start initialization.
G. Do the puller setup procedures (see paragraph 2.3.2).
Pin
Front Rail Slot Puller Mount
Puller Finger
Figure 2-92 Puller Finger (Front Wall Assembly - Rear View)

2-88 Workholder 98888-0000-JB3-01
2.9.2.2 Puller Rack
Purpose
• Replace the puller rack for the puller rack-and pinion drive. This rack is
installed on the front wall assembly.
• Puller Rack, P/N 03035-0010-047-xx
• Hand Tools
Procedure

COOLED DOWN.
C. Move the puller assembly to the right limit.

D. Remove the puller rack (see Figure 2-93):
1. Remove the two M3 screws that attach the puller rack to the front rail sup-
port.
2. Remove the puller rack and discard it.
E. Install the replacement puller rack (see Figure 2-93):
1. Put the rack on the front rail support.
2. Make sure that the teeth points to you and the screw holes are aligned to
the mounting holes in the front rail support.
3. Install the puller rack to the front rail support with the screws removed
before.
4. Carefully tighten the screws.
5. Do the backlash adjustment (see paragraph 2.3.7).
F. Push the green machine ON switch.
G. Select OK to start initialization.
2x M3 Screws Puller Rack
Front Rail Support
Figure 2-93 Puller Rack

98888-0000-JB3-01 Workholder 2-89
2.9.2.3 Puller Motor
Purpose
• Replace the puller motor. This motor has a pinion gear installed on the motor
shaft. The puller rack-and-pinion provides drive to move puller assembly along
the X axis linear slider in the X axis direction.
• Puller Motor P/N 03102-1006-000-xx
• Hand Tools
Procedure

COOLED DOWN.
C. Remove the puller finger (see paragraph 2.9.2.1).

D. Remove the puller assembly (see Figure 2-94):
1. Make sure that the electrical cables to the puller assembly are correctly
positions.
3. Disconnect all the cables connectors on the circuit panel that attach to the
puller mount.
4. Remove the two M3 screws and washers that attach the puller flex cable
assembly with circuit panel to the puller mount.
5. Pull out the puller flex cable assembly with circuit panel from the puller
assembly.
6. Remove the three M3 screws that attach the puller mount to the plate
adapter on the X axis linear slide assembly.
7. Remove the puller assembly from the indexer assembly and put it on a
work bench.
E. Remove the puller motor (see Figure 2-94):
1. Remove the four M3 screws that attach the motor to the puller mount.
2. Remove the puller motor from the puller assembly and discard it.
F. Install the replacement puller motor (see Figure 2-94):
1. Put the motor on the puller mount.
2. Make sure that the cable points to you and the pinion gear points down
through the opening in the base of the mount.
3. Install the motor to the puller mount with the screws removed before.
G. Install the puller assembly (see Figure 2-94):
1. Put the puller assembly on the plate adapter on the X axis linear guide.
2. Make sure that the motor cable points to you.
3. Install the puller assembly to the plate adapter with the screws removed
before.
4. Lightly turn the screws to attach the puller assembly to the plate adaptor
loosely.
2-90 Workholder 98888-0000-JB3-01

5. Move the puller mount forward until the rear of the mount is
flush with the rear of the plate adaptor.
6. Hold the puller mount and torque the screws to 14 in. lbs. (1.6 Nm).
7. Hold the puller flex cable assembly with circuit panel into position against
the mount until the flat surface points to the front wall.
8. Install the puller flex cable assembly with circuit panel to the mount with the
10. Connect the electrical cables to the circuit panel on the puller assembly.
11. Attach the electrical cables with cable ties and cable clamps to the indexer
assembly. Refer to your notes.
H. Install the puller finger to the puller assembly (see paragraph 2.9.2.1).
I. Do the backlash adjustment.
J. Push the green machine ON switch.
K. Select OK to start initialization.
98888-0000-JB3-01 Workholder 2-91

Puller Finger
Puller Motor
3x M3 Screws
2x M3 Screws
and Washers
Puller Mount
Puller Flex Circuit Cable

Assembly with Circuit Panel
4x M3 Screws Plate Adapter X Axis Linear Guide
Figure 2-94 Puller Motor
2-92 Workholder 98888-0000-JB3-01

2.9.2.4 Puller Solenoid
Purpose
• Replace the puller solenoid that moves the puller finger up and down.
• Puller Solenoid, P/N 03107-1080-000-xx
• Hand tools
• Allen key set
Procedure

COOLED DOWN.
C. Remove the puller finger (see paragraph 2.9.2.1).

D. Remove the puller assembly (see paragraph 2.9.2.3, step D.)
E. Remove the puller solenoid (see Figure 2-95):
NOTE: Do not loosen or tighten the top set screw in the left side of the puller
arm or it will be difficult to put the arm back to its original position.
positions.
puller mount.
4. Loosen the set screw on the puller finger mount that sets the mount to the
pivot pin.
5. Loosen the set screw that sets the arm to the pivot pin.
6. Pull the pivot pin out from the puller mount.
7. Pull the puller arm from the puller mount.
8. Remove the two nuts that attach the solenoid to the puller mount.
9. Remove the solenoid from the puller mount and discard it.
F. Install the replacement puller solenoid (see Figure 2-95):
1. Hold the puller solenoid against the right side of the wall on the puller
mount.
2. Make sure that the cable points downward and the threaded studs are to
the left side through the holes in the mount.
3. Apply a small quatity of screw locking compound to the threaded studs on
the solenoid.
4. Install the nuts and torque them to 7 in lbs. (0.8 Nm).
5. Put the puller arm to the puller mount.
6. Make sure that the finger flag on the puller arm, is at the rear and points to
the top.
7. Hold the puller arm behind the wall on the puller mount.
98888-0000-JB3-01 Workholder 2-93

8. Make sure that the hole for the pivot pin is aligned with the holes for the
bearings. The bearings are in the bearing housing in the mount.
9. Turn the pivot pin until the flat surface is at the left side.
10.Push the pivot pin into the holes for the front bearing, puller arm, and rear
bearing until it stops.
11. Tighten the set screw in the puller arm that sets the arm to the pivot pin
until the screw is aligned with the flat surface of the pin.
12.Tighten the set screw in the puller finger mount that sets the mount to the
pivot pin until the screw is aligned with the flat surface of the pin.
14.Attach the electrical cables with cable ties and cable clamps to the indexer
G. Do the backlash adjustment.
H. Push the green machine ON switch.
I. Select OK to start initialization.
Puller Motor
2x Puller Solenoid Nuts
Puller Arm Finger Flag

(set screw not in view)
Puller Finger Mount

(set screw nit in view)
2x Threaded Studs
2x Bearings
Puller Solenoid
Pivot Pin
Puller Mount and Wall
Figure 2-95 Puller Solenoid
2-94 Workholder 98888-0000-JB3-01

2.9.3 Index/Tucker Parts
2.9.3.1 Index Arm and Pin
Purpose
• Replace the index arm and pin. These part are used to index the boat to put
the device at the bond site.
• Index Arm, P/N 03201-0014-018-xx
• Index Pin, P/N 03201-0014-009-xx
• Hand Tools
• Small Press
Procedure

COOLED DOWN.
C. Remove the index arm holder (see Figure 2-96):

1. Make sure that the electrical cables to the index assembly are correctly
positions.
index mount.
4. Remove the two M3 screws and washers that attach the holder to the index
slider.
5. Remove the index arm holder from the indexer assembly and put it on a
work bench.
D. Remove the spring cap and the compression spring (see Figure 2-96):
1. Remove the two M1.6 screws from the right side of the index arm holder
that attach the spring cap to the index arm holder.
2. Remove the spring cap and the spring from the index arm holder.
E. Remove the index arm and pin (see Figure 2-96):
1. Remove the two M1.6 screws that attach the arm to the index arm holder.
2. Pull the arm away from the index arm holder.
3. Pull the sensor bar from of the index arm.
4. Go to step "E.5" to remove the pin or the arm.
5. To remove the pin and the arm, discard them and go to step "F".
NOTE: The arm is easy to damage. Carefully push the pin out from the arm.
6. Push the pin out of the arm and discard the necessary part.
98888-0000-JB3-01 Workholder 2-95

F. Install the replacement index pin and the index arm (see Figure 2-96):
1. Set the index arm to the correct position.
a. Make sure that the arm with the slot points to the right side.
b. Make sure that the tip of the pin points up and perpendicular (at a
dimension of 0.0033 in.) to the side of the arm with the slot (see suface
A on Figure 2-96).
NOTE: The arm is easy to damage. Carefully push the pin into the arm.
2. Push the round end of the pin into the arm.

3. Set the sensor bar to the correct position.
a. Make sure that the raised step on the sensor bar points to the slot in the
arm.
b. Make sure that the angle at the bar end points to the pin at the end of
the arm.
4. Install the sensor bar into the index arm with the screws removed before.
5. Set the index arm holder position.
a. Make sure the the slot on the index arm holder is at the left side.
b. Make sure that the overload sensing cables are at the top.
6. Set the index arm with the sensor bar position.
a. Make sure that the end of the pin on the index arm is at the rear of the
index assembly and points down.
7. Install the index arm with the sensor bar to the index arm holder until it
stops.
G. Install the compression spring and the spring cap (see Figure 2-96):
1. Hold the spring cap against the index arm holder.
2. Install one of the M1.6 screw removed before to the top hole of the index
arm holder to attach the spring cap to the holder.
3. Tighten the screw lightly to hold the spring cap in its position.
4. Turn the bottom of the spring cap to 90 ο clockwise until the the spring cap
is away from the index arm holder.
5. Install the spring against the round surface of the spring cap.
6. Turn the spring cap with spring against the index arm holder.
7. Install the other M1.6 screw removed before to the bottom hole of the index
arm holder to attach the spring cap.
H. Install the index arm holder (see Figure 2-96):
1. Install the index arm holder with the index arm to the top of the index slide
with the screws and washers removed before.
2. Make sure that the index arm is at the left side of the index assembly.
3. Make sure that the holes in the index arm holder are aligned to the holes in
the top of the index slide.
4. Tighten the screws lightly to hold the index arm holder in its position.
5. Pull the index arm holder forward to its maximum.
7. Connect the electrical cables to the circuit panel on the index assembly.
2-96 Workholder 98888-0000-JB3-01

8. Attach the electrical cables with cable ties and cable clamps to
the index assembly. Refer to your notes.
K. Calibrate the index home position to the center of the bond position.
2x M3 Screws
Spring Index Arm Index Pin
2x M3 Washers
Spring Cap
2x M1.6 Screws
2x M1.6 Screws
SURFACE A Sensor Bar
Overload Sensing Cable

Index holder
Index Mount
Circuit Panel
Figure 2-96 Index Arm and Pin
98888-0000-JB3-01 Workholder 2-97

2.9.3.2 Tucker
Purpose
• Replace the tucker blade. This tucker moves the boat into the output maga-
zine.
• Tucker, P/N 03201-0114-013-xx
• Hand Tools
• Small Press
Procedure

COOLED DOWN.
C. Remove the tucker (see Figure 2-97):

1. Remove the two M2 screws that attach the tucker leaf spring to the tucker
mount.
NOTE: Make sure that the tucker leaf spring do not fall into the indexer assem-
bly. Hold the tucker leaf spring in its position.
2. Remove the tucker leaf spring from the index assembly.

3. Push the dowel pin out of the tucker mount and remove it from the index
assembly.
NOTE: Make sure that the dowel pin do not fall into the indexer assembly. Put
one of your hands below the tucker mount and hold the dowel pin.
4. Move the tucker out from the slot in the tucker mount and discard it.
D. Install the replacement tucker (see Figure 2-97):
1. Set the position of the tucker until the tip is at the right side of the index
assembly and points down.
2. Put the end of the tucker into the slot on the tucker mount.
3. Make sure that the holes at the tucker end are aligned to the holes in the
tucker mount.
4. Push the pin into the tucker mount.
5. Put and hold the tucker leaf spring against the right side of the tucker
mount.
6. Install the tucker and tucker leaf spring to the index mount with the screws
removed before.
E. Push the green machine ON switch.
F. Select OK to start initialization.
G. Calibrate the tucker eject.
2-98 Workholder 98888-0000-JB3-01

2x M2 Screws
Tucker Leaf Spring
Dowel Pin
Tucker
Tucker Mount
Figure 2-97 Tucker

2.9.3.3 Tucker Soienoid
Purpose
• Relpace the tucker solenoid.
• Tucker Solenoid, P/N: 03107-1080-000-xx
• Hand Tools
• Screw Locking Compound
• Tweezers
Procedure
B. Press [MOTOR STOP] and turn off the machine power.

COOLED DOWN.
C. Remove the tucker mount (see Figure 2-98):

positions.
index mount.
4. Loosen the set screw that attach the tucker mount to the indexer mount.
5. Remove the spring from the notched groove pin in the tucker mount..
NOTE: Make sure that the pivot pin and bearings do not fall into the indexer
assembly. Hold the tucker mount with the pivot pin and bearings in its
position.
98888-0000-JB3-01 Workholder 2-99

6. Pull the pivot pin from the right side of the tucker mount.
7. Remove the pivot pin and the two bearings that attach the tucker mount to
the indexer mount.
8. Remove the tucker mount from the index assembly and put it on a work
bench.
D. Remove the two nuts that attach the tucker solenoid to the tucker mount and
discard the solenoid.
E. Install the replacement tucker solenoid (see Figure 2-98):
1. Put the solenoid against the front of the tucker mount.
2. Make sure that the cable points down and the threaded studs are into the
holes of the tucker mount.
3. Apply a small quatity of screw locking compound to the threaded studs on
the solenoid.
4. Install the solenoid to the tucker mount with the nuts removed before.
5. Tighten the nuts to 7 in. lbs. (0.79 Nm).
F. Install the tucker mount (see Figure 2-98):
1. Install the two bearings and pivot pin to the right side of the tucker mount.
2. Put the tucker mount with the bearings and the pivot pin against the index
mount.
3. Hold the tucker mount in its position and tighten the set screw.
4. Install the spring removed before to the notch groove pin on the tucker
mount.
5. Connect the electrical cables to the circuit panel on the index assembly.
6. Attach the electrical cables with cable ties and cable clamps to the index
2x Nuts
Pivot Pin
Index Mount 2x Bearings
Solenoid Tucker Mount

(notched groove pin and spring not shown)
Figure 2-98 Tucker Solenoid
2-100 Workholder 98888-0000-JB3-01

2.9.4 Rail Parts
2.9.4.1 Indexer Motor
Purpose
• Replace the indexer motor.
• Indexer Motor, P/N 08888-1066-000-xx
• Hand Tools
Procedure

COOLED DOWN.
C. Remove the indexer assembly (see paragraph 2.6).

D. Remove the indexer motor (see Figure 2-99):
1. At the front of the indexer assembly, loosen two captive screws that attach
the PCB cover to the indexer base.
3. Make sure that the electrical cable to the indexer motor are correctly identi-
fied. If not, make a note of the connection.
4. Disconnect the indexer motor cable connector J21 from the indexer inter-
mediate board.
positions.
6. Loosen the set screw in the flexible coupling that attach to the shaft of the
X-axis leadscrew assembly.
7. Remove the two M4 screws that attach the top left side of the front wall to
the front wall input support.
8. Loosen the two M4 screw top right side of the front wall to the front wall out-
put support.
9. Remove the two M5 screws with washers that attach the base of the front
wall input support to the input base support.
10.Carefully lift the front wall assembly a small distance up until the front wall
input support with shim can remove easily.
11. Remove the front wall input support with shim.
12.Hold the indexer motor with one of your hands.
13.Remove the four M4 screws with washers that attach the indexer motor
with flexible coupling to the motor mount.
14.Loosen the set screw in the flexible coupling that attach to the shaft of the
indexer motor.
15.Remove the flexible coupling.
16.Remove the indexer motor.
98888-0000-JB3-01 Workholder 2-101

E. Install the replacement indexer motor (see Figure 2-99):
1. Install the flexible coupling to the shaft of the indexer motor and tighten the
set screw.
2. Torque the set screw to 12 lbs. in. (1.36 Nm).
3. Put the indexer motor with the flexible coupling against the motor mount.
Make sure that the motor cable is at the bottom.
4. Install the indexer motor with flexible coupling to the motor mount with the
5. Make sure the shaft of the X-axis leadscrew assembly goes into the flexible
coupling hole.
6. Torque the screws to 28 lbs. in. (3.16 Nm).
7. Torque the set screw in the flexible coupling to 12 lbs. in. (1.36 Nm).
8. Carefully lift the front wall assembly a small distance up until the front wall
input support with shim can install easily.
9. Install the front wall input support with shim to the input base and front wall
with the screws and washers removed before.
10.Make sure that the base of the front wall input support is attached to the
front wall nut bar in the input base support.
11. Tighten the four M4 screws at the top, two ends of the front wall.
F. Connect the indexer motor cable to the connector J21 on the indexer interme-
diate board. Refer to your notes.
2x M4 Screws 2x M4 Screws
Top Right Side

Top Left Side of Front Wall of Front Wall
2x M5 Screws
with Washers
Shim Set Screws
Front Wall
Output Support
X Axis Leadscrew Assembly

Motor Mount
4x M4 Screws Indexer Motor Flexible Coupling
4x M4 Washers Input Base Support
Front Wall Input Support
Figure 2-99 Indexer Motor
2-102 Workholder 98888-0000-JB3-01

2.9.4.2 X Axis Leadscrew Assembly
Purpose
• Replace the X axis leadscrew assembly.
• X Axis Leadscrew Assembly, P/N 03101-0535-000-xx
• Hand Tools
Procedure

COOLED DOWN.

D. Remove the three M3 screws that attach the bearing retainer to the right side
of the front wall output support and remove the bearing retainer.
E. Remove the X axis leadscrew assembly (see Figure 2-100):
1. Loosen the set screw in the flexible coupling that attach to the shaft of the
X-axis leadscrew assembly.
2. Remove the three M4 screws and washers that attach the leadscrew nut to
the adapter nut.
3. Remove the hex nut that attach the right side (threaded) of the leadscrew
to the front rail support.
4. Move the leadscrew to the right to release the left side of the leadscrew
from the flexible coupling.
5. Tilt the leadscrew up to the left and pull it from the front wall output support
6. Discard the leadscrew.
F. Install the replacement X axis leadscrew assembly (see Figure 2-100):
NOTE: Do a preload check of the leadscrew nut. The preload of the leadscrew
nut should be on the fourth tooth from the point of the spring and clock-
wise of the leadscrew.
1. Move the leadscrew nut to the right side of the leadscrew.

2. Put the X axis leadscrew assembly to the front wall support :
a. Make sure that the smooth end of the leadscrew is at the motor mount
and into the flexible coupling hole.
b. Make sure that the threaded end of the leadscrew is at the front wall
output support and into the bearing hole.
3. Put the leadscrew nut against the adapter nut.
4. Install the leadscrew nut to the adapter nut with the screws removed
before.
5. Torque the screws to 14 lbs. in. (1.6 Nm).
6. Apply a small quatity of screw locking compound to the threads on the right
end of the leadscrew.
7. Install the hex nut and torque it to 20 lbs. in. (2.26 Nm).
8. Put the bearing retainer against the right side of the front wall output sup-
port.
98888-0000-JB3-01 Workholder 2-103

9. Install the bearing retainer to the front wall output support with the screws
removed before.
10.Torque the screws to 14 lbs. in. (1.6 Nm).
11. Torque the set screw in the flexible coupling to 12 lbs. in. (1.36 Nm).
G. Install the indexer assembly to the machine (see paragraph 2.6).
.
Flexible Coupling X Axis Linear Slider
Slide Block for Index Assembly
Leadscrew Bearing
Bearing Retainer
X Axis Leadscrew Assembly
Adapter Nut Hex Nut 3x M3 Screws

Leadscrew Nut 3x M4 Screws
Figure 2-100 X Axis Leadscrew Assembly
2-104 Workholder 98888-0000-JB3-01

2.9.4.3 Leadscrew Bearing
Purpose
• Replace the leadscrew bearing that supports the right end of the X axis lead-
screw assembly.
• Bearing, P/N 20604-6022-00
• Hand Tools
Procedure

COOLED DOWN.
C. Move the index assembly to the left limit on the X axis linear slider.
D. Remove the leadscrew bearing (see Figure 2-100):
NOTE: Make sure that the bearing retainer do not fall into the indexer assembly.
Hold the bearing retainer in its position.
1. Remove the three M3 screws that attach the bearing retainer to the front
wall output support.
2. Remove the bearing retainer from indexer assembly.
3. Remove the hex nut that attach the right end (threaded) of the leadscrew to
the front wall output support.
4. Push the bearing from the left side of the bearing housing out through the
right and discard it.
NOTE: Make sure that the bearing do not fall into the indexer assembly. Put one
of your hands below the right side of the front wall output support and
hold the bearing.
E. Use alcohol to remove the remaining of the screw locking compound on the
threads at the right side of the leadscrew.
F. Install the replacement leadscrew bearing (see Figure 2-100):
1. Push the bearing in through the right side of the bearing housing until it is
flush with the right side of the front wall output support.
2. Apply a small quatity of the screw locking compound to the threads on the
right side of the leadscrew.
3. Install the nut and torque it to 20 in lbs. (2.26 Nm).
4. Put the bearing retainer against the right side of the front rail support.
5. Install the bearing retainer to the front wall output support with the screws
removed before.
6. Torque the screws to 14 in lbs. (1.6 Nm).
98888-0000-JB3-01 Workholder 2-105

2.9.5 Sensor Assemblies

2.9.5.1 X Registration Sensor
Purpose
• Replace the X registration sensor.
• Hand tools
• X Registration Sensor, P/N 03201-0019-000-xx
Procedure

COOLED DOWN.

D. Remove the X registration sensor:
1. At the front of the indexer assembly, loosen two captive screws that attach
the PCB cover to the indexer base.
3. Make sure that the X registration sensor cable is correctly identified. If not,
make a note of the connection.
4. Disconnect the X registration sensor connector J9 from the indexer inter-
mediate board.
positions.
6. Remove the four M2 screws that attach the sensor emitter and receiver to
the mount.
7. Remove the sensor from the rear rail assembly and discard it.
E. Install the replacement X registration semsor:
1. Put the sensor emitter to the bottom of the mount with the screw holes
points down.
2. Install the sensor emitter to the mount with the screws removed before.
3. Put the sensor recevier to the top of the mount with the screw holes points
to the top.
4. Install the sensor receiver to the moun with the screws removed before.
6. Connect the X registration sensor cable to connector J9 on the indexer
intemediate board and do the cable routing. Refer to your notes.
F. Install the indexer assembly to the machine (see paragraph 2.6).
I. Calibrate the distance between the X registration sensor and the center of the
bond site.
2-106 Workholder 98888-0000-JB3-01

2x M2 Screws Receiver Sensor Mount
X Registration Sensor
Emitter
2x M2 Screws
Figure 2-101 X Registration Sensor

2.9.5.2 Optical Switch Assemblies
Purpose
• Replace the optical switch assemblies used throughout the indexer and slider
assemblies.
• Hand tools
• Tie wraps
• Optical Switch Assembly, as required:
• Indexer Home, 60 mm (2.36”) long, P/N 08888-1027-000-09
• Indexer Pin Left, 160 mm (6.30”) long, P/N 08888-1027-000-10
• Indexer Pin Right, 160 mm (6.30”) long, P/N 08888-1027-000-11
• Puller Motor Home, 120 mm (4.72”) long, P/N 08888-1027-000-12
• Puller Pin Sensor, 75 mm (2.95”) long, P/N 08888-1027-000-13
• Preheat Motor Home, 228.6 mm (9”) long, P/N 03411-1031-001-28
• Heat Block Sensor, 736.6 mm (29”) long, P/N 03411-1031-001-17
98888-0000-JB3-01 Workholder 2-107

Procedure

COOLED DOWN.

D. Remove the slider assembly (see paragraph 2.7).
E. Disconnect the optical switch(s) to be replaced.
1. Find the optical switch position. Refer to Section 4 of this manual for the
illustration on the optical switch position in the indexer assembly and slider
assembly.
NOTE: It is necessary to remove the indexer assembly and slider assembly to

replace the optical switch.
2. Make sure that the optical switch cables to the indexer intermediate board
or interface panel are correctly identified. If not, make a note of the connec-
tion.
3. Make a note on the orientation of the five (5) optical switch wires (red,
black, white, blue and yellow insulation).
positions.
5. Remove the screw that attach the optical switch to the mount.
NOTE: Make sure that the optical switch do not fall into the indexer assembly.
Hold the optical switch in its position.
6. Disconnect the optical switch cable and discard it. Make a note of the refer-
ence designator (”J” number) of the connector.
F. Install the replacement sensor.
1. Put the optical switch against the mount until the optical switch wires are in
the same way as it was removed.
2. Install the optical switch with the screw removed before.
3. Connect the optical switch cable to the connector on the indexer intermedi-
ate board or interface panel. Refer to your notes.
4. Attach the optical switch cable with cable ties and cable clamps to the
indexer assembly or slider assembly. Refer to your notes.
G. Install the indexer assembly to the machine (see paragraph 2.6).
H. Install the slider assembly to the machine (see paragraph 2.7).
J. Select OK to start initialization. Make sure that the optical switch operates cor-
rectly.
NOTE: The Sensor Diagnostic display, accessed through Diagnostic Mode, can
be used to do a check if the replacement sensor operates correctly.
Refer to paragraph 5.4.4 in Section 5 of this manual for more informa-
tion.
2-108 Workholder 98888-0000-JB3-01

2.9.5.3 J Boat Present Sensor Amplifier
Purpose
• Replace and set up the sensor amplifier that is part of the J boat present sen-
sor on the rear rail assembly of the indexer assembly (Figure 2-2, Figure 2-
102).
• Hand tools
• Sensor Amplifier Assembly, P/N 08858-1032-000-12 (for input side)
• Sensor Amplifier Assembly, P/N 08858-1032-000-13 (for output side)
Procedure

COOLED DOWN.
C. Remove the sensor amplifier from the rear rail assembly.

1. Make sure that the sensor amplifier cable to the indexer intermediate board
is correctly identified. If not, make a note of the connection.
positions.
3. Disconnect the applicable cable connector from the indexer intermediate
board connector J19 (for input) or J20 (for output). Refer to Section 4 for
connector position.
4. Identify the polarity of the two fiber optic cables with arrows on the ampli-
fier.
5. Pull up the latch on the amplifier and remove the two fiber optics.
6. Remove the sensor amplifier cable from cable clamps (if any).
7. Remove and retain the two (2) socket head cap screws (SHCSs) and flat
washers that attach the J boat present sensor amplifier for assembling as
stated in step C. Discard the failed sensor amplifier with J boat present
sensor.
Figure 2-102 J Boat Present Sensor Amplifier Controls/Indicators

98888-0000-JB3-01 Workholder 2-109
D. Install the replacement sensor amplifier.
1. Install two (2) socket head cap screws (SHCSs) and flat washers to attach
the replaced J boat present sensor amplifier to the rear side of the rear rail.
2. Put the J boat present sensor amplifier cable to the indexer intermediate
board. Close the cable clamps (if any) and attach with the cable tie if nec-
essary.
3. Connect the leadframe present sensor amplifier cable(s) to J19 connector
(for input) or J20 connector (for output) on the indexer intermediate board.
4. Lift the fiber optic latch and install the end of each fiber optic cable into its
correct hole in the amplifier. Close the fiber optics latch.
E. Turn on machine power. Select OK in the Standby Mode dialog box.
F. Set up the J boat present sensor amplifier (see Figure 2-102) .
NOTE: For maximum sensitivity, teach the J boat where most holes are present.
1. Make sure that the ”LO” and ”HS” lights are turned ON before you teach
the replaced amplifier:
a. Press and hold the TEACH (or ”-”) button of the amplifier for two to three
seconds until ”LO” and ”DO” of the Status LEDs flash after another.
b. To set the ‘unblock’ condition (without J boat), press the TEACH (or ”-”)
button one [1] time.
c. To set the ‘block’ condition, put the sample J boat on the workholder
rails and in the path of the sensor beam, then press the TEACH (or ”-”)
button one (1) time.
2. Manually index the whole J boat at the sensor and make sure the amplifier
detects the whole J boat.
3. If false triggering occurs, press Manual Adjustment Button (or ”+” and ”-”) to
change the sensitivity of amplifier.
4. Do step 1. if manual adjustment does not improve the false triggering of
amplifier.
2-110 Workholder 98888-0000-JB3-01

2.9.6 Indexer Flex Cable Assembly
2.9.6.1 Puller Flex Cable Assembly
Purpose
• Replace the puller flex cable assembly.
• Puller Flex Cable Assembly, P/N 08888-1297-000-xx
• Hand Tools
• Electrostatic Discharge (ESD) Protective Container
Procedure

COOLED DOWN.

D. Remove the puller flex cable assembly (see Figure 2-103):
CAUTION: Operation Hazard. Obey all ESD procedures before you remove or put
the PCBs into storage.
positions.
puller mount.
6. Disconnect the puller flex cable connector on connector J3 of the indexer
intermediate board.
7. Remove the two M3 screws that attach the ribbon clamp to the center of
the front wall.
8. Remove the ribbon clamp that attach the puller flex cable to the center of
the front wall.
9. Move the puller to the left limit.
10.Remove the two M2.5 screws that attach the ribbon cable clamp to the left
side of the front wall.
11. Remove the ribbon cable clamp that attach the puller flex cable along the
front wall.
12.Remove the two M3 screws and washers that attach the puller flex cable
assembly with circuit panel to the puller mount.
13.Remove the puller flex cable from the indexer assembly and put it in an
ESD protective container.
98888-0000-JB3-01 Workholder 2-111

.
Puller Assembly
Puller Flex Cable Assembly

with Circuit Panel
Ribbon Clamp
2x M3 Screws
and Washers
2x M3 Screws
Ribbon Cable Clamp
Puller Flex Cable Assembly
2x M2.5 Screws
Slide Block For Puller Assembly
Figure 2-103 Puller Flex Cable Assembly

E. Install the replacement puller flex cable (see Figure 2-103):
1. Hold the puller flex cable assembly with circuit panel against the puller
mount. Make sure the flat surface of the circuit panel points to the front
wall.
2. Install the puller flex cable assembly with circuit panel to the mount with the
4. Put the puller flex cable assembly against the left side of the front rail sup-
port behind the indexer motor, then put it along the left side of the front wall.
5. Install the ribbon cable clamp at the left side of the front wall to attach the
puller flex cable assembly.
6. Tighten the screws on the ribbon cable clamp.
7. Connect the puller flex cable assembly connector to connector J3 of
2-112 Workholder 98888-0000-JB3-01

9. Attach the electrical cables with cable ties and cable clamps to
the indexer assembly. Refer to your notes.
10.Install the ribbon clamp to the center of the front wall with the screws
removed before.
11. Make sure that the puller flex cable assembly is behind the ribbon clamp.
12.Install the PCB cover to the indexer base and tighten the captive screws.
2.9.6.2 Gripper Flex Cable Assembly
• Replace the puller flex cable assembly.
• Gripper Flex Cable Assembly, P/N 08888-1280-000-xx
• Hand Tools
• Electrostatic Discharge (ESD) Protective Container
Procedure

COOLED DOWN.

D. Remove the gripper flex cable assembly (see Figure 2-104):
CAUTION: Operation Hazard. Obey all ESD procedures before you remove or put
the PCBs into storage.
positions.
index mount.
6. Disconnect the gripper flex cable connector on connector J23 of the
7. Remove the two M3 screws that attach the ribbon clamp to the center of
the front wall.
8. Remove the ribbon clamp that attach the gripper flex cable to the center of
the front wall.
9. Move the index assembly to the right limit.
10.Remove the two M2.5 screws that attach the ribbon cable clamp to the
right side of the front wall.
11. Remove the ribbon cable clamp that attach the gripper flex cable along the
front wall.
98888-0000-JB3-01 Workholder 2-113

12.Remove the air tube clips that attach the gripper flex cable along the rout-
ing to the center of the front wall.
13.Remove the two M3 screws and washers that attach the gripper flex cable
assembly with circuit panel to the index mount.
14.Remove the gripper flex cable from the indexer assembly and put it in an
ESD protective container.
Index/tucker Assembly
Ribbon Clamp Ribbon Cable Clamp
2x M3 Screws
2x M2.5 Screws
2x M3 Screws
and Washers
Gripper Flex Cable Assembly
with Circuit Panel
Gripper Flex Cable Assembly
Slide Block For

Index/Tucker Assembly
Figure 2-104 Gripper Flex Cable Assembly

E. Install the replacement gripper flex cable (see Figure 2-104):
1. Hold the gripper flex cable assembly with circuit panel against the index
mount. Make sure the flat surface of the circuit panel points to the front
wall.
2. Install the gripper flex cable assembly with circuit panel to the mount with
the screws and washers removed before.
4. Put the gripper flex cable assembly along the right side of the front wall
behind the index assembly.
2-114 Workholder 98888-0000-JB3-01

5. Install the ribbon cable clamp at the right side of the front wall
to attach the gipper flex cable assembly.
6. Tighten the screws on the ribbon cable clamp.
7. Install the air tube clips along the gripper flex cable assembly.
8. Put the tubings to the air tube clips, along with the routing of the gripper flex
cable assembly.
9. Connect the gripper flex cable assembly connector to connector J23 of
10.Connect the electrical cables to the circuit panel on the index assembly.
12.Install the ribbon clamp to the center of the front wall with the screws
removed before.
13.Make sure that the gripper flex cable assembly is behind the ribbon clamp.
14.Install the PCB cover to the indexer base and tighten the captive screws.
98888-0000-JB3-01 Workholder 2-115

2.9.7 Heat Block Vacuum Solenoid Valve

Purpose
• Replace the solenoid valve that controls the vacuum flow to the heat block
insert.
• Hand tools
• Vacuum valve assembly, P/N 03107-1000-000-xx
Procedure (Figure 2-105)
Solenoid Valve Bracket
Fitting (Port 2) - Blue Tubing

to Heatsink manifold
Heat Block Vacuum XY Table Assembly

Solenoid Valve
Elbow Fitting (Port 1)- Blue Tubing to
2x SHCSs Vacuum quick-disconnect connector
Figure 2-105 Heat Block Vacuum Solenoid Valve (XY Table Assembly - Right View)

COOLED DOWN.
C. Remove the upper console output cover.

D. Find the heat block vacuum valve assembly (P/N 03118-0330-006-xx) attach
to the right side of the XY Table assembly (see Figure 2-105).
E. Remove solenoid valve from the solenoid bracket (see Figure 2-105).
1. Make sure that the pneumatic tubings to the vacuum valve on the XY table
are correctly identified. If not, make a note of the connection.
2. Remove all the cable clamps if necessary to release the tubings. Make a
note of the pneumatic tubings position and cable clamps positions.
3. Disconnect the pneumatic tubes from the solenoid valve.
4. Remove the two (2) SHCSs from the solenoid valve.
5. Remove the solenoid valve from the solenoid valve bracket.
6. Remove the air fittings from the solenoid valve.
2-116 Workholder 98888-0000-JB3-01

F. Install the replacement solenoid valve.
1. Install the air fittings into the solenoid valve assembly.
2. Make sure the air fittings are installed into the ports correctly (see Figure 2-
105).
3. Put the solenoid valve against the bracket. Make sure the clearance holes
in the solenoid valve are aligned with the holes in the bracket.
4. Attach the solenoid valve to the bracket with screws removed before.
6. Connect the pneumatic tubings:
a. Connect the blue pneumatic tubing from the slider assembly (via the
heatsink manifold) to the front fitting (port 2) on the valve.
b. Connect the blue pneumatic tubing (from the quick–disconnect connec-
tor on the rear of the machine) to the rear fitting on the vacuum valve
(port 1).
G. Install the upper console output cover.
J. During initialization, make sure that MHS initialization is completed success-
fully.
K. Do a cycle operation with several sample carriers through the workholder
(refer to Section 1 for procedure).
L. Stop the cycle at intervals to make sure that the vacuum attach the device at
the bond site.
98888-0000-JB3-01 Workholder 2-117

2-118 Workholder 98888-0000-JB3-01

3 Magazine Handlers
3.1 About This Section
• Section 3.2, Description, gives an overview of the Input and output magazine
handlers.
• Each section from Section 3.3 through 3.9 describes various instructions, cali-
brations, operation guidelines, maintenance and procedures for the magazine
handlers:
• Section 3.3, Setup
• Section 3.4, Magazine Handler Calibrations
• Section 3.5, Magazine Handler Configurations
• Section 3.6, Magazine Handler Adjustments
• Section 3.7, Magazine Handler Removal and Installation
• Section 3.8, Preventive Maintenance
• Section 3.9, Part Replacement Procedures
98888-0000-JB3-01 Magazine Handlers 3-1

3.2 Description
3.2.1 General
The Material Handling System contains of two magazine handler subsystems
(3035) to handle magazines during bonding operations. Each Magazine Handler
Sub-system is made up of two assemblies.
The input magazine handler uses the input Z Tower Assembly to carry magazines
containing carrier with unbonded devices for delivery to the indexer subsystem.
After bonding occurs, the index/eject assembly ejects the completed carriers into
an empty magazine held by the output Z tower Assembly at the output magazine
handler. Both magazine handlers automatically place finished magazines (empty
input or full output) onto a magazine unload tray at the Tray Assembly, and then
pick up another magazine (full input or empty output) from a magazine load tray at
the Tray Assembly.
3.2.2 Major Components

The major subassemblies/components of the magazine handlers (see Figure 3-1
and Figure 3-2) are:
• Y–Axis Drive Assembly
Moves magazine held by the Z Tower Magazine Gripper Assembly in the Y-axis
direction (forward and backward).
• Z–Axis Drive Assembly
Moves magazine held by the Z Tower Magazine Gripper Assembly in the Z-axis
direction (up and down).
• Magazine Gripper Assembly
Grips magazine at the load tray assembly of the Input/Output Tray Assembly and
holds the magazine during carrier insertion/ejection. After the magazine has been
processed, releases the magazine onto the unload tray of the Input/Output Tray
Assembly.
• Load Tray Assembly
Holds unprocessed magazines for pickup by the magazine gripper assembly.
After a magazine is removed from the load tray assembly, a belt–drive mecha-
nism positions the next magazine on the tray for pickup. The load tray is posi-
tioned so that magazines can be easily added by the user.
• Unload Tray Assembly
Holds processed magazines placed on the unload tray assembly by the magazine
gripper assembly. The unload tray assembly is positioned so that magazines can
be easily removed by the user.
• Intermediate Boards
The Magazine Handler Intermediate Boards drives and controls the Z Tower
Assembly motors and sensors. The Input/Output Tray Assemblies motors and
sensors are driven and control by the Indexer Intermediate Board. (Refer to Sec-
tion 4 of this manual for more information)
3-2 Magazine Handlers 98888-0000-JB3-01

3.2.3 Magazine Handler Positions
Separately driven motors of the Z Tower Assembly, Y and Z axes, position the
magazine gripper assembly that holds magazines during bonding operations. The
Y axis and Z axis assemblies are capable of moving to positions independently of
the each other.
3.2.3.1 Input and Output Pickup Position
Pickup position is where the Y and Z axes of Z Tower Assembly move the maga-
zine gripper assembly to pickup a magazine with unbonded carriers from the load
tray of Input Tray Assembly or an empty magazine from the load tray of the Out-
put Tray Assembly.

Z Axis Drive
Magazine Gripper
Magazine Handler Assembly
Intermediate Board
(behind Z Tower Casting)
Upper Paw Jaw Magazine
Gripper Assembly
Upper jaw Magazine

Stop Button
Lower Paw Jaw

Y Axis Drive Magazine Stop Button
Lower Jaw Magazine

Gripper Assembly
Tray Sensor
Magazine Gripper Motor (beneath

lower jaw bracket - not shown)
Z Tower Assembly
Figure 3-1 Magazine Handlers Major Components

Tray Full Sensor

(Hidden )
Input Magazine Wall
Input Retainer
Unload Tray
Magazine Present Sensor
Retainer Thumbscrew
Load Tray
(2 Places)
Driven Timing Belt (4 Places) Drive Timing Belt

(Hidden)
Input Tray Assembly
Output Magazine Wall Tray Full Sensor

(Hidden)
Output Retainer
Unload Tray
Load Tray
Retainer Thumbscrew
(2 Places)
Driven Timing Belt (4 Places)

Drive Timing Belt
(Hidden)
Output Tray Assembly
Figure 3-2 Tray Assembly (Load and Unload Trays)

3.2.3.2 Input and Output Slot Positions
At the Input Z Tower Assembly, the Y and Z axes are positioned at which the
indexer puller pulls an unbonded leadframe from a magazine slot. At the Output Z
Tower Assembly, the Y and Z axes are positioned at which the index tucker ejects
a bonded device into a magazine slot. The number of slot positions are limited to
the number of slots in the magazine.
3.2.3.3 Input Staging Position

Input Staging Position is the Input Z Tower Assembly Y and Z axes positions
where the magazine gripper assembly can release an empty magazine onto the
unload input tray.
3.2.3.4 Deposit Position

Deposit Position is the Output Z Tower Assembly Y and Z axes positions where
the paws release a filled magazine onto the unload output tray.
3.2.4 Optional Equipment

3.2.4.1 Safety Covers
Safety covers that completely enclose the magazine handlers are available as an
added-cost option. These covers prevent injury by keeping personnel away from
the moving mechanisms of the magazine handlers while the machine is operat-
ing. Each cover has an electrically–latched and interlock switch protected door
through which the operator can add new magazines or remove finished maga-
zines when the machine is stopped.
If a safety cover door is forced open during operation, the interlock switch stops
the machine by removing power from all motors and signals an error condition
that must be cleared before operation can be resumed. When magazine replace-
ment is required, software options on the Mag Handler Utilities menu are used to
unlatch the door so that it may be opened and latch the door after it has been
closed.
3.2.4.2 Bar Code Readers (Optional)

Bar code readers are available that may be mounted on the magazine handlers.
They allow machines that are connected to an external host processor to read bar
code labels attached to magazines during magazine load and unload operations
and send the bar code data to the host processor. Therefore the host processor
can track processing of the individual magazines.
3.3 Setup
The magazine handlers require no mechanical setup after the machine
is installed.

3.4 Magazine Handler Calibration
The Magazine Handler calibrations consist of software routines that are used to
calibrate the input slot, output slot, input trays and output trays. Using a series of
dialog boxes, the software steps the user through each calibration process.
NOTE: Each magazine handler calibration must be executed in its entirety.

Clicking on the CANCEL button at any time before the calibration is
complete requires a restart of the calibration procedure.
3.4.1 Input/Output Trays Calibration

The Input/Output Trays calibrations contain the software routines that prompt the
user to move the input/output magazine handler gripper assembly to specific
positions in the Y axis. It also teach the machine to move to the correct positions
for picking up and ejecting magazines.
WARNING: DURING THE CALIBRATION PROCEDURES, MAG HANDLER COM-

PONENTS MOVE. BEFORE EXECUTING EACH STEP, REMOVE
HANDS FROM THE MAG HANDLER AREA.
WARNING: THE HEAT BLOCKS AND HEAT BLOCK INSERTS ARE HOT. EXER-
CISE WITH EXTREME CAUTION WHEN WORKING IN THESE AREAS.
NOTE: a) The steps for calibrating the input trays and the output trays are the
same. Therefore, only ‘Input Trays’ calibration operation procedures are
shown here.
b) Either an empty magazine or a straightedge may be used in this cali-
bration. In the steps below, the use of a magazine is described.
Required Gauges
• Empty magazine or straightedge
• None
Procedure
A. Select CALIBRATION from the mode bar, then select MAG HANDLER from the
Calibration mode menu. The ‘Mag Handler’ menu appears.
B. From the ‘Mag Handler’ menu, select INPUT TRAYS. Follow the instructions in
the dialog boxes.
C. Remove magazines or other material from the unload and load trays of the
input magazine handler. Select OK when done.
D. Do the unload tray calibration:
1. Put an empty magazine on the rear of the unload tray.
2. Push the magazine until the rear surface of the magazine is against the
magazine stop surfaces at the rear end of the tray.
3. Use your hand and apply a force on the front of the magazine to make sure
that the magazine is fully touched against the magazine stop surfaces. At
the same time, hold the magazine at this position.
4. Use the Left and Right arrow keys on the MMI, and move the gripper (fork)
of the Z tower assembly to the unload tray.
5. Observe the gripper as you adjust the gripper position. Move the gripper
until the two buttons touch the rear surface of the magazine (see Figure 3-
3).

6. Select OK in the dialog box when the gripper is at the correct position.
E. Do the unload tray calibration check:
1. Remove the magazine from the top tray.
2. Select OK in the dialog box. The tray sensor at the front of the gripper finds
the sensor flag at the unload tray. The gripper then moves to the bottom of
the unload tray and stops. The next dialog box appears on the display.
F. Do the load tray calibration:
1. Put an empty magazine on the rear of the load tray.
2. Push the magazine until the rear surface of the magazine is against the
surfaces of the stop blocks at the rear end of the tray.
3. Use your hand and apply a force on the front of the magazine to make sure
that the magazine is fully touched against the surfaces of the stop blocks.
At the same time, hold the magazine at this position.
4. Use the Left and Right arrow keys on the MMI, and move the gripper (fork)
of the Z tower assembly to the unload tray.
5. Observe the gripper as you adjust the gripper position. Move the gripper
until the two buttons touch the rear surface of the magazine (see Figure 3-
3).
6. Select OK in the dialog box when the gripper is at the correct position.
G. Do the load tray calibration check:
1. Remove the magazine from the load tray.
2. Select OK in the dialog box. The tray sensor at the front of the gripper finds
the sensor flag at the load tray. The gripper then moves to the bottom of the
load tray and stops..
NOTE: This completes the Input Trays calibration procedures. If needed, per-
form the Output Trays calibration procedures.
Magazine Stop Surfaces or

Stop Block Surfaces
Figure 3-3 Touching Benching Buttons (Side View)

3.4.2 Input/Output Slot Calibration
The Input/Output Slot calibrations contain the software routines that prompt the
user to move the input/output magazine handler gripper assembly to specific
positions in the Y and Z axes. It also teaches the machine to move to the correct
slot positions for boat injection and ejection. Figure 3-4 shows the gauges used in
the Input/Output Slot calibrations. The figure describes each gauge relating to
how it is used when performing the Input and Output Slot calibrations. This figure
should be referenced when performing the calibrations.
Input Top Y Axis Hole

Use this end for Output
Slot Calibration
Input Bottom Y Axis Hole
Use this end for Input

Slot Calibration
Input Z Axis Hole

Input Calibration Pin
Output Calibration Pin

Magazine-Sized Gauge
Install on the load tray as shown:
1. Put the left or right side against
the magazine handler wall.
2. Make sure that the label ‘FRONT’
on the gauge points to the user . Workholder Setup
& Calibration Gauge
Figure 3-4 Magazine-Sized Gauge and Workholder Setup & Calibration Gauge
WARNING: DURING THE CALIBRATION PROCEDURES, MHS COMPONENTS
MOVE. BEFORE EXECUTING EACH STEP, REMOVE HANDS FROM
THE MAG HANDLER AND WORKHOLDER AREAS.
WARNING: HOT SURFACES EXIST ON HEAT BLOCKS AND HEAT BLOCK

INSERTS. BE CERTAIN TO EXERCISE EXTREME CAUTION WHEN
WORKING IN THESE AREAS.
NOTE: The steps for calibrating the input slot and output slot are the same.
Therefore, only the operations required to perform the ‘Input Slot’ cali-
brations are given in the steps that follow.

• Magazine-Sized Gauge, P/N 03412-0999-007-xx
• Workholder setup & calibration gauge assembly (P/N: 03035-0501-000-XX)
Procedure
A. Select CALIBRATION, from the mode bar, then select MAG HANDLER from the
Calibration mode menu.
B. From the Mag Handler menu, select INPUT SLOT. This causes the first in a
series of instructional prompts to appear.
C. Remove all boats from the workholder. Select OK.

D. Remove hands from the workholder area, then select OK in the ‘Warning’
prompt.
CAUTION: In the next step, the rail height will be measured by the bond head.
The bond head will move down and touches with the rear rail. Make
sure there is no ball at the capillary tip before you do this step.
E. Observe the warning in the dialog box and select OK to continue with the rail
height measurement.
F. Remove all material from the workholder. Remove the heat block inserts. If
present. Select OK when done.
G. Install the magazine-sized gauge and workholder setup & calibration gauge:
1. Put the magazine-sized gauge against the input magazine wall, on the load
tray. Make sure that the label FRONT points to you.
2. Put workholder setup & calibration gauge assembly between the rails (see
Figure 3-5 and Figure 3-6).
PUT THE WORKHOLDER SETUP & CALIBRATION GAUGE ASSEM-
BLY BETWEEN THE RAILS.
a. Make sure that the index slot of the gauge is on the right side, point
Rear Rail
Output Magazine
Handler Assembly
Front Rail
Index slot on the

right side.
Figure 3-5 Install the Workholder Setup & Calibration Gauge Assembly Position
c. Without moving the gauge forward, slowly lower the gauge until it is on
the front rail (see Figure 3-6).

Gauge at 45o angle
Front Rail
Rear Rail
Figure 3-6 Install the Workholder Setup & Calibration Gauge Assembly at 45o angle
3. Move the gauge to the left side of the indexer assembly to the input maga-
zine handler assembly.
4. Make sure that the pin on the left side of the workholder setup & calibration
gauge points to the input magazine handler assembly. (see Figure 3-7).
5. Select OK in the dialog box. The input mag handler picks up the magazine-
sized gauge.
H. Do the Z axis slot calibration:
1. Make sure that the magazine-sized gauge is picked up by the gripper
assembly.
2. Use the Up and Down arrow keys on the MMI, and move the gripper
assembly with the magazine-sized gauge until the Z axis hole on the gauge
is aligned to the rails position.
3. Move the workholder setup & calibration gauge to the magazine-sized
gauge.
4. Engage the input pin into the Z axis hole (see Figure 3-4) on the magazine-
sized gauge (see CAUTION below).
5. When the Z axis position is correct, move the workholder setup & calibra-
tion gauge to the preheat assembly, make sure that the pin is free from the
magazine-sized gauge. Select OK in the dialog box.
CAUTION: Do not put the input pin of the workholder setup & calibration gauge
into the magazine-sized gauge while you move the gripper with maga-
zine-sized gague.

Workholder Setup
Magazine-sized & Calibration Gauge
Gauge Slot Input Pin
Output Pin
Figure 3-7 Install the Workholder Setup & Calibration Gauge

I. Do the bottom Y axis slot calibration:
assembly.
assembly with the magazine-sized gauge until the bottom Y axis hole on
the gauge is aligned to the rails position.
gauge.
4. Engage the input pin into the bottom Y axis hole (see Figure 3-4) on the
magazine-sized gauge (see CAUTION below).
5. When the bottom Y axis position is correct, move the workholder setup &
calibration gauge to the preheat assembly, make sure that the pin is free
from the magazine-sized gauge. Select OK in the dialog box
J. Do the top Y axis slot calibration:
assembly.
assembly with the magazine-sized gauge until the top Y axis hole on the
gauge is aligned to the rails position.
gauge
4. Engage the input pin into the top Y axis hole (see Figure 3-4) on the maga-
zine-sized gauge (see CAUTION below).
5. When the top Y axis position is correct, move the workholder setup & cali-
bration gauge to the preheat assembly, make sure that the pin is free from
the magazine-sized gauge. Select OK in the dialog box
K. If necessary, adjust the retainer to remove the magazine-sized gauge when
the gauge ejects. Select OK in the dialog box to eject the magazine gauge.
L. Remove the workholder setup & calibration gauge from the rails. Select OK
when done.
M. Install the heat block and clamp inserts. Select OK when done.
NOTE: This completes the Input Slot calibration. If needed, do the Output Slot
calibration.

3.5 Magazine Handler Configuration
Magazine dimensions and magazine slot order are entered using dialog boxes
available through the Magazine Handler Configuration menu (see Figure 3-8) in
Configuration mode. Refer to Section 5 of IConn Operation Manual for descrip-
tions of GUI menus, illustrated definitions of configuration parameters and
options, and other information concerning magazine handler configuration.
Figure 3-8 Magazine Handler Configuration Menu

3.6 Magazine Handler Adjustments
3.6.1 Set-up the Belt Tension
Purpose
• Adjust the tension of the input/output load tray belts to make sure that the belts
move the magazine smoothly on the tray.
• Hand tools
• Allen Key Set
• Torque wrench
• Belt Tension Tester
A. Remove all material from the Magazine Handler Assembly.
C. Remove the input or output tray assembly. Refer to paragraph 3.7.2 step C. for
input tray assembly and paragraph 3.7.2 step C. for output tray assembly.
D. Put the input or output tray assembly on a work bench.
E. Do the driven timing belts tension setup:
1. Find the pulley holder at the bottom of the load tray.
2. Loosen the M5 screw on the pulley holder.
3. Put the sensor of the belt tension tester over the applicable driven timing
belt.
4. Loosen the M4 nut on the pulley holder.
5. Turn the M4 screw to adjust the tension of the driven belt.
6. Make sure that the measured value shows on the belt tension tester is
between 43 Hz and 48 Hz.
7. Tighten the M5 screw.
8. Tighten the M4 nut on the pulley holder to lock the M4 screw.
F. Do the drive timing belt tension setup:
1. Find the motor bracket at the bottom of the load tray.

2. Loosen the two M4 counter sunk screws that attach the load tray motor
with motor bracket and clamping plate to the bottom of the load tray.
3. Loosen the M4 nut on the tensioner block.
4. Turn the M4 screw to adjust the tension of the drive timing belt.
5. Use the torque wrench and apply a torque between 0.11 Nm (1 lb.in.) and
0.14 Nm (1.24 lb.in.) to the M4 screw to put tension on the drive timing belt.
6. Tighten the M4 nut on the tensioner block.
7. Tighten the two M4 counter sunk screws at the top of the load tray.
G. Install the input or output tray assembly to the machine. Refer to paragraph
3.7.2 step E. for input tray assembly and paragraph 3.7.2 step E. for output
tray assembly.
Driven Belts Pulley Holder M5 Screw
Load Tray Assembly

Driven Belt
(Hidden - Not Shown Here)
Tensioner Block
Drive Belt
M4 Nut
M4 Screws
M4 Screws M4 Nut Load Tray Motor
Motor Bracket with

Clamping Plate
M4 Counter Sunk Screws
Idler Pulley Motor Pulley

Drive Belt
Common
Pulley
Drive Belt
Common Pulley Driven Belt

Pulley
Driven Belts (4 places)

Detail - Timing Belt Routing
Figure 3-9 Load Tray, Belt Tension Components

3.6.2 Tray Adjustment
Purpose
• Adjust the retainer to the specified magazine length.
• None
Procedure
A. Loosen the two thumbscrews below the unload tray.
B. Move the retainer along the guide rails to set the distance for the magazines
that you use.
C. Tighten the two thumbscrews.
3.7 Magazine Handler Removal and Installation
The procedures for removing and installing the input magazine handler are basi-
cally the same for the output magazine handler. The user should also read and
understand the Warnings and Cautions listed throughout the procedures before
removing or installing the magazine handler.
WARNING: THE Z TOWER ASSEMBLY WEIGHS APPROXIMATELY 33 POUNDS

(15 KILOGRAMS) AND TRAY ASSEMBLY WEIGHS 15.6 POUNDS (7.08
KILOGRAMS). ONLY ONE PERSON SHOULD BE PRESENT TO LIFT
THE SUBASSEMBLIES OFF FROM THE MACHINE ONE AT A TIME
(STEP B AND C) AND INSTALL IT ON THE MACHINE (STEP D AND E).
WARNING: THE BONDER’S X AND Y MOTORS CONTAIN HIGH MAGNETIC

FIELDS WHICH MAY AFFECT MAGNETICALLY SENSITIVE DEVICES
(PACEMAKERS, IMPLANTS, WATCHES, ELECTRICAL COMPO-
NENTS, ETC.). KEEP ALL MAGNETICALLY SENSITIVE DEVICES
CLEAR OF XY MOTORS.
CAUTION: Comply with the ESD requirements procedure for all electrostatic dis-
charge precautions and restrictions used during the removal and
installation of the input magazine handler.
3.7.1 Input Magazine Handler

The illustration in Figure 3-10 shows an input magazine handler and various
points of interest the user should refer to when performing the removal or installa-
tion procedures.
Purpose
• Remove/install input magazine handler for maintenance.
• Straight hex driver set (metric)
• 5mm hex tip, 3/8” drive
• 3/8” drive, 6” extension
• Ball hex driver set (metric)
• 3/8” drive male to 1/4’ drive female adaptor
• 5mm long ball hex tip, 3/8” drive
• 1/4” drive ratchet wrench
• Torque wrench, 70 in. lb. (7.91 Nm), 3/8” drive
• Shim, 0.001” (0.025 mm)
• Crosshead Screwdriver

Procedure
A. Turn off machine power. Remove magazines (if any) from the input magazine
handler. Remove input tower cover, tower flap cover and Y-axis motor cover.
B. Remove Z Tower Assembly (Figure 3-10).
CAUTION: When lifting the Z Tower Assembly and Input Tray Assembly during its
removal or installation, do not grasp the assembly at the ends of the
base plate. Doing this may cause the base plate to bow. Grasp and lift
the assembly at points near the center of the base plate.
1. At the rear of the Z Tower Assembly, disconnect connector P2 of Input

Magazine cable (P/N 08888-1054-000-06) from connector J1 on the Input
Magazine Handler Intermediate Board. See Figure 3-10 for connector loca-
tion.
2. Disconnect connector P3 of Input Magazine cable (P/N 08888-1054-000-
06) from Y-axis motor cable connector (P/N 08888-1070-000-xx) .
3. Loosen the M4 socket head cap screw (SHCS) that secures the Y-axis
motor’s ground wire cable of Input Magazine cable (P/N 08888-1054-000-
06) to the Y-axis motor. Disconnect the ground wire.
4. Disconnect the Input MHS sensor bus cables (P/N 08888-1082-000-07 and
08888-1082-000-08) from connectors J2 and J3 on the Input Magazine
Handler Intermediate Board. See Figure 3-10 for connectors location on
the board
5. Locate two (2) M4 x 10 mm SHCS that secure the E-chain bracket (with
flexible cable track - E-chain) to the rear of the Z Tower Machining Plate.
Loosen the two (2) screws and lift up the E-chain bracket. See Figure 3-10
6. Remove four (4) M6 x 20 mm SHCSs with washers that secure the Z Tower
Assembly to the base plate. The screws located at the front and rear of the
Z Tower base machining plate. Move the Z Tower forward in Y-axis direc-
tion towards the user to access the screws at the rear and backwards to
access the screws at the front.
7. Using sufficient personnel, lift the Z Tower Assembly off from the machine
(see Caution).
8. Perform Z Tower Assembly maintenance, if required.

Remove Four SHCSs from Base

Plate. (two SHCSs at both front and
rear of Z Tower Assembly)
Disconnect Appropriate Cables Remove Two SHCS Securing The

from Input Magazine Handler E-Chain Bracket to The Rear of
Intermediate Board (see below) Z Tower Machining Plate (see below)
MHS Sensor Bus

Cable Connector (J2)
MHS Sensor Bus

Cable Connector (J3)
E-Chain Bracket Two SHCSs
Rear of Z Tower Assembly
Backplane Magazine
Handler Cable
Connector (J1) (Y Axis
Motor Cable is connected
to this cable)
Input Magazine Handler Intermediate Board (top view)
Figure 3-10 Remove/Install Magazine Handler (Input Magazine Handler Shown)

C. Remove the Input Tray Assembly:
one to two person(s) to lift and move the assembly.
1. Make sure that the electrical cables to the input tray assembly are correctly
positions.
3. Loosen the two captive screws that attach the PCB cover to the indexer
base.
5. Disconnect the input/output tray cable connector from the connector J14 of
the indexer intermediate board (see Figure 3-11).
to the input base plate and lower console top plate.
7. Remove the input tray assembly from the machine.
8. Use sufficient personnel to remove the input tray assembly from the
machine (see Caution).
9. Do the maintenance on the input tray assembly, if necessary.

.
Indexer Assembly
Disconnect the applicable

cables from the Indexer
Intermediate Board (see below)
Input Tray Assembly
In/Out Cable for Output Tray Cable to Connector J15

In/Out Cable for Input Tray Cable to Connector J14
contains:
contains:
- Tray Motor Cable
- Tray Motor Cable
- Tray Full Sensor Cable
- Tray Full Sensor Cable
- Magazine Present Sensor
- Magazine Present Sensor
Indexer Intermediate Board (top view)

Figure 3-11 Input Tray Assembly
D. Install the Input Z Tower Assembly
CAUTION: When lifting the Z Tower Assembly and Input Tray Assembly during its
removal or installation, do not grasp the assembly at the ends of the
base plate. Doing this may cause the base plate to bow. Grasp and lift
the assembly at points near the center of the base plate.
1. Using sufficient personnel, lift the Input Z Tower Assembly and place it onto
the left side of the lower console top plate, besides the XY Table Assembly.
2. Make sure the two (2) benching surfaces on the right side of Z Tower base
machining plate position against the two (2) benching pins on the base
plate.
3. Slide the Z Tower Assembly to the rear. Make sure the rear of Y-axis motor
mounting surface locates against the benching pin on the base plate.
4. Install four (4) M6 x 20 mm SHCSs with washers to secure the Z Tower
Assembly to the base plate.

5. Slide the Z Tower forward in Y-axis direction towards the user to access the
screws at the rear and backwards to access the screws at the front. In a
crisscross pattern, torque each of the four (4) SHCSs to 70 in. lb. (7.91Nm).
6. At the rear of the Input Z Tower Assembly, mount the E-chain bracket (with
flexible cable track - E-chain) onto the rear of the Z Tower Machining Plate.
Tighten the two (2) M4 x 10 mm SHCS.
7. Connect connector P2 of Input Magazine cable (P/N 08888-1054-000-06)
to connector J1 on the Input Magazine Handler Intermediate Board.
8. Connect connector P3 of Input Magazine cable (P/N 08888-1054-000-06)
to Y-axis motor cable connector (P/N 08888-1070-000-xx).
9. Secure the Y-axis motor’s ground wire cable of Input Magazine cable (P/N
08888-1054-000-xx) to the Y-axis motor with the existing M4 SHCS.
Tighten the screw.
10.Connect the Input MHS sensor bus cables P/N 08888-1082-000-07 to con-
nector J2 and P/N 08888-1082-000-08 to connector J3 on the Input Maga-
zine Handler Intermediate Board.
11. Install the input tower cover, tower flap cover and Y motor cover.
E. Install the input tray assembly
1. Put the input tray assembly on the front edge of the input base plate.
2. Attach the input tray assembly to the input base plate with the captive
3. Make sure the ‘C’ plates on the input wall and the input fixed wall interlock
each other.
4. Connect the input/output tray cable connecor to the connector J14 of the
indexer intermediate board (see Figure 3-11). Refer to your notes.
F. Install the PCB cover to the indexer base and tighten the two captive screws.

3.7.2 Output Magazine Handler
The user should read and understand the Warnings and Cautions listed below
before removing or installing the output magazine handler. See Figure 3-10 for
connector locations.
WARNING: THE Z TOWER ASSEMBLY WEIGHS APPROXIMATELY 33 POUNDS

(15 KILOGRAMS) AND TRAY ASSEMBLY WEIGHS 15.6 POUNDS (7.08
KILOGRAMS). ONLY ONE PERSON SHOULD BE PRESENT TO LIFT
THE SUBASSEMBLIES OFF FROM THE MACHINE ONE AT A TIME
(STEP B AND C) AND INSTALL IT ON THE MACHINE (STEP D AND E).
WARNING: THE BONDER’S X AND Y MOTORS CONTAIN HIGH MAGNETIC

FIELDS WHICH MAY AFFECT MAGNETICALLY SENSITIVE DEVICES
(PACEMAKERS, IMPLANTS, WATCHES, ELECTRICAL COMPO-
NENTS, ETC.). KEEP ALL MAGNETICALLY SENSITIVE DEVICES
CLEAR OF XY MOTORS.
CAUTION: Comply with the ESD requirements procedure for all electrostatic dis-
charge precautions and restrictions used during the removal and
installation of the input magazine handler.
Purpose
• Remove/install output magazine handler for maintenance.
• Straight hex driver set (metric)
• 5mm hex tip, 3/8” drive
• 3/8” drive, 6” extension
• Ball hex driver set (metric)
• 3/8” drive male to 1/4’ drive female adaptor
• 5mm long ball hex tip, 3/8” drive
• 1/4” drive ratchet wrench
• Torque wrench, 90 in. lb. (10.2 Nm), 3/8” drive
• Shim, 0.001” (0.025 mm)
• Screwdriver
Procedure
A. Turn off machine power. Remove magazines (if any) from the output magazine
handler. Remove output tower cover, tower flap cover and Y-axis motor cov-
ers.
B. Remove Z Tower Assembly.
CAUTION: When lifting the Z Tower Assembly and Output Tray Assembly during
its removal or installation, do not grasp the assembly at the ends of
the base plate. Doing this may cause the base plate to bow. Grasp and
lift the assembly at points near the center of the base plate.
1. At the rear of the Z Tower Assembly, disconnect connector P2 of Output

Magazine cable (P/N 08888-1054-000-07) from connector J1 on the Out-
put Magazine Handler Intermediate Board. See Figure 3-10 for connector
location.
2. Disconnect the connector P3 of Output Magazine cable (P/N 08888-1054-
000-07) from Y-axis motor cable connector (P/N 08888-1070-000-xx).
3. Loosen the M4 socket head cap screw (SHCS) that secures the Y-axis
motor’s ground wire cable of Output Magazine cable (P/N 08888-1054-
000-07) to the Y-axis motor. Disconnect the ground wire.
4. Disconnect the Output MHS sensor bus cables (P/N 08888-1082-000-12
and 08888-1082-000-18) from connectors J2 and J3 on the Output Maga-
zine Handler Intermediate Board respectively. See Figure 3-10 for connec-
tors location on the board.
5. Locate two (2) M4 x 10 mm SHCS that secure the E-chain bracket (with
flexible cable track - E-chain) to the rear of the Z Tower Machining Plate.
Loosen the two (2) screws and lift up the E-chain bracket. See Figure 3-10
6. Remove four (4) M6 x 20 mm SHCSs and washers that secure the Z Tower
Assembly to the output base plate. The screws are located at the front and
rear of the Z Tower base machining plate. Move the Z Tower forward in Y-
axis direction towards the user to access the screws at the rear and back-
wards to access the screws at the front.
7. Using sufficient personnel, lift the Z Tower Assembly off from the machine
(see Caution).
8. Perform Z Tower Assembly maintenance, if required.
C. Remove the Output Tray Assembly:
CAUTION: Injury Hazard. The Output Tray Assembly weight approximately 23 kg

(50 lbs). To prevent injury, use approved equipment or two persons to
lift and move the assembly.
1. Make sure that the electrical cables to the output tray assembly are cor-
positions.
3. Loosen the two captive screws that attach the PCB cover to the indexer
base.
5. Disconnect the input/output tray cable connecor from the connector J15 of
the indexer intermediate board (see Figure 3-11).
6. Loosen the four (4) M6 captive screws that attach the output tray assembly
to the output base plate and lower console top plate.
7. Remove the output tray assembly from the machine.
8. Use sufficient personnel to remove the output tray assembly from the
machine (see Caution).
9. Do the maintenance on the output tray assembly, if necessary.
D. Install the Output Z Tower Assembly
CAUTION: When lifting the Z Tower Assembly and Output Tray Assembly during
its removal or installation, do not grasp the assembly at the ends of
the base plate. Doing this may cause the base plate to bow. Grasp and
lift the assembly at points near the center of the base plate.
1. Using sufficient personnel, lift the Output Z Tower Assembly and put it on
the output base plate, adjacent to the right side of the XY Table Assembly.
2. Make sure that the two (2) benching surfaces on the left side of Z Tower
base machining plate position is against the two (2) benching pins on the
base plate.
3. Slide the Z Tower Assembly to the rear. Make sure the rear of Y-axis motor
mount locates against the benching pin on the output base plate.
4. Install four (4) M6 x 20 mm SHCSs and washers to secure the Z Tower
Assembly to the output base plate.

5. Slide the Z Tower forward in Y-axis direction towards the user
to access the screws at the rear and backwards to access the screws at
the front. In a crisscross pattern, torque each of the four (4) SHCSs to 70
in. lb. (7.91 Nm).
6. At the rear of the Output Z Tower Assembly, mount the E-chain bracket
(with flexible cable track - E-chain) onto the rear of the Z Tower Machining
Plate. Tighten the two (2) M4 x 10 mm SHCS.
7. Connect connector P2 of Output Magazine cable (P/N 08888-1054-000-07)
to connector J1 on the Output Magazine Handler Intermediate Board.
8. Connect connector P3 of Output Magazine cable (P/N 08888-1054-000-07)
to Y-axis motor cable connector (P/N 08888-1070-000-xx).
9. Secure the Y-axis motor’s ground wire cable of Output Magazine cable
(P/N 08888-1054-000-07) to the Y-axis motor with the existing M4 SHCS.
Tighten the screw.
10.Connect the Output MHS sensor bus cables P/N 08888-1082-000-12 to
connector J2 and P/N 08888-1082-000-18 to connector J3 on the Output
Magazine Handler Intermediate Board.
11. Install the output tower cover, tower flap cover and Y motor cover.
E. Install the output tray assembly:
1. Put the output tray assembly on the front edge of the output base plate.
2. Attach the output tray assembly to the output base plate with the captive
3. Make sure the ‘C’ plates on the output wall and the output fixed wall inter-
lock each other.
4. Connect the input/output tray cable connecor to the connector J15 of the
indexer intermediate board (see Figure 3-11). Refer to your notes.
F. Install the PCB cover to the indexer base and tighten the two captive screws.

3.8 Preventive Maintenance

A preventive maintenance schedule for the magazine handlers is outlined in Table
3-1.

SECURITY AND INTEGRITY OF THE MAGAZINE HANDLER’S ELEC-
TRICAL CONNECTIONS. IF WORKING IN THE AREA OF THE WORK-
HOLDER, MAKE SURE ALL HEATING SURFACES HAVE COOLED
BEFORE PROCEEDING.

TIGHTNESS OF THE MAGAZINE HANDLER’S ATTACHING HARD-
WARE. IF WORKING IN THE AREA OF THE WORKHOLDER, MAKE
SURE ALL HEATING SURFACES HAVE COOLED BEFORE PRO-
CEEDING.
Table 3-1 Magazine Handler Preventive Maintenance Schedule

Clean magazine handlers 40 hours Vacuum Hose Remove any dirt or contaminates
from exposed and moving parts of
the input and output magazine han-
dler.
Check hardware tightness 1000 hours Hand Tools Make sure all attaching hardware
(screws, washers, nuts, etc.) is
securely installed.
Inspect electrical connec- 1000 hours Check for security and integrity of all
tions electrical connections on input mag-
azine handler, and output magazine
handler. Refer to Section 4 for con-
nector locations.
Replace magazine stop 2000 hours Hand Tools Replace all six (6) magazine stop
buttons buttons. One (1) stop button is
located on the upper jaw magazine
gripper assembly; two (2) stop but-
tons are located on the lower jaw
magazine gripper assembly. See
paragraph 3.9.6.2 for procedure.


Lubricate Y-slide bearings 3 months to 6 1. Lubricant (10 ml, 1. Push the [Motor Stop] button.
on Magazine Handler months in syringe), P/N: 2. Remove the Magazine Handler
Assembly 27790-5020-000 assembly cover.
2. Lint-Free Cloth 3. Move the Z Tower assembly to the
3. Hand gloves front or rear manually when necc-
4. Cotton buds essary.
5. Hex Wrench Set
4. Clean the v-grooves of the Y-slide
bearings on the Z Tower assem-
bly using the lint-free cloth.
lubricant to the left and right sides
of the v-grooves of the Y-slide
bearings.
6. Move the Z Tower assembly along
the Y-slide bearings manually for
10 times.
7. Do steps 5 to 6 again for four
times.
8. Remove the unwanted lubricant
from the Y-slide bearings with the
lint-free cloth.
Lubricate Z-slide bearing 3 months to 6 1. Lubricant (10 ml, 1. Push the [Motor Stop] button.
on Magazine Handler months in syringe), P/N: 2. Remove the Magazine Handler
Assembly 27790-5020-000 assembly cover.
2. Lint-Free Cloth 3. Move the magazine gripper
3. Hand gloves assembly up or down manually
4. Cotton buds when neccessary.
5. Hex Wrench Set
4. Clean the v-grooves of the Z-slide
bearing on the Z Tower assembly
using the lint-free cloth.
of the v-grooves of the Z-slide
bearings.
6. Move the magazine gripper
assembly along the Z-slide bear-
ings manually for 10 times.
times.
lint-free cloth.

3.9 Part Replacement Procedures

3.9.1 Replace Sensor Assemblies
Purpose
• Replace the optical switch (sensor) assemblies in a magazine handler assem-
bly (See Figure 3-12 and Figure 3-13).
• Hand tools
• 29–Inch Optical Switch Assembly, P/N 03411-1031-001-17
Procedure
A. Press [MOTOR STOP]. Turn off machine power.
B. Disconnect the sensor that is to be replaced.
1. Locate the sensor. See input magazine handler example in Figure 3-12 and
Figure 3-13 for sensor locations. See Section 4, paragraph 4.3.2.7 for wir-
ing diagrams illustrating cable and sensor connections.
NOTE: Sensor locations are shown in Figure 3-12 and Figure 3-13. load and
unload tray sensors are shown in Figure 3-2. See Section 4 for wiring
diagrams illustrating cable and sensor connections.
2. Trace the sensor cable to its mating connector on the magazine handler
intermediate board and indexer intermediate board (for tray assembly sen-
sors) (see Note above). Disconnect the sensor cable. Note the label on the
mating connector.
C. Loosen cable clamps (if any) that secure the sensor cable. Note how the cable
is routed through the clamps. Remove the sensor cable from the cable clamps.
D. Remove the screw that secures the sensor to its mount. Note the orientation of
the colored wires within the cable. Remove the sensor assembly from the
machine.
E. Read the sensor part number from the label on the sensor cable. Obtain a
replacement sensor assembly that has the same part number.
F. Install the replacement sensor.
1. Mount the sensor at its mounting location. Use one (1) screw to secure the
sensor. Make sure the sensor wires are oriented in the same way as the
original sensor.
2. Route the sensor cable to its connection point on the input or output maga-
zine handler intermediate board or the appropriate interconnect board.
Refer to Figure 3-12, Figure 3-13 and the sensor location and cable routing
illustrations in Section 4. Connect the sensor to the mating connector on
the appropriate board.
3. Route the sensor cable through flexible cable track(s) and cable clamps (if
necessary). Secure the cable clamps.

G. Turn on machine power. Select OK in the Standby Mode dialog box
to start machine initialization. Verify that initialization is completed success-
fully.
Z Axis Motor
Z-Axis Motor Cable:

Connects to J4 on
Input Magazine Handler
Intermediate Board
Input Magazine Handler Intermediate Board

See Section 4 for Connector Locations
Y Axis Home Z-Axis Brake Cable: Z Axis Brake (not

Sensor Cable Connects to J19 on shown - Located
Input Magazine underneath the
Intermediate Board Z Tower Assembly
Y-Axis Motor Cable: Y Axis Motor Flexible Cable (E-chain):

Connects to J9 on Housing MHS Sensor
DMHS Backplane Bus Cables and Backplane
Magazine Cable
Figure 3-12 Cable Routing & Sensors (Input Magazine Handler Shown - Detail A)

Flexible Cable (E-chain) Containing:

- Z Axis Home Sensor Cable
- Magazine Gripper Assembly Motor Cable
- Tray Sensor Cable
- Magazine Gripper Home Sensor Cable
- Top Paw Home Sensor Cable
- Bottom Paw Home Sensor Cable
Z Axis Home Sensor

Cable Connects to J9 on
Input Magazine Handler
Intermediate Board
Z Axis Home Sensor
Top Paw Home Sensor Cable

Top Paw Home Sensor Connects to J11 on Input
(not shown - mounted under Magazine Handler
the Upper Jaw Plate near the Intermediate Board
Top Paw Assembly
Magazine Gripper
Assembly Motor
(not shown - mounted
under Lower Jaw Plate)
Magazine Gripper
Home Sensor
Magazine Gripper
Assembly Motor
Cable Connects
to J5 on Input
Magazine Handler
Bottom Paw Home Sensor Intermediate Board
(not shown - mounted under
the Lower Jaw Plate near the Bottom Paw Home
Bottom Paw Assembly Sensor Cable
Connects to J17 on
Input Magazine
Tray Sensor Handler Intermediate
Board
Figure 3-13 Cable Routing & Sensors (Input Magazine Handler Shown - Detail B)

3.9.2 Replace Cable Assemblies
The following topics list the procedures required to remove and replace motor
cables (refer to Figure 3-12 and Figure 3-13 ) from the magazine handler interme-
diate boards (input/output). The magazine handler is fitted with flexible cable
tracks (E-chain) that house some of the cables. The flexible cable tracks can be
disassembled for easy cable removal. Refer to Section 4 for connector locations.
3.9.2.1 Magazine Gripper Assembly Motor Cable
Purpose
• Replace the magazine gripper assembly motor cable. The cable is routed from
the magazine handler intermediate board through the flexible cable track to
the motor.
• Hand tools
• Tie wraps
• Magazine Gripper Assembly Motor Cable, P/N 08888-1081-000-00
Procedure
A. Press [MOTOR STOP]. Turn machine power off. Remove all covers required to
access the input or output magazine handler.
B. Locate the flexible cable track that houses the magazine gripper assembly
motor cable.
C. Cut tie wraps along the route of the magazine gripper assembly motor cable.
Unfasten the cable clamps at the entry and exit points of the flexible cable
track.
D. Remove and retain the magazine gripper assembly motor cable from cable
clamps on the Z Tower Assembly. Save hardware for reuse.
E. Disconnect the magazine gripper assembly motor cable connector J5 from the
magazine handler intermediate board (see Figure 3-12 and Section 4 for con-
nector locations).
F. Remove one (1) SHCS that secures the magazine gripper assembly motor
cable’s ground wire to the Lower Jaw Block.
G. Disconnect the magazine gripper assembly motor cable from its connector on
the motor.
H. Starting at one end of the flexible cable track, unsnap the top portion of each
chain link section until enough sections are removed to extract the cable.
I. Remove the magazine gripper assembly motor cable from the cable track.
Note how the cable is routed through the cable track.
J. Insert the replacement magazine gripper assembly motor cable in the flexible
cable track making sure that the polarity of the cable is correct (motor connec-
tor to motor). Route and dress the cable as it was before removal. Snap in
place the top portion of each chain link section of the cable track that was
removed in step H..
K. Install one (1) SHCS securing the magazine gripper assembly motor cable’s
ground wire to the Lower Jaw Block. Tighten the screw.
L. Connect the magazine gripper assembly motor cable to its connector on the
motor.
M. Secure the magazine gripper assembly motor cable into cable clamps on the Z
Tower Assembly.
N. Connect the magazine gripper assembly motor cable to connector J5 on the
magazine handler intermediate board.

O. Place the magazine gripper assembly motor cable and other cables into cable
clamps at the entry and exit points of the flexible cable track. Close the cable
clamps. Install tie wraps where needed.
P. Replace all covers removed in step A.
Q. Turn on machine power. Select OK in the Standby Mode dialog box to start
machine initialization. Verify MHS operation during initialization and that initial-
ization completes successfully.
3.9.2.2 Y Axis Motor Cable
Purpose
• Replace the Y axis motor cable that connects from the magazine handler inter-
face board to the Y axis motor.
• Hand tools
• Y Axis Motor Cable, P/N 08888-1070-000-xx
Procedure
B. Remove the Y axis motor cable from cable clamps.
C. Disconnect the Y axis motor cable connector from backplane magazine cable
P/N 08888-1054-000-XX (see Section 4 for connector location).
D. Remove one (1) SHCS that secures the cable’s ground wire to the Y axis
motor.
E. Disconnect the Y axis motor cable from its connector on the Y axis motor.
Remove and discard the cable.
F. Connect the motor-end of the replacement cable to the Y axis motor.
G. Use one (1) SHCS to secure the cable’s ground wire to the Y axis motor.
H. Connect the other end of the cable to backplane magazine cable. Dress and
route the cable through the cable clamps.
I. Replace all covers removed in step A.
J. Turn on machine power. Select OK in the Standby Mode dialog box to start
3.9.2.3 Z Axis Motor Cable
Purpose
• Replace the Z axis motor cable that is routed from the magazine handler inter-
mediate board to the Z axis motor.
• Hand tools
• Tie wraps
• Z Axis Motor Cable, P/N 08888-1093-000-XX
Procedure (refer to Figure 3-12 and Figure 3-13)
B. Cut and remove tie wraps (if any) and unfasten any cable clamps securing the
Z axis motor cable to the rear of Z Tower Plate. Note how cable is routed and
dressed.
C. Disconnect the Z axis motor cable from its mating connector J4 on the maga-
zine handler intermediate board (see Figure 3-12 and Section 4 for connector
location).

D. Remove one (1) SHCS that secures the Z axis motor cable’s
ground wire to the rear of Z Tower Plate.
E. Disconnect the Z axis motor cable from its connector on the Z axis motor.
Remove and discard cable.
F. Connect the motor-end of the replacement cable to the Z axis motor.
G. Use one (1) SHCS to secure the Z axis motor cable’s ground wire to the rear
of Z Tower Plate.
H. Connect the other end of the cable to its mating connector J4 on the magazine
handler intermediate board. Route and dress the cable as it was before
removal. Fasten cable with cable clamp and tie wraps where needed.
I. Replace all covers removed in step A..
J. Turn on machine power. Select OK in the Standby Mode dialog box to start
3.9.3 Replace Magazine Handler Circuit Board Assembly

Refer to the magazine handler board replacement procedure in Section 4 of this
manual.
3.9.4 Replace Load Tray Timing Belt

3.9.4.1 Replace Driven Timing Belt
Purpose
• Replace the driven timing belt in the load tray assembly of the magazine han-
dler assembly.
• Hand tools
• Torque Gauge
• Belt Tension Tester
• Driven Timing Belts, P/N 21060-6140-000
A. Press [MOTOR STOP]. Turn machine power off. Remove magazine(s) from the
load tray if any are present.
B. Loosen the two captive screws that attach the PCB cover to the indexer base.
C. Remove the PCB cover to access the indexer intermediate board.
D. Remove load tray from the tray assembly (input and output).
1. Make sure that the electrical cables to the tray assembly are correctly iden-
tified. If not, make a note of the connection.
2. Disconnect the in/out tray extension cable from the intermediate indexer
board.
3. Disconnect the tray full sensor cable connector from the sensor on the bot-
tom of the unload tray.
4. Loosen the four (4) M5 screws from the load tray assembly.
5. Remove the load tray assembly from the machine.
E. Loosen the two (2) M4 screws from the front of the load tray assembly.
F. Remove the tray cover and loading plate.
G. Disconnect the electrical connections from the load tray motor. Make a note of
the connection.

H. Remove the driven timing belt(s):
1. Loosen the applicable M3 screw(s) on the stop block (if installed).
2. Loosen the applicable M4 nut(s) and M4 screw(s) on the pulley holder.
3. Loosen the applicable M5 screw(s) that attach the drive pulley to the pulley
holder.
4. Loosen the applicable two (2) M4 counter sunk screw that attach the pulley
holder to the tray.
5. Carefully remove the applicable driven timing belt(s) from the drive and
common pulleys.
I. Install the driven timing belt(s):
1. Put the timing belt(s) in position on the applicable drive and common pul-
leys.
2. Tighten the applicable two (2) M4 screws that loosen before.
3. Tighten the applicable M3 screw(s) on the stop block (if installed).
4. Tighten the applicable M5 screw(s) loosen before to attach the pulley.
5. Tighten the applicable M4 nut(s) and screw(s).
6. Adjust the tension of the timing belt. Refer to paragraph 3.6.1.
J. Connect the electrical connections to the load tray motor. Use your notes.
K. Put the tray cover and loading plate to the front of the load tray.
L. Attach the tray cover and loading plate to the load tray with the two (2) M4
M. Install the load tray to the tray assembly:
1. Put the load tray in position on the tray assembly.
2. Make sure that the applicable side of the load tray touches the bottom sur-
face of the inner side plate. The inner side plate is attached to the input/out-
put wall plate.
3. Attach the load tray to the tray assembly with the four (4) M5 screws
removed before.
4. Connect the electrical cables to the module. Use the labels or your notes.
5. Connect the tray full sensor cable connector to the sensor on the bottom of
the unload tray.
6. Connect the in/out tray extension cable to the intermediate indexer board.
3.9.4.2 Replace Drive Timing Belt
Purpose
• Replace the drive timing belt in the load tray assembly of the magazine han-
dler assembly.
• Hand tools
• Torque Gauge
• Drive Timing Belt, P/N 21059-6003-000

D. Remove load tray from the tray assembly (input and output).
1. Make sure that the electrical cables to the tray assembly are correctly iden-
tified. If not, make a note of the connection.
2. Disconnect the in/out tray extension cable from the intermediate indexer
board.
3. Disconnect the tray full sensor cable connector from the sensor on the bot-
tom of the unload tray.
4. Loosen the four (4) M5 screws from the load tray assembly.
5. Remove the load tray assembly from the machine.
the connection.
H. Remove the drive timing belt:
1. Loosen the locknut on the tensioner block.
2. Turn the M4 screw to release the tension on the drive timing belt.
3. Remove the two (2) M4 counter sunk screws from the rod support block.
4. Remove the four (4) M4 counter sunk screws at the two sides of the load
tray assembly, at the front.
5. Remove the pulley rod with all the common pulleys.
NOTE: Remove the driven timing belts from the common pulleys when you
remove the pulley rod.
6. Carefully remove the drive timing belt from the drive and common pulleys.
I. Install the drive timing belt:
1. Put the drive timing belt in position on the motor pulley, together with the
common pulley and pulley rod.
2. Put the driven timing belts in position on the drive and common pulleys.
3. Put the pulley rod with the pulleys to the bottom front of the tray.
4. Attach the rod support block to the bottom of the tray with the counter sunk
5. Attach the pulley rod with the pulleys with the four (4) M4 screws removed
before, at the two sides of the load tray assembly.
6. Install the driven timing belt(s). Refer to paragraph 3.9.4.1, step I.
7. Apply a torque of between 0.11 Nm (1 lb.in.) and 0.14 Nm (1.24 lb.in.) to
the M4 screw on the tensioner block to put tension on the drive timing belt.
8. Tighten the locknut.
J. Connect the electrical connections to the load tray motor. Use your notes.
K. Put the tray cover and loading plate to the front of the load tray.
L. Attach the tray cover and loading plate to the load tray with the two (2) M4
M. Install the load tray to the tray assembly. Refer to paragraph 3.9.4.1, step M..

Motor Pulley Drive Timing Belt
Motor Bracket
with Clamp Plate
Load Tray Motor

Electrical Cable
Positions
4x M3 Screws
M3 Grub Pulley Holder
Screws
Drive Pulley
M5 Screw
Rod Support Block
4x Driven Timing Belts
5x Common Pulleys
M4 Screw
and Nut
4x M4 Counter Sunk Screws Tension Block
Tray Cover
Stop
Block
Loading Plate
M3 Screws
M4 Counter Sunk Screws

M4 Screw
and Nut
2x M4 Screws
Figure 3-14 Load Tray Assembly (Exploded View - Bottom of Tray)

3.9.5 Replace Load Tray Motor
Purpose
• Replace the motor that operates the belts in the load tray on the input and out-
put tray assemblies.
• Hand tools
• Torque Gauge
• Load Tray Motor, P/N 13565-6070-018
Procedure (see Figure 3-14)
D. Remove the load tray from the tray assembly (input and output) (see para-
graph 3.9.4, step D.).
the connection and the electrical cable positions on the motor.
H. Remove the load tray motor:
1. Loosen the locknut on the tensioner block.
2. Turn the M4 screw to release the tension on the drive timing belt.
3. Remove the two (2) M4 counter sunk screws from the tray that attach the
motor bracket.
4. Remove the motor together with the motor bracket and the clamp plate.
5. Remove the two (2) M3 grub screws from the motor pulley.
6. Remove the motor pulley from the motor.
7. Remove the four (4) M3 screws from the motor bracket.
8. Remove the load tray motor.
I. Install the load tray motor:
1. Put the load tray motor in position on the motor bracket. Make sure that the
positions of the electrical cable on the motor is the same as before (see
Figure 3-14).
2. Attach the motor bracket to the motor with the four (4) M3 screws removed
before.
3. Attach the motor pulley to the motor with the two (2) M3 grub screws
removed before.
4. Loosely attach the motor bracket, together with the clamp plate and the
motor, to the bottom of the tray with the two (2) M4 counter sunk screws
removed before.
5. Put the drive timing belt in position on the motor pulley, together with the
common pulley and pulley rod.
6. Connect the electrical connections to the load tray motor. Use your notes.
7. Apply a torque of between 0.11 Nm (1 lb.in.) and 0.14 Nm (1.24 lb.in.) to
the M4 screw on the tensioner block to put tension on the drive timing belt.
8. Tighten the locknut on the tensioner block.
9. Tighten the two (2) M4 counter sunk screws.
J. Put the tray cover and loading plate to the front of the load tray.
K. Attach the tray cover and loading plate to the load tray with the two (2) M4
L. Install the load tray to the tray assembly. Refer to paragraph 3.9.4.1, step M.
3.9.6 Replace Magazine Gripper Parts

3.9.6.1 Replace Magazine Gripper Paw/Paw Return Springs
Purpose
• Replace magazine gripper paw and/or paw return springs on the upper or
lower magazine gripper assembly (see Figure 3-15 and Figure 3-16). The pro-
cedure is the same for magazine grippers on both magazine handlers.
• Hand tools
• Paw, Top, P/N 03401-0512-000-xx
• Paw, Bottom, P/N 03401-0543-000-xx
• Paw Return Spring, Right, P/N 03101-0122-039-xx
• Paw Return Spring, Left, P/N 03101-0122-040-xx
Procedure (See Figure 3-15 and Figure 3-16)
A. Press [MOTOR STOP]. Turn machine power off.
B. Remove the bottom paw assembly
1. Remove one (1) M4 x 20mm SHCS on the Magazine Stop Button Assem-
bly. Remove the assembly. Retain the hardware for reuse.
2. Locate the pivot shaft set screw in the paw bracket of the bottom paw
assembly. It may be necessary to move the lower jaw magazine gripper
assembly to the center in the Y axis direction to gain access to the set
screw.
3. Loosen the pivot shaft set screw. Do not remove the set screw.
4. While holding the bottom paw assembly in place, use a small tool to push
the pivot shaft out of the lower jaw magazine gripper assembly. Retain the
pivot shaft for reuse.
5. Slowly remove the bottom paw assembly away from the lower jaw maga-
zine gripper assembly. While removing the bottom paw assembly, take note
that two (2) compressed springs may fall out from the assembly. Retain the
springs for reuse.
6. Place the bottom paw assembly on a clean work surface.
C. Remove the bottom paw
1. Locate the pivot shaft set screw at the underside of the bottom paw assem-
bly.
3. While holding the bottom paw in place, use a small tool to push the pivot
shaft out of the bottom paw assembly.
4. Slowly remove the bottom paw away from the assembly, making sure that
the two (2) paw return springs do not escape.
5. Retain the pivot shaft for reuse. Discard the bottom paw and return springs.

D. Install the replacement bottom paw and return springs on the bot-
tom paw assembly.
1. Position the two (2) replacement paw return springs in the bottom paw as
shown in Figure 3-15. Make sure the spring arms are positioned in the cor-
ners of the paw pocket as shown in the figure. Make sure the spring coils
are aligned with the holes in the paw.
2. Place the bottom paw on the bottom paw assembly. Press the paw against
the paw bracket so that the springs compress and the holes in the paw are
aligned with the mounting hole on the paw bracket.
Bottom Paw Assembly Lower Jaw Bracket

Magazine Stop
Pivot Shaft Set Screw Button Assembly
Bottom Paw
Pivot Shaft Magazine Stop
Buttons (2 places)
Bottom Paw
Assembly
Flat Cutout
Compressed
Spring (2 places)
Bottom Paw Assembly
Paw Bracket Pivot Shaft
Bottom Paw Bottom Paw Pivot
Shaft Set Screw
Paw Return
Spring (2 places)
Magazine Gripper Assembly Motor
Figure 3-15 Bottom Paw/Spring Replacement (Lower Jaw Gripper Assembly)

3. Insert the pivot shaft into one side of the bottom paw, through the paw
bracket mounting hole, and into the other side of the bottom paw. Make
sure the flat cutout in the pivot shaft is facing down toward the set screw at
the underside of the paw bracket.
4. Tighten the set screw to secure the pivot shaft.

E. Install the bottom paw assembly
1. Place the bottom paw assembly onto the lower jaw magazine gripper
assembly. Position two (2) compressed springs retained from step B.5.
between the guided slots in the paw bracket and lower jaw bracket.
2. Press the bottom paw assembly against the lower jaw magazine gripper
assembly so that the springs compress and the holes in the paw bracket
are aligned with the mounting hole on the lower jaw bracket.
3. Insert the pivot shaft into one side of the lower jaw bracket, through the bot-
tom paw assembly mounting hole, and into the other side of the lower jaw
bracket. Make sure the flat cutout in the pivot shaft is facing up toward the
set screw in the top of paw bracket.
4. Tighten the set screw to secure the pivot shaft. Make sure that the bottom
paw assembly sensor flag (part of the paw bracket) can pass between the
bottom paw assembly sensor elements without interference.
5. Use one (1) M4 x 20mm SHCS to secure the Magazine Stop Button
Assembly to the lower jaw magazine gripper assembly. For Input Magazine
Handler, insert the SHCS to the far right mounting hole of the button holder,
and far left mounting hole for Output Magazine Handler.
F. Remove the top paw
1. Locate the pivot shaft set screw in the upper jaw bracket of the upper jaw
magazine gripper assembly. It may be necessary to move the upper jaw
magazine gripper assembly to the center in the Y axis for access to the set
screw.
3. While holding the top paw in place, use a small tool to push the pivot shaft
out of the upper jaw magazine gripper assembly. Retain the pivot shaft for
reuse.
4. Slowly move the top paw away from the upper jaw magazine gripper
assembly, making sure that the two (2) paw return springs do not escape.
5. Retain the pivot shaft for reuse. Discard the top paw and paw return
springs.
G. Install the replacement top paw and return springs on the upper jaw magazine
gripper assembly.
1. Position the two (2) replacement paw return springs in the top paw as
shown in Figure 3-16. Make sure the spring arms are positioned in the cor-
ners of the paw pocket as shown in the figure. Make sure the spring coils
are aligned with the holes in the top paw.
2. Place the top paw on the upper jaw bracket. Press the top paw against the
jaw bracket so that the springs compress and the holes in the top paw are
aligned with the mounting hole on the jaw bracket.

Leadscrew Nut
Paw Return
Spring (2 places)
Top Paw Pivot

Shaft Set Screw Upper Jaw Bracket
Flat Cutout
Top Paw
Pivot Shaft
Top Paw
Magazine Stop Button

Figure 3-16 Top Paw/Spring Replacement (Upper Jaw Magazine Gripper Assembly Shown)
3. Insert the pivot shaft into one side of the top paw, through the jaw bracket
mounting hole, and into the other side of the top paw. Make sure the flat
cutout in the pivot shaft is facing up toward the set screw in the upper jaw
bracket.
4. Tighten the set screw to secure the pivot shaft. Make sure that the top paw
sensor flag (part of the top paw) can pass between the top paw sensor ele-
ments without interference.
H. Turn on machine power and initialize the machine. During operation, make
sure that the magazine gripper assembly successfully grasps and locates the
magazine against the wear points and benching buttons.

3.9.6.2 Replace Magazine Stop Buttons
Purpose
• Replace magazine stop buttons (see Figure 3-15 and Figure 3-16). One (1)
button is located on the upper jaw magazine gripper assembly; two (2) buttons
are located on the lower jaw magazine gripper assembly. The procedure is the
same for magazine gripper assembly on both magazine handlers.
NOTE: The magazine stop buttons should be replaced as a set. The buttons
should be replaced according to the preventive maintenance schedule
outlined in Table 2-2. If a single button is worn, it may be time to replace
all six buttons (three in each magazine handler).
Frequency
• The stop buttons on both magazine handler assemblies should be replaced
after every 2000 hours of machine operation.
• Hand tools
• Magazine, Stop Button, P/N 03401-0020-042-xx
Procedure (refer to Figure 3-15 and Figure 3-16)
B. Replace stop buttons on lower jaw magazine gripper assembly.
1. Locate the magazine stop button assembly on the lower jaw magazine
gripper assembly.
2. Locate the stop buttons on the magazine stop button assembly. Remove
one (1) SHCS from each button. Remove the buttons and save hardware
for reuse.
3. Use one (1) SHCS to secure each replacement button to the button holder.
Do not over-tighten the screws.
C. Replace stop button on upper jaw magazine gripper assembly.
1. Locate the stop button on the upper jaw magazine gripper assembly.
2. Remove one (1) SHCS from the stop button. Remove the button and save
hardware for reuse.
3. Before removing the button, take note of its orientation and position in the
counter bore.
4. Use one (1) SHCS to secure the replacement button to the upper jaw
bracket of the upper jaw magazine gripper assembly. Do not over-tighten
the screw.

3.9.7 Replace Brake Assembly
To replace the Brake Assembly, the entire Z Tower Assembly must be removed
from the machine.
Purpose
• Replace the brake assembly that resides at the underside of the input/output Z
Tower Assembly (see Figure 3-17). The brake assembly prevents Z-axis
movement when the Z-axis stepper motor power is off.
• Hand tools
• Tie wraps
• Vernier Calipers
• Brake assembly, P/N 08888-1085-000-XX
Procedure
B. Remove input/output tower cover, tower flap cover and Y motor cover.
C. Remove Z Tower Assembly. Refer to paragraph 3.7.1 step B. for Input Z Tower
Assembly and paragraph 3.7.2 step B. for Output Z Tower Assembly.
D. Place the Z Tower Assembly on a flat work surface. Position the assembly
such that the tower lay horizontally on the work surface in order to the to gain
access to the brake assembly at the underside of the Z Tower Assembly.
E. Remove brake assembly.
1. Disconnect the brake cable connector J19 from the Input/Output Magazine
Handler Intermediate Board (refer to Figure 3-12 and Section 4 for connec-
tor locations). Loosen the screws that secure the cable clamps and cut tie
wraps as needed to release the brake assembly cable routed to the under-
side of the Z Tower Assembly.
2. Remove one (1) SHCS that secures the brake ground cable to the under-
side of the Z Tower Assembly.
3. Note the position of the brake cable relating to how the brake assembly is
mounted at the underside of the Z Tower Assembly. Remove three (3)
SHCSs that secure the brake assembly to the underside of Z Tower
Assembly. Remove the brake assembly.
4. Remove the brake square nut attach to the end of Z-axis leadscrew by
loosening two (2) set screws in the nut. See Figure 3-17.
F. Install replacement brake assembly.
1. Remove the brake square nut from the replacement brake assembly.
2. Slide the square nut onto the end of the Z-axis leadscrew. Orientate the nut
such that the two (2) set screws in the nut are positioned on the two flat
surfaces on the leadscrew. Set a gap of 16 mm (630 mil) between the nut
surface and the base surface of the Z Tower Machining plate using the ver-
nier calipers. See Figure 3-17. Tighten the set screws.
3. Mount the replacement brake assembly onto base of the Z Tower machin-
ing plate ensuring that the cable exits the brake assembly in the direction
noted in step E.3.. Align the brake assembly mounting holes with the
tapped holes in the base of Z Tower plate.
4. Install three (3) SHCSs to secure the replacement brake assembly and one
(1) SHCS to secure the ground wire to the underside the Z Tower Assem-
bly. Tighten all four screws.

5. Connect the brake cable to connector J19 on the input/output magazine
handler intermediate board. Route and secure the cable in the cable
clamps and tie wraps as it was before being removed in step E.1.
G. Install Z Tower Assembly.Refer to paragraph 3.7.1 step D. for Input Z Tower
Assembly and paragraph 3.7.2 step D. for Output Z Tower Assembly.
H. Turn on machine power. Select OK when the Standby Mode dialog box
appears to start initialization. Verify that MHS initialization completes success-
fully.
I. Use the Magazine Utilities menu to load a magazine full of carriers onto the
magazine handler where the brake was replaced. Press [MOTOR STOP], then
turn off machine power. Verify that the magazine gripper assembly does not
drop, which indicates that the brake is operating correctly.
J. Replace input/output tower cover, tower flap and Y motor cover.

Z axis Leadscrew
Flat Cutout on Shaft

(2 places) Set Screws
Square Nut
Z Tower Base
16 mm
Bearing
Z-Axis Leadscrew
Brake Assembly
Z Brake Assembly Square
Brake Mounting
Nut Mounting Detail SHCSs (3 places)
Cable Clamps Brake assembly

(2 places) square nut (hidden)
(see mounting detail)
Figure 3-17 Brake Assembly Replacement

3.9.8 Replace Stepper Motors

3.9.8.1 Z Axis Motor
Purpose
• Replace the motor that drives the Z Tower Z axis leadscrew
(see Figure 3-18).
• Hand tools
• Feeler Gauge
• Torque wrench, 12 in. lb., 28 in. lb.
• Torque Screw Driver with 3/32 in. Hex Insert Bit
• Torque Screw Driver with 3mm Hex Insert Bit
• Z motor assembly, P/N 08888-1093-000-xx
Procedure
B. Remove the tower cover, tower flap cover and motor cover on the Input/Output
Magazine Handler Assembly.
C. Locate the Z-axis motor at the top of the Z Tower. Disconnect the Z-axis motor
cable from connector J4 on the Magazine Handler Intermediate Board. Make
note of the connector position on the Z motor.
D. Turn the screw in the Z-axis motor such that the screws on the rigid coupling
are accessible through the opening of Z Tower. This procedure may lift up or
bring down the magazine gripper assembly.
E. Loosen two (2) SHCSs in the rigid coupling to release the leadscrew from the
coupling by using a torque screw driver with 3/32 in. hex insert bit.
F. Remove four (4) SHCSs that secure the Z-axis motor to the motor mounting
surface, located at the top of Z Tower. Remove the motor with rigid coupling.
G. Loosen two (2) SHCSs in the rigid coupling to release the coupling from the
motor shaft by using a torque screw driver with 3/32 in. hex insert bit. Set aside
the rigid coupling for reuse.
H. Insert a 20 mils feeler gauge into the center slot in the rigid coupling. Install the
rigid coupling with feeler gauge onto the shaft of replacement motor. Tighten
the screw in the rigid coupling to a torque of 12 Ib. in., securing the coupling to
the motor shaft. Remove the feeler gauge.
NOTE: Before installing the rigid coupling onto the motor shaft, use a lint-free
cloth to remove any grease or dirt on the motor shaft and rigid coupling
hole.
I. Place the replacement Z-axis motor with rigid coupling against the motor
mounting surface at the top of Z Tower.
J. Position the Z-axis motor properly (check position of connector on motor) and
align the motor mounting holes with the tapped holes in the motor mounting
surface. Make sure the end of the Z axis leadscrew enters the hole in the rigid
coupling. Install four (4) SHCSs to secure the motor to the motor mounting sur-
face. Tighten the four (4) screws to a torque of 28 lb. in.
K. Tighten the two (2) bottom screws in the rigid coupling to secure the leadscrew
to the coupling, to a torque of 12 in.lb.
L. Connect the Z-axis motor cable to connector J4 on the Magazine Handler
Intermediate Board.
M. Install the tower cover, tower flap and motor cover onto the Input/Output Mag-
azine Handler Assembly. Turn on machine power.

N. Select OK from the Standby Mode dialog box to start machine ini-
tialization. Verify that MHS initialization is completed successfully.
SHCS in Z axis
Motor (hidden) SHCS
(4 places)
Z Axis Motor
Rigid Coupling Z Tower Plate
Motor Mounting
Surface
Leadscrew Nut
Z Axis Leadscrew
Figure 3-18 Remove/Replace Z Axis Motor

3.9.8.2 Y Axis Motor
Purpose
• Replace the motor that drives the Z Tower Assembly Y axis leadscrew (see
Figure 3-19).
• Hand tools
• Feeler Gauge
• Y motor assembly, P/N 08888-1070-000-xx
Procedure
A. Press [MOTOR STOP]. Turn machine power off. Remove the tower, tower flap
and motor covers on the Input/Output Magazine Handler Assembly.
B. Disconnect the Y-axis motor cable connector P1 from connector P3 of back-
plane magazine cable (P/N 08888-1070-000-xx), which is routed from the
DMHS backplane.
C. Turn the screw in the Y-axis motor to move the Z Tower Assembly towards the
operator, in order to access the rigid coupling screws.
D. Loosen two (2) SHCSs in the rigid coupling to release the Y-axis leadscrew
from the coupling by using a torque screw driver with 3/32 in. hex insert bit.
E. Take note of the connector position on the Y-axis motor. Remove four (4)
SHCSs that secure the Y-axis motor to the motor mounting surface, located at
the rear of Z Tower Base Plate. Remove the motor with rigid coupling.
F. Loosen two (2) SHCSs in the rigid coupling to release the coupling from the
G. Insert a 20 mils feeler gauge into the center slot in the rigid coupling. Install the
hole.
H. Place the replacement Y-axis motor with rigid coupling against the motor
mounting surface at the rear of Z Tower Base.
I. Position the Y-axis motor properly (check position of connector on motor) and
align the motor mounting holes with the tapped holes in the motor mounting
surface. Make sure the end of the Y axis leadscrew enters the hole in the rigid
coupling. Install four (4) SHCSs to secure the motor to the motor mounting sur-
face. Tighten the four (4) screws to a torque of 28 in. lb.
J. Tighten the two (2) screws in the rigid coupling to secure the leadscrew to the
coupling, to a torque of 12 in. Ib.
K. Connect the Y-axis motor cable connector P1 to connector P3 of backplane
magazine cable (P/N 08888-1070-000-xx)
L. Install the tower cover, tower flap cover and motor cover onto the Input/Output
Magazine Handler Assembly. Turn on machine power.
M. Select OK from the Standby Mode dialog box to start machine initialization.
Verify that MHS initialization is completed successfully.

.
Leadscrew Nut
Y Axis Leadscrew
Rigid Coupling
SHCS in Y axis
Motor (hidden)
SHCS Y Axis Motor

(4 places)
Z Tower Base
Figure 3-19 Remove/Replace Y Axis Motor

3.9.8.3 Magazine Gripper Assembly Motor
Purpose
• Replace the motor that drives the magazine gripper leadscrew and controls
the gripping motion of the upper and lower jaws in Z-axis. (see Figure 3-15)
• Hand tools
• Magazine Gripper Assembly motor, P/N 13565-6049-003-xx
Procedure
A. Press [MOTOR STOP]. Turn machine power off. Remove the tower cover, tower
flap and motor cover on the Input/Output Magazine Handler Assembly.
B. Locate the magazine gripper assembly motor. Turn one (1) SHCS in the Z Axis
motor to lift up the magazine gripper assembly to the center position of Z linear
bearing assembly. Make sure the screws in the rigid coupling are accessible.
C. Disconnect the magazine gripper assembly motor cable (P/N 08888-1081-
000-xx) from its connector on the magazine gripper motor. Place the cable in
an out-of-the-way safe location. Take note of the connector position on the
motor.
D. Loosen two (2) SHCSs in the rigid coupling to release the leadscrew from the
coupling by using a torque screw driver with 3/32 in. hex insert bit.
E. Remove four (4) M4 x 12 mm SHCSs at the underside of the magazine gripper
assembly that secure the magazine gripper motor with rigid coupling to the
lower jaw bracket. Pull the motor with rigid coupling downwards from the
underside of the magazine gripper assembly. Remove the motor with rigid
coupling.
F. Loosen two (2) SHCSs in the rigid coupling to release the coupling from the
G. Insert a 20 mils feeler gauge into the center slot in the rigid coupling. Install the
hole.
H. Place the replacement motor with rigid coupling at the underside of the lower
jaw bracket against the motor mounting surface. Make sure the end of the Y
axis leadscrew enters the hole in the rigid coupling.
I. Position the motor such that its cable connector is in the same position as it
was when removed in step C. Align the motor mounting holes with tapped
holes in the motor mounting surface.
J. Install four (4) SHCSs to secure the motor to the motor mounting surface.
Tighten the screws to 28 in. lb.
K. Tighten the two (2) screws in the rigid coupling to secure the leadscrew to the
coupling, to a torque of 12 in. Ib.
L. Connect the magazine gripper assembly motor cable to its connector on the
motor.
M. Move the magazine gripper assembly down to the bottom of the Z linear bear-
ing assembly.
N. Install the tower cover, tower flap cover and motor cover. Turn on
machine power.
O. Select OK from the Standby Mode dialog box to start machine initialization.
Verify that MHS initialization is completed successfully.


4 Electronics
• Section 4.2, Overall Description, gives an overview of the Electronics function

of the IConn High Performance Wire Bonder and a brief description of each
item in the calibration menu.
• Each section from Section 4.3 through 4.5 describes a calibration feature and
the operation guidelines on carrying out the various calibration procedures.
• Section 4.3, Subsystem/Board Descriptions
• Section 4.4, MHS Sensor
• Section 4.5, Cable Assemblies
98888-0000-JB3-01 Electronics 4-1

4.2 Overall Description

4.2.1 System Organization
The electronic control system for the Material Handling System (MHS) is con-
trolled by the Distributed Material Handling System (DMHS) back plane board
mounted at the rear of the card rack assembly. This backplane interconnects the
circuit boards and provides electrical connections to external devices such as
motors, sensors, solenoids and other interface circuit boards mounted on the
MHS.
Figure 4-1 provides a simplified diagram of the MHS electronics system. The
DMHS backplane is communicated via the ethernet (host) from the PC-On-A-
Board (PCOAB).
The sensor logic on the Stepper Controller board monitors the status of all sen-
sors on the workholder, input magazine handler, and output magazine handler,
receiving sensor data from the interface boards via a synchronous serial inter-
face. The sensor logic converts the sensor data into a form that is usable by other
boards in the system and makes the sensor data available through the backplane.
(Paragraphs 4.2.3 and 4.4 provide descriptions and show locations of MHS sen-
sors.)
An additional function of the stepper controller board is to generate motor control
signal to three stepper driver boards that can control up to 16 motors. Motor con-
trol signals are passed to stepper driver boards via the ethernet. Motor drive sig-
nals from the stepper drivers are passed through backplane connectors to
individual steppers motors via the interface boards. The controller monitors fault
signals from the driver boards and home/limit sensor data from the sensor logic.
(Refer to paragraph 4.2.2 for more information concerning stepper motor drive.)
The Indexer Solenoid Driver board is to generate solenoid drive enable signals
from DMHS data. These signals each activate one of the 24 individual solenoid
driver circuits on the Solenoid Driver board, which operate workholder solenoids,
MHS solenoid valves, magazine handler Z–axis brakes, and load tray motors.
Temperatures of the two workholder heating zones (Preheat and Bond Site) are
controlled by the I/O and Temperature Controller circuit board, which has eight (8)
temperature control circuits. The controller heats a workholder zone by switching
a solid–state relay that connects 56V to a resistive heater, and monitors tempera-
ture with a type K thermocouple mounted close to the heater. The Input/Output (I/
O) portion of the circuit board generates a board enable signal for the solenoid
driver logic (enables or disables all drivers). Refer to IConn Maintenance Manual
for more information concerning the I/O and Temperature Controller board.
Most of the printed circuit boards are located in a card rack within the IConn
machine lower console. MHS interface boards are mounted on the input maga-
zine handler, output magazine handler, and indexer assembly.
4-2 Electronics 98888-0000-JB3-01

Serial Interface, Motor Out

.
Micro/TripleHalf
96
DMHS Backplane
Solenoids
1 to 24 . Stepper Driver Board
Motors . Serial Interface, Motor Out

1 to 16 . 96 HEX Half Stepper Board
Sensor Serial Interface, Motor Out
Indexer Bus HEX Half Stepper Board
96
Input Mag
Output Mag
SPI, Solenoid Out
sensors
96 Indexer/Solenoid Driver
Direct Board
Sensor Input HEX Serial Interface,
0 to 7 SPI, Ethernet,
Ethernet Sensor Bus, Sensors Stepper Fans
Host 96
Controller Board 1&2
With speed sensor
Power 5V, 12V, 48V, Gnd
Figure 4-1 Model 3131 Control System Organization
98888-0000-JB3-01 Electronics 4-3

4.2.2 Stepper Drive

Figure 4-2 shows the signals generated by the stepper controller logic for control
of a typical stepper motor and shows how the motor is connected to its driver cir-
cuit on the stepper driver board in the card rack via an interface board.
Stepper
Motor
A1 B2
A2 B1
Motor Cable
Cable
P1 P2 P3 P4
MHS Interface
Board
Power Cable
P1 P2 P3 P4
Backplane Board
A1 A2 B1 B2
P1 P2 P3 P4
STEP
Stepper/Sensor
1/2 Step Driver PCOAB
Board
MOTOR SERIAL BUS ETHERNET
Figure 4-2 Typical Stepper Motor Control Path
4-4 Electronics 98888-0000-JB3-01

All motors are operated in an open–loop mode where there is no
motor or equipment position feedback to the control system during motions. The
controller determines the position of motor–driven equipment by finding a sensor–
marked home position (zero point) and keeping track of the motion commands
issued to the motor.
For specific information concerning motor connections at the interface boards and
motor drive signal paths from the interface board to the backplane, driver circuit,
and stepper/sensor logic, refer to the diagrams in paragraph 4.3.
4.2.3 Sensor Handling

Figure 4-3 shows how the status of a typical MHS sensor can be read by the con-
trol system. Sensor state data is sent to the sensor logic on the Stepper/Sensor
board by means of a synchronous serial data stream. At the interface board, the
states of all sensors connected to the board are loaded onto multiple eight–bit
long “frames” of data by a serial data transmitter, with the status of each sensor
being assigned to one bit of a frame. As many or as few frames as needed are
assigned to each board. If there are eight sensors or less connected to a board,
then only one frame will be needed.
A frame is sent onto the serial sensor data bus that also carries frames of sensor
state data from the other two MHS Interface boards. The sequence in which the
frames are transmitted is determined by the master serial transmitter on the Step-
per/Sensor board, which sends commands and a synchronizing clock signal to
the serial transmitters on the interface boards via the serial sensor data bus. Each
interface board is assigned unique time slots in which to transmit their frames of
data. From the output magazine handler interface board (last device in the serial
communications path), the serial data stream is sent via the backplane to the sen-
sor logic, which strips out the sensor state data and makes them available to the
stepper controller logic, CPU2 (servo CPU), and I/O board through the VME bus.
Figure 4-6 shows the serial communications path.
98888-0000-JB3-01 Electronics 4-5

Fiber
Photo Optic
Sensor Sensor
Amp
Output
Diode GND +5V GND

Voltage
Serial Output
Data Serial Serial Data
Serial Communications Transmitter +12V
Path (Figure 4-4) GND
MHS Interface
PC Board
Power Cable
Serial Data
+12V +5V GND
Backplane Board
Serial Sensor
Input/Serial
Interface Control Sensor Data Bits
(SENB1 - SEN B53)
Stepper/Sensor CPU2 I/O & Temp.

Board Controller
Board
Figure 4-3 Sensor Data Input to Control System
4-6 Electronics 98888-0000-JB3-01

4.2.4 DMHS Backplane Assembly
The DMHS Backplane circuit board assembly (P/N:08888-4000-000-xx) (see Fig-
ure 4-4) is attached to the rear of the upper card rack assembly. It interconnects
all MHS related circuit boards assemblies in the upper card rack, supplies operat-
ing power to the MHS related circuit boards, and provides connection points for
external equipment. Signals transmitted through the backplane include:
• Stepper Controller Board connected to backplane are communicated via host
ethernet connection (from integrated magnetics transformer).
• Differentiate pair for the LVDS is assigned for the individual 4 channel of motor
serial bus and indexer/solenoid communication.
• Single RJ45 connector provides connection for the sensor bus connecting
between the individual intermediate board and the stepper controller board.
• Fan speed signal is routed to both the stepper controller and the indexer/sole-
noid board to detect fan failure condition.
• To distribute all signal, power and driver to the individual intermediate board.
• Interconnect for parallel sensors that is connected to stepper controller board.
• Provide test point for DMHS supply monitoring.
The backplane board requires no preventive maintenance and should require no

other maintenance action during the life of the machine. In the event of a malfunc-
tion traced to the backplane, the board should be replaced. No attempt should be
made to repair the board.
Figure 4-4 DMHS Backplane Board P/N 08888-4000-000-xx, Major Components
98888-0000-JB3-01 Electronics 4-7

4.3 Subsystem/Board Descriptions

4.3.1 Circuit Board Locations
Circuit board assembly locations within the card rack assembly are shown in Fig-
ure 4-7 and the boards are identified in Table 4-1. Any circuit board may be
located by noting its slot number in the appropriate table, then finding the circuit
board assembly with that slot number in Figure 4-7. Locations of the MHS inter-
face circuit boards and the solid–state relay circuit board are shown in Figure 4-8
For more information concerning the card rack circuit board assemblies, the card
rack, and other control system assemblies, refer to IConn Maintenance Manual.
NOTE: All circuit board assemblies are considered Field Replaceable Units
(FRUs). Refer to paragraphs 4.3.3 through 4.3.5 for circuit board
replacement procedures.
Fiber
Photo Optic
Sensor Sensor
Amp
Output
Diode GND +5V GND

Voltage
Serial Output
Data Serial Serial Data
Serial Communications Transmitter +12V
Path (Figure 4-4) GND
MHS Interface
PC Board
Power Cable
Serial Data
+12V +5V GND
Backplane Board
Serial Sensor
Input/Serial
Interface Control Sensor Data Bits
(SENB1 - SEN B53)
Stepper/Sensor CPU2 I/O & Temp.

Board Controller
Board
Figure 4-5 Sensor Data Input to Control System
4-8 Electronics 98888-0000-JB3-01

Input MH Output MH
Sensor States Sensor States
A
Serial J20A*
J2 J20A*
J3 Serial
Data Data
Transmitter J20B*
J3 J20B*
J2 Transmitter
Workholder
Sensor States
Input Magazine
Input MagazineHandler Output Magazine
Intermediate Board
Handler Interface B Handler Interface
08888-4116-000-xx
08001--4116--000--xx 08001--4116--000--xx
Serial
J1
J2 Data
Transmitter
C
Indexer Intermediate
Indexer Interface Board
08888-4202-000-xx
08002--4207--000--xx
J45
J16
Sensor Cables
A: 08888-1082-000-18
08088---3027---000---00
B: 08888-1082-000-17
08088---3027---000---03
C: 08888-1082-000-12
08088---3027---000---00
DMHS Backplane
Backplane
08888-4000-000-xx
08002--4191--000--xx
Figure 4-6 Serial Communications Path
98888-0000-JB3-01 Electronics 4-9

Table 4-1 DMHS Circuit Boards, 3U Circuit Board (Top Level)
Slot No. Part Number PCB Assembly Name Function/Reference

B 08888-4000-000-xx DMHS Backplane Board Controls, drives, and monitors the
indexer and solenoid operations
1 08888-4032-000-xx DMHS Indexer/ Solenoid Monitor and controls operations
Board on solenoid driver circuits, sole-
noid valves, Puller Assembly,
Index Assembly, DMHS fan moni-
tor and Stepper Controller Board
Communication. See paragraph
4.3.2.1.
2 08888-4166-000-xx DMHS Hex-half Stepper Each board drives six half stepper
Driver Board motors in the Input Z Tower
Assembly, Input Tray Assembly .
Drives the Input Z, Input Gripper,
Input Y, Heat Block Motor. See
paragraph 4.3.2.2.
3 08888-4300-000-xx DMHS Stepper Controller Controls all MHS Stepper motors.
Board See paragraph 4.3.2.3.
4 08888-4166-000-xx DMHS Hex-half Stepper Drives the Output Z, Output Grip-
Driver Board per, Output Y, Input and Output
Tray, Motors. See paragraph
4.3.2.2.
5 08888-4214-000-xx DMHS Micro/Tri-Half Step- Drives the Indexer X Motor. See
per Driver Board paragraph 4.3.2.4.
4-10 Electronics 98888-0000-JB3-01

98888-0000-JB3-01
Lower Deck Boards Upper Deck Boards
Flash Disk
A
Air Filter
11800-7000-00X
Circuit Boards
Circuit Boards
Upper Deck 3U
2x Cooling Fans
Lower Deck 6U
2x Exhaust Fans
Cable Routing Track
Main CPU DMHS Indexer/ Solenoid
1
1
08001-4327-000-xx Driver Board
08888-4032-000-xx
2
Spare Slot
DMHS Hex Half Stepper
Ultrasonic Generator Board
2
Driver Board
Electronics
08888-4302-000-xx 08888-4166-000-xx 1
1
Servo CPU Board
4
DMHS Stepper Controller
3
2
08001-4261-000-xx
3
4
Board
5
08888-4300-000-xx
3
5
Spare Slot
6
DMHS Hex Half Stepper

4
I/O Temperature Board

7
4
Driver Board
6
08828-4010-000-xx
8
5
08888-4166-000-xx
7
Spare Slot
DMHS Tri- Half Stepper 5
Wire Clamp Driver Board Driver Board
Figure 4-7 Card Rack Circuit Board Assembly Locations

08888-4165-000-xx 08888-4214-000-xx
4-11
Output Magazine
Input Magazine Intermediate Board
Intermediate Board
Input Z Tower Assembly Output Z Tower Assembly

(without PCB cover)
J Boat Indexer Assembly
Figure 4-8 MHS Interface Locations
4-12 Electronics 98888-0000-JB3-01

Power Supply
Air Filter
Hinged Card Cage DMHS Back Plane

(Out position) Board
Main Back Plane

Board
General Servicing Area

at Lower Console Components
Cooling Fans (2x)

Lower Console Frame
(Covers Removed)
Upper Deck DMHS Circuit Boards
Hinged Card Cage Cover
PC-on-a-Board Assembly
Flash Disk
Lower Deck Circuit Boards
Exhaust Fans (2x)
Lower Console
Figure 4-9 Power Supply Locations
98888-0000-JB3-01 Electronics 4-13

4.3.2 Circuit Board Assemblies

4.3.2.1 DMHS Indexer/Solenoid Driver Board
Table 4-2 provides a summary of the functions, controls/indicators, and test points
of the Indexer/Solenoid driver board. In addition, a listing of pertinent references
is included in the table.
Table 4-2 DMHS Indexer/Solenoid Driver Board, P/N 08888-4032-000-xx
Functions Controls/Indicators Test Points Reference
• Contains sixteen (16) solenoid The board consist of two TP1: DGND Figure 4-7
driver circuits. Each can be oper- seven-segment LEDs for TP2: AGND Figure 4-10
ated individually by a signal from error code displaying TP3: GRIP3_VREF
the DMHS Stepper Controller and board diagnostic. TP4: GRIP1_VREF
Board. As a group, the drivers are The function of the LED TP5: PULLER_VREF
enabled or disabled by a signal display should be TP6: ENDCODER_A
from the I/O board.
changeable through host TP7: Index Gripper
• Each driver circuit has overcurrent command. Control Hall Sensor
detection circuit and back EMF pro- Input Signal.
tection. TP8:Spare PWM cur-
• FAULT LED
• Board generates a fault signal if (RED): Goes on rent control driver 2 ref-
any driver indicates an overcurrent if overcurrent erence voltage.
condition.
detected or if board is TP9:Spare PWM cur-
• Contain six (6) channels of current- disabled. rent control driver 4 ref-
controllable drivers (48V, 0-2A) for • ENABLE LED erence voltage.
solenoid/DC motor actuator control. (GRN): On when
• Contain sixteen (16) channels of board enable signal
ON/OFF solenoid drivers (12V, 0- is active.
700mA) with external OT protec-
tion.
DS2 - LED: Green indi-
• Contain eight (8) channels of ON/ cates board has power
OFF solenoid drivers (optional, up.
12V, 0-400mA)
• Contain multiple jam detect inter-
face and handling circuit.
• Contain two (2) channels of DMHS
fan monitor
Test
Points
TP10
To J4 DMHS
Back Plane
TP1
Figure 4-10 DMHS Indexer/Solenoid Driver Board, P/N 08888-4032-000-xx,

Major Components
4-14 Electronics 98888-0000-JB3-01

4.3.2.2 DMHS Hex Half Stepper Driver Circuit Boards
of the DMHS Hex Half Stepper Driver Circuit Board. There are two (2) DMHS
Hex Half Stepper Driver Circuit Boards present in the DMHS card rack assembly.
In addition, a listing of pertinent references is included in the table.
Table 4-3 DMHS Hex Half-Stepper Drivers, P/N 08888-4166-000-xx
• Drives six half stepper • D14 - LED: Red indi- TP1: +48V DRV Figure 4-7
motors under control cates communication TP2: PGND DRV Figure 4-11
of the DMHS Stepper error occurs with Step- TP3: +5V DRV
Controller Board by per Controller Board. TP4: DGND DRV
motor serial bus. LED - OFF indicates TP5: STEP CLOCK SIGNAL
• Motor current and sup- communication enable. of:
ply voltage monitored • LED1 to LED5 and 1) Input Y-axis motor when
for each driver. Step- LED12 (six Half-stepper connected to J2 of DMHS
per fault is returned to motors): Each LED rep- backplane.
stepper controller and resent a driver motor. 2) Output Y-axis motor when
driver is disabled if Light turns red if over
connected to J5 of DMHS
overcurrent detected current or fault occur.
or supply voltage lost. Light turns green when backplane.
• Each driver is set for 2 signal is active. LED
Amp peak run current unlit if over-temperature TP6: STEP CLOCK SIGNAL
condition occurs or of Heat Block motor when
driver is disabled. connected to J2 of DMHS
• LED6 (Power Supply): backplane.
Light turns red if fuse
blow or fault occur. Light TP7: STEP CLOCK SIGNAL
turns green indicates of Clamp motor when con-
high voltage enable. nected to J2 of DMHS back-
LED unlit if power sup- plane.
ply is disabled.
J1 pin 6: STEP CLOCK SIG-
NAL of:
1) Index Theta motor when
backplane.
2) Eject Theta motor when
backplane.
98888-0000-JB3-01 Electronics 4-15

To J5 DMHS
Back Plane
TP8
Test
Points
TP1
Figure 4-11 DMHS Hex Half-Stepper Drivers, P/N 08888-4166-000-xx,

Major Components
4-16 Electronics 98888-0000-JB3-01

4.3.2.3 DMHS Stepper Controller Board
of the DMHS Stepper Controller board. In addition, a listing of pertinent refer-
ences is included in the table.
Table 4-4 DMHS Stepper Controller Board, P/N 08888-4300-000-xx
• Receives synchronous • RESET (S1): Push but- TP1: \REQA - PCI bus
serial sensor data from ton switch. Resets the request A (low active)
sensors interface boards. stepper control CPU. TP2: \REQB - PCI bus
• Distributes sensor state • D1 - LED (Yellow): Light request B (low active)
through ethernet bus. blinking indicates signal TP3: \GNTA - PCI bus
• Interface for communica- present in network traffic; grant A (low active)
tions with index board digi- light unlit indicates no net- TP4: \GNTB - PCI bus
tal signal processor (DSP). work present. grant B (low active)
• Monitors MHS sensor data • D2 - LED (Green): Light TP5: GND
and stepper fault signals indicates FPGA is ready. TP6: PGND
from stepper drivers. • D3 - LED (Green): Light TP7: SFRAME
• Send stepper motor indicates motor serial bus TP8: SLOCK
motion commands to is active. TP9: MBTEST0
DMHS hex half stepper • D4 - LED (Red): Light TP10: MBTEST1
driver boards, DMHS indicates board error. TP11: MBTEST2
Indexer/Solenoid driver TP12: MBTEST3
• W1 - Jumper: Ethernet
board and DMHS micro-tri MAC address (optional).
half stepper driver board When it is shorted,
by motor serial bus. Can another MDM (Material
control up to 16 stepper handling Distributed Mod-
motors. ule board) is supported.
• Sends solenoid control • W2 - Jumper: FPGA flash
data from host to indexer/ programming. During SPI
solenoid board in JDC flashing programming,
command. Controls 24 this jumper is shorted.
solenoids.
Figure 4-12 DMHS Stepper Controller Board, P/N 08888-4300-000-xx,

Major Components
98888-0000-JB3-01 Electronics 4-17

4.3.2.4 DMHS Micro/Tri Half Stepper Driver Board
of the Indexer Interface Circuit Board. In addition, a listing of pertinent references
is included in the table.
Table 4-5 DMHS Micro/Tri Half Stepper Board, P/N 08888-4214-000-xx
• Drives the workholder • D14 (Communication Indicator TP1: +48V
indexer microstepper LED): Red indicates communi- TP2: PGND DRV
motor under control of the cation error occurs from DMHS TP3: +5V DRV
Stepper Controller Board. Stepper Controller board (K&S TP4: DGND DRV
• Motor current and supply P/N: 08888-4300-000-XX). Light TP5: PROG1(Commu-
voltage monitored for each unlit indicates communication is nication error signal)
driver. Stepper fault is in operation.
TP6: PROG2 (Signal
returned to stepper control- • LED1 (Indexer Microstepper from Indexer Micro-
ler and driver is disabled of motor): Light turns red if over- stepper Motor)
overcurrent detected, sup- current or fault occur, motor TP7: PROG3 (Signal
ply voltage lost or over- stop. Light turns green when sig-
from Front Rail Motor)
temperature. nal is active. LED unlit if over-
• Provide stepper pulse temperature condition occurs or J1pin 6: STEP
driver is disabled. CLOCK SIGNAL of
signal to Index board for Rear Rail Motor.
jam detection. • LED2 (48V Power Supply): Light
• Control a microstepper turns red if fuse blow or fault
motor and three (3) hex occur. Light turns green indi-
half stepper motor. cates high voltage enable. LED
unlit if power supply is disabled
• LED3 (Front Rail motor): Light
turns red if over-current or fault
occur, motor stop. Light turns
green when signal is active. LED
unlit if over-temperature condi-
tion occurs or driver is disabled.
• LED4 (Rear Rail motor): Light
turns red if over-current or fault
occur, motor stop. Light turns
green when signal is active. LED
unlit if over-temperature condi-
tion occurs or driver is disabled.
• LED5 (Programmable Focus
motor): Light turns red if over-
current or fault occur, motor
stop. Light turns green when sig-
nal is active. LED unlit if over-
temperature condition occurs or
driver is disabled.
4-18 Electronics 98888-0000-JB3-01

Figure 4-13 DMHS Micro/Tri Half Stepper Driver Board, Major Components
98888-0000-JB3-01 Electronics 4-19

4.3.2.5 Magazine Handler Intermediate Board (08888-4116-000-xx)
The function of the Magazine Handler Intermediate board is listed in Table 4-6 .
The circuit board layout and cable connections are shown in Figure 4-14.
Figure 4-16 Illustrates cable and sensor connections for the Gripper Interface Cir-
cuit Board.
Table 4-6 Magazine Handler Intermediate Board, P/N 08888-4116-000-xx
Functions Controls/Indicators Reference
• Provides connections for mag- W1: Input Magazine Handler Figure 4-14,
azine handler motors, sensors W2: Output Magazine Handler
and Z axis brake.
• Has circuitry to load sensor NOTE: Remove jumper on W1 will set the
state data onto the synchronous board for use on the Input Magazine Handler.
serial sensor data bus.
NOTE: Remove jumper on W2 will set the
board for use on the Output Magazine Handler.
J13, Tray Sensor J14, Y Axis Home Sensor
J19, Z Brake Solenoid
J16, Spare
J8, In Used
Jumper W1: Input
Magazine Handler
J15, Spare
Jumper W2: Output

Magazine Handler J7, In Used
J9, Z Axis Home
Sensor J12, Spare
J4, Z Axis Motor
J18, Spare
J10, Magazine Gripper
Home Sensor
J17, Bottom Paw

Home Sensor
J11, Top Paw Sensor
J5, Magazine Gripper

Axis Motor
J2, MHS Sensor J1, Backplane J3, MHS Sensor
Bus Cable Magazine Cable Bus Cable
Figure 4-14 Magazine Handler Intermediate Board Layout, Major Components

4-20 Electronics 98888-0000-JB3-01
4.3.2.6 Indexer Intermediate Board (08888-4226-000-xx)
Table 4-7 shows the connection points of the cable and sensor assemblies on the
Indexer Intermediate Board. The connection points receive interface signals from
the DMHS Backplane board through J2. The circuit board layout and cable con-
nections are shown in Figure 4-15.
Table 4-7 Indexer Intermediate Board, P/N 08888-4226-000-xx
• Provides connections for • Jumper W1 - W3: Not con- None Figure 4-15,
workholder motors, sensors nected. Use for new option.
and flex cable assembly.
• Has circuitry to load sensor
state data onto the synchro-
nous serial sensor data bus.
• Has circuitry to process jam
detector signal.
• Two channels of high current
solenoid for driving tray
motor.
J10, Preheat Motor J3, Puller Flex

Home Sensor Cable Assembly Cable
J19, J Boat Present
Sensor Cable (input) J23, Gripper Flex J21, Indexer J4 Preheat J1, Indexer J15, In/Out Tray
Assembly Cable Motor Cable Motor Cable DMHS Cable Extension Cable
J14, In/Out Tray J9, X Sensor J25, Grip Air Press J6, Solenoid Cable J2, MHS Sensor
Extension Cable Cable Assembly Cable Bus Cable
J20, J Boat Present
Sensor Cable (output)
Figure 4-15 Indexer Intermediate Board Connection Points
98888-0000-JB3-01 Electronics 4-21

4.3.2.7 Magazine Handler Connections
Figure 4-16 shows the connection points for cable and sensor assemblies for the
input and output magazine handlers. The Z Tower Assembly and Tray Assemblies
connections are controlled by the Magazine Handler Intermediate Board and
Indexer Intermediate Board. The connection points receive interface signals from
the DMHS Backplane board through MHS Sensor Bus cable.
Figure 4-16 Input or Output Interconnect Boards, Cable and Sensor Connections
4-22 Electronics 98888-0000-JB3-01

4.3.3 Replace DMHS Card Rack Circuit Boards
Purpose
• Replace a circuit board in the DMHS card rack assembly (see Figure 4-7).
Tools/ Equipment
• Screw drivers (for slotted or Phillips head screws)
• ESD Protective Equipment/Materials
CAUTION: OBEY ALL ESTABLISHED ESD PROCEDURES WHEN HANDLING OR

STORING CIRCUIT BOARD ASSEMBLIES.
CAUTION: MAKE SURE MACHINE POWER IS OFF BEFORE REMOVING ANY CIR-
CUIT BOARD FROM THE CARD RACK. WAIT AT LEAST FIVE (5) SEC-
ONDS AFTER SWITCHING OFF POWER AT THE CIRCUIT BREAKER
BEFORE PULLING ANY CIRCUIT BOARD OUT OF THE RACK. THIS
DELAY ALLOWS ANY RESIDUAL CHARGE IN THE POWER SUPPLY
TO DISSIPATE.
CAUTION: PC BOARDS MUST BE INSTALLED IN THE CORRECT SLOT IN THE

RACK, PER THE LABEL ON THE CARD RACK DOOR. IF A BOARD IS
IN THE WRONG SLOT, THE BOARD OR OTHER MACHINE EQUIP-
MENT MAY BE DAMAGED WHEN POWER IS APPLIED
Procedure
A. Press [MOTOR STOP]. Turn off machine power and wait for five [5] minutes to
discharge all hazardous voltages. Open the front door of the lower console.
B. Remove circuit board assembly from the DMHS card rack.
1. Loosen the captive screw on the cardcage door and open the door. Locate
the DMHS card rack at the top level of the card cage assembly.
2. Using each hand to hold on to the card puller on the top and bottom edge
of the card, eject the card by pulling out the card puller.
3. Immediately place the circuit board assembly in an ESD–protective enclo-
sure.
C. Install the replacement circuit board in the card rack.
1. Slide the circuit board into its slot in the card rack until connector(s) seats in
mating connector(s) on the DMHS backplane board.
2. Press firmly on the top and bottom edges of the card, with equal pressure
applied until the board connector(s) fully seats in the backplane connec-
tor(s). Do not press against connectors, switches, or indicators on the
board edge (if any).
3. Close the card cage door and tighten the captive screw.
D. Close the lower console front door.
E. Turn on machine power. Start machine and verify that the machine operates
normally.
98888-0000-JB3-01 Electronics 4-23

4.3.4 Replacing the Input/Output Magazine Handler Intermediate Board

Purpose
• Replace the input/output magazine handler intermediate circuit board assem-
bly mounted at the rear of the Input/output Z Tower Assembly. (see Figure 4-
17).
Tools/ Equipment
• Hex wrench set
• Magazine Handler Intermediate Board Assembly,
P/N 08888-4116-000-xx
Procedure
A. Press [MOTOR STOP]. Turn off machine power.

B. Remove the magazine handler intermediate board from the rear of the input or
output Z Tower assembly.
1. Remove input/output tower cover, tower flap cover and Y axis motor cover.
2. Locate the magazine handler intermediate board at the rear of the Z Tower
Assembly (Z Tower machining structure).
3. Disconnect sensors, motors, and cables from the Z Tower Assembly con-
nected to the magazine handler intermediate board (mounted at the rear of
the Z Tower Assembly). (see Figure 4-16 for connector location).
a. MHS Sensor Bus cables, connectors J2 and J3
b. Z Brake Motor cable, connector J19
c. Z Motor cable, J4
d. Z Home Sensor cable, J9
e. G Motor cable, J5
f. G Home Sensor cable, J10
g. Touch Home Sensor cable, J11
h. Tray Sensor cable, J13
i. Grip Home Sensor cable, J17
j. Y Home Sensor cable, J14
k. Y Motor cable, J1
4. Remove four (4) SHCSs that secure the board to the four (4) hex standoffs
on the rear of the input/output Z Tower assembly.
5. Remove the board from the machine and store it in an ESD–protective
enclosure.
4-24 Electronics 98888-0000-JB3-01

.
Z Tower Assembly
Standoffs
(4 places)
Magazine Handler
Intermediate Board
SHCS
(4 places)
NOTE: a) Input/output Magazine Handler Intermediate Boards are mounted

with the component side facing the rear of the machine. b) See Figure 4-
16 for magazine handler intermediate board connector locations and ref-
erence designators. Reference designators are also printed on the sol-
der side of the board. c) See Figure 4-16 for part numbers of cables,
sensors, and motors connected to board.
Figure 4-17 Replace Input or Output Magazine Handler Intermediate Board (Input Side)
C. Install the replacement board on the input or output magazine handler.
1. Position the board on the rear of the Z Tower machining structure with its
component side facing the rear of the machine. Place the board against the
standoff on the rear of the Z Tower machining structure.
2. Install four (4) SHCSs through the board and into the standoffs to secure
the board
98888-0000-JB3-01 Electronics 4-25

3. Connect sensors, motors, and cables to the following board connectors:
• J1: Y Motor Cable, 08888-1070-000-xx
• J2 and J3: MHS Sensor Bus Cables, 08888-1082-000-xx
• J4: Z Motor Cable, 08888-1093-000-xx
• J5: G Motor Cable, 08888-1081-000-00
• J9: Z Home Sensor Cable, 03411-1031-000-19
• J10: G Home Sensor Cable, 03411-1031-001-17
• J11: Touch Home Sensor Cable, 03411-1031-001-21
• J13: Tray Sensor Cable, 03411-1031-001-18
• J14: Y Home Sensor Cable, 03411-1031-001-23
• J17: Grip Home Sensor Cable, 03411-1031-001-20
• J19: Z Brake Motor Cable, 08888-1085-000-xx
4. Setup for board use on the Input Magazine Handler and Output Magazine
Handler.
a. For Magazine Handler Intermediate board installed on the Input Maga-
zine Handler, remove the jumper on W1. This will set the board for use
on the Input magazine handler.
b. For Magazine Handler Intermediate board installed on the Output Mag-
azine Handler, remove the jumper on W2. This will set the board for use
on the Output magazine handler.
D. Mount the input/output tower cover, tower flap cover and Y motor cover.
E. Turn on machine power. Verify that the magazine handler operates properly
during MHS initialization.
4.3.5 Replace Indexer Intermediate Board

Replace the indexer intermediate circuit board assembly installed in the front of
the J boat indexer assembly.
Tools/ Equipment
• Hex wrench set
• Open–end wrench set
• Indexer Intermediate Board Assembly, P/N 08888-4226-000-xx

Procedure
A. Press [MOTOR STOP] and turn off machine power.
D. Make sure that the electrical cables to the indexer intermediate board are cor-
E. Disconnect the following electrical cables from the indexer intermediate board
at the front of the indexer assembly. (See Figure 4-15 for connector locations
on the intermediate board.)
• DMHS Indexer cable from connector J1
• MHS Bus Sensor Cable from connector J2
• Solenoid Cable from connector J6
4-26 Electronics 98888-0000-JB3-01

• In/Out Tray Cable from connector J14
• In/Out Tray Cable from connector J15
• Gripper Flex Cable Assembly from connector J23
• Puller Flex Cable Assembly from connector J3
• Grip Air Press Assy from connector J25
• Preheat Motor Home Sensor Cable from connector J10
• Indexer Motor Cable from connector J21
• Preheat Motor Cable from connector J4.
• See Through Sensor Assembly Cable (X sensor) connector J9
• J Boat Present Sensor Cable (input) connector J19
• J Boat Present Sensor Cable (output) connector J20
F. Remove the Indexer Intermediate Board from the J boat indexer assembly.
1. Remove the six M3 screws and washers that attach the Indexer Intermedi-
ate board to the front of the indexer base (see Figure 4-18.)
2. Remove the board from the indexer base and keep it in an ESD–protective
container.
G. Install the replacement indexer intermediate board on the workholder.
1. Put the indexer intermediate board on the front of the indexer base.
2. Attach the board with the screws and washers removed before.
3. Connect the electrical cables to the indexer intermediate board removed
before. Refer to your notes.
6 x M3 Screws
6x M3 Washers
Indexer Base
Figure 4-18 Replace Indexer Intermediate Board (Front View of J Boat Indexer Assembly)
H. Install the PCB cover to the indexer base and tighten the two captive screws.
I. Turn on machine power.
98888-0000-JB3-01 Electronics 4-27
4.4 MHS Sensors

4.4.1 Sensor Types
Three types of sensors are used on the MHS:
• Reflective fiber optic sensors
The reflective sensors trigger when light from the sensor fiber optic reflects
from a surface (in this case a leadframe) and returns to the fiber optic. These
sensors have amplifiers that must be adjusted for sensitivity by the user.
• Optical switch sensors (photosensors)
Optical switch sensors mark positions for the axes of motion or indicate the
location of material in the MHS. A flag on the moving part of an axis, or on a
mechanism that can be displaced by a piece of material, interrupts the sensor
light beam which signals the control system.
• Jam Detector
The jam detector on the index/tucker arm can sense the increased resistance
to carrier motion during indexing or ejection, which indicates that a carrier is
jammed. A signal from this sensor will stop the ejection and indicate an error.
The operator can then clear the jam at the output magazine. Components of
this sensor include two contact pins and a spring-loaded bar that electrically
connects the pins (part of the index arm). When the carrier is jammed, the bar
loses contact with the pins, breaking the electrical connection between them.
4-28 Electronics 98888-0000-JB3-01

4.4.2 Workholder Sensor Locations
The locations of workholder sensors are shown in Figure 4-19.
Heat Block Home Sensor
Detail- Slider Assembly, Rear View
Indexer Pin Left Sensor Indexer Pin Right Sensor

J Boat Present Sensor (Input) (Hidden - not shown) (Hidden - not shown)
X Registration Sensor
Puller Pin Sensor Carrier Jam Sensor
(Hidden - not shown)
J Boat Present
Sensor (Output)
Puller Connector Board

(Part of Flex Cable)
Index Connector Board

(Part of Flex Cable)
Puller Motor Home Sensor
Preheat Motor Home Sensor

Indexer Home Sensor
J Boat Indexer Assembly, Front View
Figure 4-19 Workholder Sensor Locations

98888-0000-JB3-01 Electronics 4-29
4.4.3 Magazine Handler Sensor Locations

The locations of sensors and routing of sensor cables, for both input and output
magazine handlers, are shown in Figure 4-20, Figure 4-21 and Figure 4-22.
Figure 4-20 and Figure 4-21 show the z tower assembly on the input magazine
handler. The z tower assembly is identical on both the input and output magazine
handlers. Figure 4-22 shows the load and unload tray sensors for the output mag-
azine handler. The tray assembly on the input magazine handler is a mirror image
of output magazine handler.
Y Axis Home
Sensor Cable Y Axis Home Sensor (not shown)
Mounted under Z Tower Base
Machining Plate - Connects to
J14 on Magazine Handler
Intermediate Board.
Figure 4-20 Magazine Handler Sensors - Detail A (Input Magazine Handler Shown)
4-30 Electronics 98888-0000-JB3-01

Flexible Cable Track Containing:

- Z Axis Home Sensor Cable
- Tray Sensor Cable
- Magazine Gripper Home Sensor Cable
- Top Paw Home Sensor Cable
- Bottom Paw Home Sensor Cable
Z Axis Home Sensor Cable Connects to J9 on

Input Magazine Handler Intermediate Board
Z Axis Home Sensor
Top Paw Home Sensor Cable

Top Paw Home Sensor Connects to J11 on Input
(not shown - mounted under Magazine Handler
the Upper Jaw Plate near the Intermediate Board
Top Paw Assembly
Magazine Gripper
Home Sensor
Bottom Paw Home Sensor

(not shown - mounted under
the Lower Jaw Plate near the Bottom Paw Home
Bottom Paw Assembly Sensor Cable
Connects to J17 on
Tray Sensor Input Magazine
Handler
Intermediate Board
Figure 4-21 Magazine Handler Sensors - Detail B (Input Magazine Handler Shown)
98888-0000-JB3-01 Electronics 4-31

Output Magazine Wall

Tray Full Sensor
(Hidden - bottom of unload tray)
Unload Tray
Load Tray
NOTE: See Figure 4-16 for magazine handler cable, motor and sensor part
numbers. See Section 3 for complete cable routing.
Figure 4-22 Tray Assembly Sensors - Detail C (Output Tray Assembly Shown)
4-32 Electronics 98888-0000-JB3-01

4.4.4 Reflective Sensor Amplifier Setup
There are two (2) reflective sensors in the MHS (refer to Figure 4-23). The J Boat
present amplifiers/sensors, one mounted on the input side (left side) of the rear
rail assembly and the other one is one mounted on the output side (right side).
This sensor finds a J boat is between the indexer assembly and the magazine.
The control system will attempt to move a magazine only if the appropriate sensor
is clear.
The procedures that follow provide only a sensitivity adjustment for the sensor
amplifiers. Other adjustments may be necessary.
Rear Rail Assembly
J Boat Present Sensor

Amplifier (Input)
J Boat Present Sensor Amplifier (Output)

J Boat Indexer Assembly, Rear View
Switching
Threshold
Configuration Power LED

Status LEDs (Green)
(Green)
Programing Bargraph Display

Push Buttons (Red) Yellow
Output LED
Sensor Amp Controls/Indicators

Figure 4-23 Reflective Sensor Amplifier Setup
98888-0000-JB3-01 Electronics 4-33

4.4.4.1 J Boat Present Sensor Setup
Tools/ Materials
• Sample J Boat
Procedure
A. Locate the sensor amplifier. The input (load) J boat present sensor amplifier is
mounted on the rear left side of the rear rail assembly. The output (unload) J
boat present sensor amplifier is mounted on the rear right side of the rear rail
assembly.
B. Setup and teach the J boat present sensor amplifier.
NOTE: At factory setting, the LED lights (green) on the ‘LO’ and ‘HS’ are turned
ON.
1. Make sure that the ”LO” and ”HS” lights are turned ON before you teach
the replaced amplifier:
a. Press and hold the TEACH (or ”-”) button of the amplifier for two to three
seconds until ”LO” and ”DO” of the Status LEDs flash after another.
b. To set the ‘unblock’ condition (without J boat), press the TEACH (or ”-”)
button one [1] time.
c. To set the ‘block’ condition, put the sample J boat on the workholder
rails and in the path of the sensor beam, then press the TEACH (or ”-”)
button one (1) time.
Table 4-8 Recommended Signal values for output signal
Bargraph LED Relative Signal Difference
6 to 8 Excellent: Very stable Operations.
4 to 5 Good: Minor sensing variables will not affect sensing reliability.
2 to 3 Low: Minor sensing variables may affect sensing reliability.
1 Unreliable: Consider an alternate sensing scheme.
2. If teach is accepted, the amplifier returns to Run mode. If not accepted, the
Power (green) LED will be OFF and the bargraph signal will flash after
another at 1 & 3 and 5 & 7 which will automatically return to step B1. b. for
the ‘unblock’ condition re-setup.
3. Manually moves the J boat to the sensor and make sure that the amplifier
detects the whole J boat and the output signal integrity is not affected by
the movement of the J boat. If affected, reteach again. See Table 4-8 for
the relative output signal difference.
4.4.5 Sensor Status Display

The MHS sensors are monitored and their status is updated continuously by the
machine control system. Sensor state information can be displayed on the moni-
tor by selecting an option in Diagnostic Mode. Sensor status is updated continu-
ously by the control system. If the user manually triggers the sensor the result
should appear immediately in the display. Refer to Section 5, paragraph 5.4.4,
Maintenance Diagnostics for more information concerning the sensor status dis-
play.
4-34 Electronics 98888-0000-JB3-01

4.5 Cable Assemblies
Cable assemblies involved in MHS functions are listed in Table 4-9. Part number,
name, and cable terminations are provided in the table. See Section 3, paragraph
3.9, for routing cables on the input and output magazine handler assemblies.
NOTE: Table 4-9 lists cables for the MHS with magazine handlers assembly (z
tower and tray input assembly. There are some differences (additional
cables, part number changes) when the magazine handlers are config-
ured for back load or top load operation.
Table 4-9 MHS Cable Assemblies

Cable Part No. Cable Name From To
08888-1082-000-xx MHS Sensor Bus Indexer Intermediate Board, J2 Input Magazine Handler
Cable Intermediate Board, J3
Input Magazine Handler Inter- Output Magazine Handler
mediate Board, J2 Intermediate Board, J3
DMHS Backplane, J16 Output Magazine Handler
Intermediate Board, J2
08888-1250-000-xx Indexer DMHS cable DMHS Backplane, J7, J19 and Indexer Intermediate Board,
J21 J1
08888-1251-000-xx Solenoid Cable DMHS Backplane, J11, J14, Indexer Intermediate Board,
J39 and J42 J6
08858-1032-000-xx Remote Teach Fiber Remote Teach Fiber Sensor Indexer Intermediate Board,
Sensor Assembly (Amplifiers) J19
Cable Indexer Intermediate Board,
J20
08888-1280-000-xx Gripper Flex Cable Indexer Intermediate Board, Gripper Board
J23
08888-1297-000-xx Puller Flex Cable Indexer Intermediate Board, J3 Puller Board
08089-1016-000-xx TC Ext I/O Temperature Board, J1 Interface Panel - MHS Ther-
mocouples:
A1: Preheat
A2: Bond Site
08888-2009-000-xx Heater Power cable TDI RoHS PDU/Cable Assy, J6 Interface Panel - MHS Heat-
ers:
P2: Preheat
P3: Bond Site
08888-1069-000-xx Backplane Vacuum DMHS Backplane, J18 XY Table Assembly - MHS
Valve cable Vacuum Assembly
08888-1061-000-xx Heat Block & Clamp DMHS Backplane, J6 Interface Panel - Heat Block
Ext cable Motor Assembly
P2: Heat Block
08888-1084-000-xx Heat Block & Clamp DMHS Backplane, J29 (P1) & Interface Panel - Heat Block
Sensor Ext cable J30 (P2) Sensor Assembly
P3: Heat Block
08888-1054-000-06 Backplane Input DMHS Backplane, J9 Input Magazine Handler
Magazine Handler Intermediate Board, J1
cable
98888-0000-JB3-01 Electronics 4-35

Cable Part No. Cable Name From To

08888-1054-000-07 Backplane Output DMHS Backplane, J8 Output Magazine Handler
Magazine Handler Intermediate Board, J1
cable
08888-1283-000-00 In/Out Tray Ext. Indexer Intermediate Board, Input Tray Motor, Input Tray
Cable J14 Full Sensor and Input Maga-
zine Present Sensor.
08888-1283-000-01 In/Out Tray Ext. Indexer Intermediate Board, Output Tray Motor, Output
Cable J15 Tray Full Sensor and Output
Magazine Present Sensor.
4-36 Electronics 98888-0000-JB3-01

5 Maintenance
• Section 5.2, Preventive Maintenance Schedule, gives an overview of the MHS

maintenance plan.
• Each section from Section 5.3 through 5.6 offers information on toolings and
MHS related errors and help.
• Section 5.3, Special Tools and Gauges
• Section 5.4, Troubleshooting
• Section 5.5, MHS Errors
• Section 5.6, MHS Related Bonding Problems
98888-0000-JB3-01 Maintenance 5-1

5.2 Preventive Maintenance Schedule

Table 5-1 lists the required preventive maintenance (PM) procedures for the J
boat material handling system. This schedule combines the PM schedules found
in Sections 2 and 3 of this manual.
WARNING: REMOVE THE POWER FROM THE MACHINE BEFORE CHECKING

THE ELECTRICAL CONNECTIONS OF THE MHS OR BEFORE CHECK-
ING HARDWARE TIGHTNESS AND INSPECTING PNEUMATIC LINES
OF THE MHS. MAKE SURE ALL HEATING SURFACES HAVE COOLED
BEFORE PROCEEDING.
Table 5-1 MHS Preventive Maintenance Schedule
Action Period Tools/Parts/Supplies Procedure
Clean heat block 8 hours 1. Vacuum Hose 1. Remove dirt or contaminates from
2. Solvent the heat block area.
2. Remove heat block insert and
inspect heat block vacuum hole
screen. Remove and clean screen if
it appears clogged.
3. If screen cannot be cleaned suc-
cessfully, replace the screen.
Clean workholder and mag- 40 hours Vacuum Hose Remove any dirt or contaminates
azine handlers from exposed and moving parts.
Replace heat block vacuum 1000 hours Tubing, Silicone Rub- Remove vacuum tube between rear
hose. ber of heat block and heatsink. Replace
it with a 9” (228 mm) length of the
specified tubing. Make sure that
there are no air leaks or kinks in the
hose before resuming operation.
Check hardware tightness 1000 hours Hand Tools Make sure all attaching hardware
(screws, nuts, etc.) are securely
installed.
Inspect electrical connec- 1000 hours — Check for security and integrity of all
tions on workholder and electrical connections. Refer to Sec-
magazine handlers tion 4 for connector locations.
Inspect pneumatic lines on 1000 hours — Check for cracks, cuts, leaks, etc.
workholder Check for loose fittings or signs of
stretching or wear. Correct as
required. See Sections 2 and 3 for
tubing and pneumatic fitting loca-
tions.
Replace magazine stop 2000 hours Hand Tools Replace all six (6) magazine stop
buttons on magazine han- buttons (see paragraph 3.9.6.2 for
dlers procedure).
Lubricate puller drive rack 1000 hours Lubriplate #630-2 Apply a thin coat of Lubriplate to
on workholder P/N: 39086-6004-000 rack teeth, make sure that all the
teeth are completely filled. Remove
excess lubricant from top of rack and
around rack when done.
5-2 Maintenance 98888-0000-JB3-01

Lubricate X-slide bearing 3 months to 6 1. Lubricant (10 ml, in 1. Push the [Motor Stop] button.
on the indexer assembly months syringe), P/N: 2. Remove the indexer assembly
1001140 front cover.
2. Lint-Free Cloth 3. Move the gripper assembly to the
3. Hand gloves left or right side manually when
4. Cotton buds neccessary.
5. Hex Wrench Set
4. Clean the v-grooves of the X-slide
bearing on the front wall using the
lint-free cloth.
lubricant to the top and bottom of
the v-grooves of the X slide bear-
ings.
6. Move the gripper assembly along
the X-slide bearing manually for
10 times.
times.
from the X-slide bearing with the
lint-free cloth.
Lubricate Y-slide bearings 3 months to 6 1. Lubricant (10 ml, in 1. Push the [Motor Stop] button.
on Magazine Handler months syringe), P/N: 2. Remove the Magazine Handler
Assembly 1001140 assembly cover.
2. Lint-Free Cloth 3. Move the Z Tower assembly to the
3. Hand gloves front or rear manually when necc-
4. Cotton buds essary.
5. Hex Wrench Set
4. Clean the v-grooves of the Y-slide
bearings on the Z Tower assembly
of the v-grooves of the Y-slide
bearings.
6. Move the Z Tower assembly along
the Y-slide bearings manually for
10 times.
times.
lint-free cloth.
98888-0000-JB3-01 Maintenance 5-3


Lubricate Z-slide bearing on 3 months to 6 1. Lubricant (10 ml, in 1. Push the [Motor Stop] button.
Magazine Handler Assem- months syringe), P/N: 2. Remove the Magazine Handler
bly 1001140 assembly cover.
2. Lint-Free Cloth 3. Move the magazine gripper
3. Hand gloves assembly up or down manually
4. Cotton buds when neccessary.
5. Hex Wrench Set
4. Clean the v-grooves of the Z-slide
bearing on the Z Tower assembly
of the v-grooves of the Z-slide
bearings.
6. Move the magazine gripper
assembly along the Z-slide bear-
ings manually for 10 times.
times.
lint-free cloth.
5-4 Maintenance 98888-0000-JB3-01

5.3 Special Tools and Gauges
Table 5-2 list the special K&S tools and gauges that are required for setup and
calibration of the MHS. The table also gives a description of each tool.
Table 5-2 Special Tools and Gauges
Part Number Description Quantity
03035-0501-000-00 Workholder Setup & Calibration Gauge Assembly 1

03035-0502-000-00 Preheat Setup Gauge Assembly 1
03035-0908-001-00 Workholder Setup Gauge 1
03035-0908-005-00 Gauge Pin 2
NOTE: Items listed above are part of the IConn J Boat Adjustment Tool Kit,
which can be ordered under part number 03035-0909-000-XX
5.4 Troubleshooting
The MHS provides software options designed to aid the operator in assessing the
performance of the system. These options are available in:
• MHS Diagnostics mode
• MHS Utilities Menus (Toolbar Options)
• MHS Manual Mode Utilities
• Maintenance Diagnostics
Procedures for software options can be found in IConn Operation Manual. The
paragraphs that follow contain short descriptions of the software options.
5.4.1 MHS Workholder and Motor Cycling Diagnostics

Diagnostics mode allows the user to home and cycle the motors of MHS subsys-
tems by selecting options from Graphical User Interface (GUI) dialog boxes (see
Figure 5-1). The following diagnostic dialog boxes are available:
• Indexer Diagnostics (See 5.4.1.1)
• Puller Diagnostics (See 5.4.1.2)
• Heat Block Diagnostics (See 5.4.1.3)
• Input Magazine Handler (Mag Handler In) Diagnostics (See 5.4.1.4)
• Output Magazine Handler (Mag Handler Out) Diagnostics (See 5.4.1.4)
Select #1 Select #1
Select #2 Select #2
Select #3
Select #5
Select DONE to exit
Select #1
Figure 5-1 Access to Workholder and Magazine Handler Cycling Menus
98888-0000-JB3-01 Maintenance 5-5

5.4.1.1 Indexer Diagnostics
Displayed by selecting (1) INDEXER from the MHS Workholder menu (Figure 5-1).
Provides the user with options (Figure 5-2) to home the index gripper X–axis
motor, cycle the motor (either for an operator–entered number of times or continu-
ously), and stop the motor (if cycling).
If the CYCLE option is selected, the SET TIMES TO CYCLE value controls how many
cycles will be performed and the CYCLE PERIOD value controls the duration of a
dwell (delay period) between each cycle. The operator can enter a value or select
the default for either setting.
If the CYCLE CONTINUOUSLY option is selected. the motor will cycle until the oper-
ator selects the STOP CYCLING option. The CYCLE PERIOD value controls the dura-
tion of dwell between each cycle.
Enter Number of times
to Cycle Indexer Motor
(Cycle function)
Enter Duration of Dwell Between Enter Default

Cycles in milliseconds Value
(Cycle and Cycle Con-
tinuously Functions)
Function Selections
(Select One)
Activate Selected Function
Activate Selected Function and Exit Dialog Box Exit Dialog Box
Figure 5-2 Indexer Motor Diagnostics Dialog Box

5.4.1.2 Puller Diagnostics
Displayed by selecting (3) PULLER from the MHS Workholder menu (Figure 5-1).
Provides the user with options (Figure 5-3) to home the puller motor, cycle the
motor (either for an operator-entered number of times or continuously), and stop
the motor (if cycling). If the CYCLE option is selected, the SET TIMES TO CYCLE
value controls how many cycles will be performed and the CYCLE PERIOD value
controls the duration of each cycle. The operator can enter a value or select the
default for either of these settings.
If the CYCLE CONTINUOUSLY option is selected. the motor will cycle until the oper-
ator selects the STOP CYCLING option. The CYCLE PERIOD value controls the dura-
tion of each cycle.
Enter Number of times to cycle

Puller Motor (Cycle function)
Enter Duration of Dwell Between
Cycles in milliseconds (Cycle and
Cycle Continuously Functions) Enter Default
Value
Function Selections
(Select One)
Activate Selected Function Exit Dialog Box

and Exit Dialog Box
Figure 5-3 Puller Diagnostics Dialog Box
5-6 Maintenance 98888-0000-JB3-01

5.4.1.3 Heat Block Diagnostics
Displayed by selecting (4) HEAT BLOCK from the MHS Workholder menu (Figure
5-1). Provides the user with options (Figure 5-4) to select the preheat block motor,
bond site heat block motor, or both motors. The selected motor or motors can be
homed, cycled for an operator–entered number of times, or cycled continuously.
There is also an option to stop the motor if it is cycling.
cycles will be performed and the CYCLE PERIOD value controls the duration of a
dwell (delay period) between each cycle. The operator can enter a value or select
the default for either of these settings.
If the CYCLE CONTINUOUSLY option is selected. the motor(s) will cycle until the
operator selects the STOP CYCLING option. The CYCLE PERIOD value controls the
duration of each cycle.
Enter Number of times to cycle

Selected Motor (Cycle function)
Enter Duration of Dwell Between

Cycles in milliseconds (Cycle and
Cycle Continuously Functions)
Enter Default
Motor Selection Value
(Select One)
Function Selections
(Select One)

Exit Dialog Box
and Exit Dialog Box
Figure 5-4 Heat Block Diagnostics Dialog Box
5.4.1.4 Magazine Handler Diagnostics
Displayed by selecting (1) MAG HANDLER IN or (2) MAG HANDLER OUT from the
MHS Magazine Handlers menu (Figure 5-1). Provides the user with options (Fig-
ure 5-5) to select the magazine handler Y axis motor, Gripper motor, Z axis motor,
or all three motors in the magazine handler assembly. Separate menus are avail-
able for the input magazine handler (shown in Figure 5-5) and output magazine
handler. The selected motor or motors can be homed, cycled for an operator–
entered number of times, or cycled continuously. There is also an option to stop
the motor when it is cycling.
cycles will be performed. The operator can enter a value or select the default for
this setting. The CYCLE PERIOD parameter can not be set on this menu; dwell
between cycles duration is controlled by machine programming.
If the CYCLE CONTINUOUSLY option is selected. the motor(s) will cycle until the
operator selects the STOP CYCLING option.
98888-0000-JB3-01 Maintenance 5-7

Enter Number of times

to Cycle Selected Motor(s)
(Cycle function)
Cycle Period Value entry Enter Default Value

not active on this dialog box
Motor Selection
(Select One)
Function Selections
(Select One)
Activate Selected Function and Exit Dialog Box Exit Dialog Box
Figure 5-5 Magazine Handler Motor Diagnostics Dialog Box

5.4.2 Temperature Controller Diagnostics
The Temperature Control Diagnostics option allows the user to display error sta-
tus indicators that relate to the temperature control system for the two workholder
heating zones. This option should be used to investigate a suspected tempera-
ture control problem. Selecting [3] TEMPERATURE CONTROLLER from the Diagnos-
tic Mode menu displays the Temperature Control Diagnostics dialog box (see
Figure 5-6). Clicking on the DONE button in the dialog box ends the Temperature
Control Diagnostics session and displays the Diagnostic Mode menu.
5.4.2.1 System Errors
The System Errors section of the dialog box reports errors that relate directly to
the temperature control circuitry on the I/O and Temperature Controller circuit
board. When the bonder is powered up, the temperature controller circuitry under-
goes power–on confidence testing. If any portion of the circuitry named in the
System Errors section fails the confidence test, the error is logged into the soft-
ware that displays the Temperature Control Diagnostics dialog box. Later, when
this dialog box is displayed, the appropriate indicator will be colored Red.
If an error exists, the user should ensure that it is a valid error by removing power
from the bonder, then:
• Checking all electrical connections in the thermocouple temperature sensor
input circuit
• Reseating the board in the card rack connectors
• Reapplying power
If the same error appears when the Temperature Control Diagnostics dialog box is
displayed again, then the I/O and Temperature Controller circuit board probably
needs replacement.
5-8 Maintenance 98888-0000-JB3-01

Select #3 Select Diagnostic
Error Indicators
Red = Error
Green = Normal Operation
Select Done to exit
Figure 5-6 Temperature Controller Diagnostics Dialog Box

5.4.2.2 Any Zone Errors
The Any Zone Errors indicator will be RED if a zone error exists in either the Pre-
heat or Bond Site heating zones. The error that is active in the zone will have its
error indicator colored Red in the Zone Errors section of the dialog box. The zone,
Preheat, Bond, or Post Heat, for which errors are displayed can be selected using
the ZONE button. When selected, a drop down menu will appear from which the
user can select the desired zone.
5.4.2.3 Zone Errors
Unlike system errors, zone errors are monitored in real time. For example, if the
user displays the Temperature Control Diagnostics dialog box and, at that instant,
a zone error occurs, the user would see the corresponding error indicator change
its state from Green to Red. If a zone error does occur, the problem may be a
faulty temperature controller circuit, thermocouple sensor, heater power control
relay, or heater element.
• Loop Break
Loop break indicates an open circuit in the output circuit of the temperature con-
troller (heater relay control).
• Sensor Out A/D Range
Sensor out of analog–to–digital (A/D) range indicates a probable open thermo-
couple input circuit
• Sensor Over Range
Over range is an input value that is higher than the normal upper limit of the con-
trol loop. This is often an indication of an open thermocouple input circuit.
98888-0000-JB3-01 Maintenance 5-9

• Sensor Under Range
Under range is an input value that is lower than the normal lower limit of the con-
trol loop. This is often an indication of a shorted thermocouple or short elsewhere
in the sensor input circuit.
• Low Alarm
Low alarm is a condition in which the measured temperature is below the control
band specified relative to the control set point. For example, if a ±5 degree alarm
limit is set, this indicates the temperature is more than 5 degrees below set point.
• High Alarm
High alarm is a condition in which the measured temperature is above the band
specified relative to the control set point. For example, if a ±5 degree alarm limit is
set, this indicates the temperature is more than 5 degrees above set point.
5.4.3 Re–Initialize MHS

Selecting option 4 RE-INITIALIZE MHS from the Diagnostic Mode menu starts an
MHS initialization sequence, the same sequence that is performed whenever the
machine exits Standby Mode. (See Figure 5-6 for Diagnostics Menu.) All axes of
motion in the MHS workholder and magazine handlers are sent to their home
positions. Each stepper motor will turn in the direction that will drive the equip-
ment toward its home sensor. When the home sensor is actuated, the motor will
stop, then turn in the opposite direction to place the equipment at its programmed
home position.
If there is any material in the workholder (carriers), or magazines in the magazine
handler grippers, the user will be asked to remove the material and magazines.
When the user signals that this has been done by selecting OK in the dialog box,
the initialization begins. Magazines on load/unload trays may remain in place.
Refer to Section 1 of this manual for material removal procedures.
NOTE: Any stepper motor driven assembly can be sent to home position indi-
vidually by selecting an option in the appropriate motor cycling dialog
box. Refer to paragraph 5.4.1 for more information.
5.4.4 Maintenance Diagnostics

The Maintenance Diagnostics allows the user to view and test all of the sensors
throughout the bonder and material handler system. To access the Maintenance
Diagnostics dialog box, select MAINTENANCE DIAGNOSTICS from the Diagnostic
menu (see Figure 5-7).
Select #5
Select DONE to exit
Figure 5-7 Maintenance Diagnostics Dialog Box
5-10 Maintenance 98888-0000-JB3-01

Selecting SENSOR from the Maintenance Diagnostics dialog box
causes the Sensor Diagnostics dialog box to appear (see Figure 5-8) after a slight
delay. The delay is due to the software collecting and computing all of the sensor
data throughout the machine.
The Sensor Diagnostics dialog box contains indicators which reflect the change
status and the On/Off (i.e., blocked /unblocked) state of the sensor. The dialog
box also contains a color legend informing the user how to decode the meaning of
an indicator when it is set to a specific color.
Status: Sensor values (ON or OFF)
White = ON, Black = OFF
White Black
Figure 5-8 Sensor Diagnostics Dialog Box
The control buttons that appear in the “Sensor Diagnostics” dialog box are
defined as follows.
• FREEZE
• Clicking on this button freezes the display of the indicators in the “Sensor
Diagnostics” dialog box.
• UNFREEZE
• Clicking on this button unfreezes the display of the indicators in the “Sensor
Diagnostics” dialog box.
• DONE
• Exits the Sensor Diagnostics dialog box and displays the Maintenance
Diagnostics main dialog box.
The following topics define the workholder and magazine handler sensors that
appear in the Sensor Diagnostics dialog box.
• INPUT Z HOME
• Optical switch sensor used to detect when the Z axis movement of the
input magazine handler is at its home position. The magazine handler Z
axis controls the up and down positioning of the gripper assembly.
98888-0000-JB3-01 Maintenance 5-11

• INPUT G HOME
• Optical switch sensor used to detect when the upper and lower paws of the
input magazine handler gripper assembly are at their home position (i.e.,
the gripper is fully opened, ready to grip magazine).
• INPUT_GRIP
• Sensor located under the lower paw if the input mag handler gripper
assembly. Used to detect when the lower paw of the gripper assembly
comes in contact with (grips) a magazine. This sensor informs the software
that the magazine is properly registered in the gripper jaws.
• INPUT TOUCH
• Sensor located on the upper paw of the input mag handler gripper assem-
bly. Used to detect when the upper paw of the gripper assembly comes in
contact with (grips) a magazine. This sensor informs the software that the
magazine is properly registered in the gripper jaws.
• INPUT TRAY DETECT
• Sensor located at the bottom of the input mag handler’s gripper assembly.
As the gripper assembly moves forward in the Y axis, this sensor detects
the edge of the tray. The sensor informs the software that the gripper is at
the correct position to pick up a magazine.
• INPUT Y HOME
• Sensor located on the input mag handler load tray. Used to detect when a
magazine on the input load tray is in the correct position to be picked up
(gripped) by the gripper assembly. The input load tray feeds magazines to
the gripper containing unprocessed material.
• OUTPUT Z HOME
• Optical switch sensor used to detect when the Z axis movement of the out-
put magazine handler is at its home position. The magazine handler’s Z
axis controls the up and down positioning of the gripper assembly.
• OUTPUT G HOME
• Optical switch sensor used to detect when the upper and lower paws of the
output magazine handler gripper assembly are at their home position (i.e.,
the gripper is fully opened, ready to grip magazine).
• OUTPUT_GRIP
• Sensor located under the lower paw if the output mag handler gripper
assembly. Used to detect when the lower paw of the gripper assembly
comes in contact with (grips) a magazine. This sensor informs the software
that the magazine is properly registered in the gripper jaws.
• OUTPUT TOUCH
• Sensor located on the upper paw of the output mag handler gripper assem-
bly. Used to detect when the upper paw of the gripper assembly comes in
contact with (grips) a magazine. This sensor informs the software that the
magazine is properly registered in the gripper jaws.
• OUTPUT TRAY DETECT
• Sensor located at the bottom of the output mag handler’s gripper assembly.
As the gripper assembly moves forward in the Y axis, this sensor detects
the edge of the tray. The sensor informs the software that the gripper is at
the correct position to pick up a magazine.
• OUTPUT Y HOME
• Sensor located on the base plate of the output mag handler assembly.
Used to detect when the Y-axis movement of the magazine handler is at its
home position. The magazine handler’s Y-axis controls the forward and
backward positioning of the gripper assembly.
• PULLER HOME
• Optical switch sensor that detects when the puller assembly is at its home
position. The sensor is located on the puller assembly.
5-12 Maintenance 98888-0000-JB3-01
• PREHEAT BLOCK HOME
• Optical switch sensor that detects when the preheat block is at its home
position.
• PULLER PIN
• Optical switch sensor that reports the up/down position of the puller pin.
• REGISTRATION X
• Sensor that detects the leading edge of a boat as it is pulled into the work-
holder by the puller assembly. The puller will continue making an attempt to
pull more of the boat into the workholder until this sensor is blocked or the
software times out. The sensor is on the rear rail assembly.
• INDEXER HOME
• Optical switch sensor that detects when the index/tucker assembly is at its
home position. The sensor is on the index/tucker assembly.
• INDEXER JAM DETECT
• Mechanical-contact sensor that detects when a jam occurs in the index/
tucker area. The sensor is spring loaded and detects a jam when a force
pushes the index pin to its left. This force can be the result of a jammed
boat during an index (pin in the boat) or the tucker pushing against the
index pin because of a jam during boat ejection.
• INDEXER PIN LEFT
• Optical switch sensor that detects the presence of a boat under the index
pin.
• INDEXER PIN RIGHT
• Optical switch sensor that detects the up/down position of the index pin.
• INPUT TRAY 1
• Sensor located on the input mag handler unload tray. Used to detect when
the unload tray is full of magazines.
• INPUT TRAY 2
• Sensor located on the input mag handler load tray. Used to detect when a
magazine on the input load tray is in the correct position to be picked up
(gripped) by the gripper assembly. The input load tray feeds magazines to
the gripper containing unprocessed device.
• INPUT WALL
• Referred to the J Boat Present Sensor. The sensor detects that a J boat
has been injected into the workholder. The sensor is on the left side of the
rear rail assembly. It contains the fiber optic and sensor amplifier.
• OUTPUT TRAY 1
• Sensor located on the output mag handler unload tray. Used to detect
when the unload tray is full of magazines.
• OUTPUT TRAY 2 / GUIDE DOOR
• Sensor located on the output mag handler load tray. Used to detect when a
magazine on the output load tray is in the correct position to be picked up
(gripped) by the gripper assembly. The output load tray feeds empty maga-
zines to the gripper.
• OUTPUT WALL
• Referred to the J Boat Present Sensor. The sensor detects that a J boat
has been ejected from the workholder. The sensor is on right side of the
rear rail assembly. It contains the fiber optic and sensor amplifier.
• JAM MODULE
• For internal use only.
• SYSTEM LOW PRESSURE
• Sensor located in the main input air assembly at the lower console.
98888-0000-JB3-01 Maintenance 5-13

• HEAT BLOCK HOME
• Sensor located in the slider assembly that is used to detect when the bond
site heat block is at its home position.
• HEAT BLOCK VACUUM
• Vacuum sensor used to detect the presence of vacuum at the bond site
heat block.
5.4.5 MHS Toolbar Utility Menus

Selecting one of the MHS utilities buttons from the toolbar in the display provides
a dialog box from which common workholder or magazine handler functions can
be carried out. Entry into other modes to use these functions can thus be avoided.
5.4.5.1 MHS Workholder Utilities
The Workholder Utilities menu appears when W/H OPER is selected from the tool
bar (see Figure 5-9).The functions listed in this menu allow the operator to send a
command to the workholder to do a single action.
Tool Bar
Select DONE to exit dialog
Select #8
Figure 5-9 Access to Workholder and Mag Handler Utilities (without safety cover)
The workholder utilities are defined as follows:
• [1] STOP INDEXING: Stop the indexing of boat through the workholder.
• [2] PULL BOAT IN: Causes the workholder to pull a boat from the supply
(left-side) magazine.
• [3] EJECT BOAT: Causes the workholder to push a boat into the receiving
(right-side) magazine.
• [4] CLEAR WORKHOLDER: Causes the workholder to remove all boats.
5-14 Maintenance 98888-0000-JB3-01

• [5] BOAT INJECT: Opens another dialog box (see Figure 5-10)
that allows the operator to set the ON or OFF status of the puller for pulling
boats from the supply (left-side) magazine. Once the desired setting is
made, the user selects DONE which causes the Workholder Utilities dialog
box to appear.
Figure 5-10 Boat Inject Dialog Box

• [1] BOAT INJECT OFF: Stop boat injection. No additional boats are pulled
into the workholder. Those boats in the workholder are processed nor-
mally unless Stop Indexing is activated.
• [2] BOAT INJECT ON: Restores normal operation.
• [6] HEAT BLOCK: Allows the user to perform heat block related functions. The
dialog box shown in Figure 5-11 appears. Once the desired setting is made,
the user selects DONE which causes the Workholder Utilities dialog box to
appear.
Figure 5-11 Heat Block Dialog Box

• [1] LOWER HEAT BLOCK: Causes the heat block to be lowered to the index-
ing height (i.e., the position below the boat, so as to clear the boat during
the indexing of a device).
• [2] RAISE HEAT BLOCK: Causes the heat block to be raised to the bonding
height.
• [3] HOME HEAT BLOCK: Causes the heat block to be lowered to the home
position.
• [7] HEAT BLOCK VACUUM: Opens the dialog box (see Figure 5-12). The user
may then set the vacuum to On or Off. Once the desired setting is made, the
user selects DONE which causes the Workholder Utilities dialog box to appear.
Figure 5-12 Heat Block Vacuum Dialog Box

• [1] HEAT BLOCK VACUUM ON: Applies heat block vacuum.
• [2] HEAT BLOCK VACUUM OFF: Removes heat block vacuum.
98888-0000-JB3-01 Maintenance 5-15

5.4.5.2 MHS Magazine Utilities
The Magazine Handler Utilities menu appears when MAG OPER is selected from
the tool bar (see Figure 5-9).The functions listed in this menu allow the operator to
send a command to either magazine handler to do a single action.
The magazine handler utilities are defined as follows:
• JOG MAGAZINE (Input and Output)
• Moves the magazine held in the gripper to its next slot, as defined by the
programmed sequenced or user–defined slot order. If no magazine is in the
gripper, a magazine will be picked up from the load tray.
• REVERSE JOG MAGAZINE (Input and Output)
• Moves the magazine held in the gripper to its previous slot, as defined by
the programmed sequenced or user–defined slot order.
• EJECT MAGAZINE (Input and Output)
• Deposits the magazine held by the gripper on the unload tray.
• MAG SELECTION
• Toggles INPUT mode or OUTPUT mode.
5.4.6 MHS Manual Mode Utilities

Manual mode has MHS utility dialog boxes that allow the user to operate the MHS
subsystems through the Graphical User Interface (GUI) (See Figure 5-13). The
following utility dialog boxes are available:
• Index Utilities
• Heat Block Utilities
• Preheat Block Utilities
• Pin Utilities
Select #3
Select DONE to exit
Figure 5-13 Access to MHS Utilities (Manual Mode)

5.4.6.1 Index Utilities
Provides options that allow the user to operate the workholder either continuously
or for a user–entered number of index cycles (Figure 5-14). Indexing can be done
with material in the MHS (“Normal” index commands) or with no material in the
MHS (“Dry” index commands). A count of index cycles is kept and displayed in
the dialog box, which can be reset to zero at any time by the user. Boat injection
can be set to On or Off before index cycling is started. Index commands available
on the menu are:
5-16 Maintenance 98888-0000-JB3-01

• NORMAL INDEX and DRY INDEX
• When either command is selected, the workholder will perform the number
of index cycles shown in the INDEX TIMES area at the top of the dialog box
(unless stopped by the user before completion). Normal index requires
material (boats) in the workholder. Dry index will take place without material
in the workholder. The number of cycles completed appears in the TOTAL
INDEX COUNT area.
• NORMAL INDEX CONTINUOUSLY and DRY INDEX CONTINUOUSLY
• Workholder will operate until stopped by the user. Normal Index Continu-
ously requires material (boats) in the workholder. Dry Index Continuously
will take place without material in the workholder. The number of index
cycles completed appears in the TOTAL INDEX COUNT area.
• STOP INDEXING
• Stops workholder operation when the workholder is cycling.
• PARK INDEXER
• Moves indexer to “parked” position. When parked, each subsystem is at a
programmed distance from its sensor–marked home position.
• HOME INDEXER
• Indexer seeks its home sensor then moves to its home position.
Set number of index cycles to perform
(Normal Index and Dry Index Commands)
Set the bond time to perform Enter Default
(Normal Index Command) Value
Number of Indexes Performed
Reset Total Index

Enable/Disable Boat Inject Function
Count to Zero
Command Selection
(Select One)

Activate Selected Function Exit Dialog Box
and Exit Dialog Box
Figure 5-14 Index Utilities Dialog Box (Manual Mode)
Setup Options available in the dialog box are:
• INDEX TIMES
• Controls how many index cycles will be performed for Normal Index and
Dry Index Commands. User can enter a value or select the default number
of cycles.
• BOND TIME
• Controls the bonding time that will be performed for Normal Index Com-
mands. User can enter a value or select the default time.
• CLEAR TOTAL INDEX COUNT
• Resets the index cycle counter to zero.
98888-0000-JB3-01 Maintenance 5-17

• BOAT INJECT
• Can be set to ON or OFF. If OFF, boats will not be pulled in from the input
magazine handler when required during a Normal Index cycle or Normal
Index Continuously cycle. After the last boat in the workholder is moved
into the output magazine handler, the index cycle will stop. If ON, lead-
frames will be injected as needed.
5.4.6.2 Heat Block Utilities
The Heat Block Utilities allow the user to force or set several bond site operations.
Selecting [2] HEAT BLOCK UTILITIES from the MHS Utilities menu displays the heat
block dialog box (see Figure 5-15). Utilities available are:
• LOWER HEAT BLOCK
• When this command is selected the bond site heat block moves to its boat
clearance level which it is placed at during an index cycle.
• RAISE HEAT BLOCK
• When this command is selected the bond site heat block is raised to its
bond plane level, where it is placed during bonding operations.
• CLOSE OFFSET
• When this command is selected, the bond site heat block is positioned at
the entered offset value from its raised position.
• HOME HEAT BLOCK
• When this command is selected the bond site heat block moves to its home
position.
Figure 5-15 Heat Block Utilities Dialog Box (Manual Mode)

5.4.6.3 Preheat Block Utilities
The Preheat Block Utilities allow the user to force or set several preheat block
operations. Selecting [3] PREHEAT BLOCK UTILITIES from the MHS Utilities menu
displays a dialog box (see Figure 5-16). Utilities available are:
• LOWER PREHEAT BLOCK
• When this command is selected the preheat heat block moves to its boat
clearance level which it is placed at during an index cycle.
• RAISE PREHEAT BLOCK
• When this command is selected the preheat heat block is raised to its
device heating level.
• HOME PREHEAT BLOCK
5-18 Maintenance 98888-0000-JB3-01

• When this command is selected the preheat heat block moves
to its home position.
Figure 5-16 Preheat Block Utilities Dialog Box (Manual Mode)

5.4.6.4 Pin Utilities
Options on the Pin Utilities dialog box allow the user to operate the puller arm,
indexer pin, and tucker actuator (see Figure 5-17). The user can also
home the puller and the indexer. Puller functions available in the dialog box are:
• LOWER PULLER PIN

• When this command is selected the puller pin is lowered to its reset posi-
tion. The puller pin solenoid is energized when the puller pin is in this posi-
tion.
• HOME PULLER
• Moves the puller assembly to its home position.
• LOWER TUCKER
• When this command is selected the tucker is lowered to its tucking position
(tucks the boat into the output magazine). The tucker solenoid is energized
when the tucker is in this position.
• LOWER INDEXER PIN
• When this command is selected the indexer pin is lowered to its indexing
position (within the index hole on the boat). The indexer pin solenoid is
energized when the indexer pin is in this position.
• LIFT PULLER PIN
• When this command is selected the puller pin is raised to its "boat pulling"
position. The puller pin solenoid is de-energized when the puller pin is in
this position.
• LIFT TUCKER
• When this command is selected the tucker is raised to its reset position.
The tucker solenoid is de-energized when the tucker is in this position.
• LIFT INDEXER PIN
• When this command is selected the indexer pin is raised to its reset posi-
tion (above the top surface of the boat). The index pin solenoid is de-ener-
gized when the indexer pin is in this position.
Command Selection
(Select One)

Exit Dialog Box Exit Dialog Box
Figure 5-17 Pin Utilities Dialog Box (Manual Mode)
98888-0000-JB3-01 Maintenance 5-19
5.5 MHS Errors

5.5.1 Error Indications
5.5.1.1 Error Recovery Options Dialog Box
When the machine detects an error in MHS operation, it displays a dialog box on
the monitor screen. The error may also light one of the signal lights on the light
tower and sound the audible alarm (depending upon signal light/alarm program-
ming), and stop machine operation if necessary.
Figure 5-18 illustrates the dialog flow for a typical error event. Dialog Box ‘A’,
which appears as soon as the error is detected, displays error information plus
gives the user up to five error recovery options from which to choose. Depending
upon the error event that is reported, certain options may be inactive (grayed).
One of the error recovery options (MORE) supplies the user with additional infor-
mation related to the error event (Dialog box ‘B’ in Figure 5-18.) Selecting DONE in
this dialog box will display Dialog box ’A’.
Error messages are listed in paragraph 5.5.2. The options found in most error dia-
log boxes are:
• CONTINUE
• Ignore the error and proceed with the current operation.
• RETRY
• Retries the operation. Checks if error condition still exists.
• RECOVER
• When this option is selected, the operation being performed when the error
was detected is continued or restarted. If the error indication is not
repeated, machine operation will continue and no other user action is
required. If it is repeated, the user should select the ABORT button and trou-
bleshoot for the cause of the error.
• ABORT
• When this option is selected, the operation being performed when the error
was detected is stopped and not retried. The user must manually restart
the operation or troubleshoot for the cause of the error before proceeding.
• MORE
• When this option is selected, a second dialog box appears that shows the
error number, a more detailed error message than the one in the recovery
options dialog box, and additional information that may be helpful when try-
ing to correct the error (see Figure 5-18 , Dialog Box ‘B’). When done read-
ing the dialog box text, the DONE button is selected to return to the error
recovery options dialog box.
5.5.1.2 Signal Lights and Audible Alarm
The signal light tower at the top of the machine has three colored lamps: Red,
Amber, and Green. The green lamp is usually lit to indicate normal automatic
operation. The red and amber lamps are lit to indicate machine errors, material
requirements, or changes in machine status, accompanied by an audible alarm.
Machine software allows the users to program the conditions under which the sig-
nal lamps light and the alarm sounds. Refer to Section 1 of this manual and IConn
Operation Manual for more information.
5-20 Maintenance 98888-0000-JB3-01

Select MORE to
display next dialog
box (B)
Dialog Box A
Select DONE to
display options
dialog box (A)
Dialog Box B
Figure 5-18 Error Recovery Options Dialog Boxes

5.5.2 Error and Status Messages
5.5.2.1 ”Home Not Found” or ”Not Out of Home” Errors
[SUBSYSTEM] HOME NOT FOUND
[SUBSYSTEM] IS NOT OUT OF HOME
MAGAZINE HANDLER MOTOR Y, Z, OR G HOME ERROR
[Subsystem] may be Puller, Index/Tucker, Heat Block, Puller Pin or Index Pin.
• Error Recovery
• Select CONTINUE in the dialog box. If the error is repeated, use the options
in the error recovery dialog box to try to identify the cause of the error:
• Check for mechanical problem.
• Check sensor operation.
• Check motor or actuator electrical connections and wiring.
• Check motor or actuator operation.
5.5.2.2 Material Condition Errors
MATERIAL IN WORKHOLDER
WORKHOLDER NOT EMPTY
DEVICE OVERHEATED
EYEPOINT TEACH FAILURE
MATERIAL CANNOT BE PULLED IN - ALREADY PRESENT
NO MATERIAL IN SLOT
MAGAZINE HANDLER FAILED ON GET MAGAZINE
REMOVE BOAT FROM RAILS
BOAT IS NOT PRESENT IN WORKHOLDER
LOAD TRAY EMPTY (INPUT MAG OR OUTPUT MAG)
UNLOAD TRAY FULL (INPUT MAG OR OUTPUT MAG)
• Error Recovery
• Supply MHS with material or remove material as indicated, then restart
operation.
98888-0000-JB3-01 Maintenance 5-21

5.5.2.3 Status Messages
WHL WANTS BOND HEAD MOVED
WHL WANTS BOND HEAD POSITIONED
MHS INDEX TERMINATED
INDEX SEQUENCE ABORTED
MHS DEVICE INDEXED
MHS DEVICE SKIPPED
MHS CARRIER PULLED IN
MHS CARRIER EJECTED
MHS INITIALIZATION EXECUTED
MHS PWRFAIL (POWER FAILURE) RECOVERY EXECUTED
MHS JAMMED CARRIER REMOVED
MH TEACH OPERATION WORKED
MH CAL SLOT OPERATION WORKED
MH CAL TRAY OPERATION WORKED
MHS MAG LOADED
MHS MAG LOADED_O
MHS MAG UNLOADED
MHS MAG UNLOADED_O
• No error recovery action required from the user. Select OK to remove
the message.
5.5.2.4 Calibration Messages
MHS [ANY DEVICE] CALIBRATION SUCCESSFUL
WORKHOLDER CALIBRATION TERMINATED
HEAT BLOCK CALIBRATION TERMINATED
TUCKER EJECT CALIBRATION TERMINATED
SLOT CALIBRATION TERMINATED
TRAY CALIBRATION TERMINATED
• Error Recovery
• Select OK to remove message. Repeat calibration procedure if error mes-
sage indicated that the calibration was terminated before successful com-
pletion.
5.5.2.5 Magazine Handling Errors
[INPUT/OUTPUT] MAG HANDLER DETECTED SLOT SENSOR BLOCKED
• Error Recovery
• Check whether there is a boat extended between the magazine and the
workholder rails. If so, move the boat into the magazine and select CON-
TINUE. If there is no boat at the slot sensor fiber optic, set up the J Boat
present sensor amplifier (refer to Section 4 for procedure.)
[INPUT/OUTPUT] MAGAZINE HANDLER WILL ALSO HOME Y
• Error Recovery
• Select CONTINUE to resume operation. No other action is required.
[INPUT/OUTPUT] MAGAZINE HANDLER G HOME WILL ALSO HOME [Y OR Z]
• Error Recovery
• Select CONTINUE to resume operation. No other action is required.
[INPUT/OUTPUT] MAGAZINE HANDLER G HOME WILL DROP MAGAZINE
• Error Recovery
• Grasp magazine held by the gripper of indicated magazine handler, then
select CONTINUE. Gripper will release magazine.
5-22 Maintenance 98888-0000-JB3-01

MH LOSS OF PWRFAIL DATA
• Error Recovery
• Use the arrow keys to move the gripper to a location where it will not con-
tact any part of the magazine handler during initialization. Initialize the
MHS. Y, Z, and Gripper axes must find home position before operation can
be resumed.
[INPUT/OUTPUT] MAG HANDLER: MAG INTERFERENCE POSSIBLE
• Error Recovery
• Grasp magazine held by the gripper, then select CONTINUE. Gripper will
release magazine.
[INPUT/OUTPUT] MAG HANDLER: OPERATION SUSPENDED
• Error Recovery
• Use the arrow keys to move the gripper to a location where it will not con-
tact any part of the magazine handler during initialization. Initialize the
MHS. Y, Z, and Gripper axes must find home position before operation can
be resumed.
[INPUT/OUTPUT] MAG HANDLER TRAY DETECT SENSOR NOT BLOCKED
• Error Recovery
• Select CONTINUE. Gripper will attempt to locate tray again. If it fails to
locate tray, check position of gripper when it tries to find the tray. If not
good, perform tray calibration. If gripper position is good, then gripper tray
sensor is probably defective and should be replaced.
[INPUT/OUTPUT] MAG HANDLER TRAY DETECT SENSOR BLOCKED
• Error Recovery
• Select CONTINUE. Gripper will attempt to locate tray again. If gripper is posi-
tioned so tray sensor is not blocked and the error is repeated, then gripper
tray sensor is probably defective and should be replaced.
[INPUT/OUTPUT] MAG HANDLER TRAY DETECT SENSOR STATE ERROR
• Error Recovery
• Select CONTINUE. Gripper will attempt to locate tray again. If it fails to
locate tray, check position of gripper when it tries to find the tray. If no good,
perform tray calibration. If gripper position is good, then gripper tray sensor
is probably defective and should be replaced.
[INPUT/OUTPUT] MAG HANDLER GRIPPING SENSORS NOT BLOCKED
• Error Recovery
• Hold magazine in gripper (if present) and initialize the MHS. Gripper axis
must find home position before operation can be resumed. If error is
repeated, check gripper sensor operation and replace sensor assemblies
as needed.
98888-0000-JB3-01 Maintenance 5-23

[INPUT/OUTPUT] MAG HANDLER GRIPPING SENSORS BLOCKED
• Error Recovery
as needed.
[INPUT/OUTPUT] MAG HANDLER GRIPPING SENSOR STATES NOT SAME
• Error Recovery
as needed.
[INPUT/OUTPUT] MAG HANDLER GRIP SENSOR BLOCKED
• Error Recovery
• Initialize the MHS. If error is repeated, check grip sensor operation and
replace sensor assembly as needed.
MH FAILED TO UNLOAD MAGAZINE

[INPUT/OUTPUT] MAG HANDLER FAILED LOAD
[INPUT/OUTPUT] MAG HANDLER FAILED UNLOAD
• Error Recovery
• Remove magazines from unload tray at the input or output magazine han-
dler (as indicated). Select CONTINUE to resume operation.
[INPUT/OUTPUT] MAG HANDLER FAILED TO LOAD MAGAZINE
• Error Recovery
• Make sure there are magazines on load tray. Select CONTINUE. Gripper will
attempt to load magazine again. If it fails, check position of gripper when it
tries to find the tray. If not good, perform tray calibration. If gripper actually
has loaded magazine, then grip sensor is probably defective and should be
replaced.
TOO MUCH ROTATION FOUND WHEN TEACHING MAGAZINE
• Error Recovery
• Select ABORT. Use magazine handler utilities menu (tool bar selection) to
place magazine on unload tray. Move magazine to load tray and select
option to move magazine to first slot position. Restart procedure to
teach magazine.
TEACH OPERATION FAILED
• Error Recovery
• Select ABORT. Restart procedure to teach magazine handler.
5-24 Maintenance 98888-0000-JB3-01

MHS MOTOR DRIVER ERROR
• Error Recovery
• Fault reported in driver circuit board that operates one of the stepper
motors in the magazine handler or workholder. Make sure no MHS motor is
stalled. If motors are good, then driver circuit board should be replaced.
Refer to Section 4 for circuit board locations and replacement procedure.
5.5.2.6 Injection, Indexing, and Ejection Errors
CARRIER X REGISTRATION EDGE NOT FOUND
• Error Recovery
• X–registration sensor did not detect carrier leading edge during injection.
Check:
• X–registration sensor while blocking and unblocking sensor elements in
the rear rail. Make sure the sensor display (Diagnostic mode) indicates
when the sensor is blocked. If not, check sensor electrical connections.
If good, the sensor should be replaced.
• Carrier dimensions and other indexing parameters.
• Puller operation - make sure that the puller arm engages a hole in the
boat and can pull the boat into the workholder input.
DEVICE’S EYEPOINT NOT FOUND

• Error Recovery
• PRS could not find device eyepoint after index. Check:
• Diffuser air pressure. Increasing pressure may enable PRS to find eye-
point.
• Material condition and type.
• Device illumination. Make sure that there is a high contrast between
bordering eyepoint features. Make sure that there is no variation in
brightness with eyepoint features. Reteach eyepoint after any illumiina-
tion adjustment. Refer to eyepoint selection guide in IConn Operation
Manual.
CARRIER JAMMED DURING INDEX OR EJECTION
• Error Recovery
• Verify that there is actually a jammed carrier in the workholder or at the
workholder output. If so, clear the jam manually and select CONTINUE. If
this error is displayed often with no jammed carrier in the workholder,
check:
• Condition of the index overload contact pins on the indexer. Increased
resistance in the contact pin circuit caused by pin corrosion or contami-
nation may cause false carrier jam signals
• Operation of the spring-loaded bar that electrically connects the contact
pins. Except when there is a jam, the bar must be in contact with the
pins.
• Electrical wiring and connections from the pins to the indexer interface.
Any open circuit condition will signal an carrier jam.
• If actual carrier jams occur frequently, check:
• Rail parallelism - make sure that gap between rails at output end of
workholder is equal to gap at the input end. Refer to the rail alignment
procedure in section 2 for more information.
98888-0000-JB3-01 Maintenance 5-25

• Rail Height - perform rail height adjustment. Follow the displayed
instructions precisely when using the rail height adjuster.
• Carrier width - make sure boat width parameter value is accurate for
device being processed.
• Magazine dimensions and slot calibration - if carriers jam at magazine
slot lead–ins or against sidewall, make sure Slot Pitch, Magazine Width,
and Distance from Bottom parameter values are correct. If they are,
perform an output slot calibration.
• Magazine positioning - If leadframes pass partway into magazine and
then jam, make sure rear magazine wall is in contact with the three (3)
magazine stop buttons on the gripper jaws. If not, eject and reload the
magazine. Also, perform an output slot calibration and make sure that
both wear plates in the lower gripper jaw contact the calibration gauge
at the same time. If not, loosen four (4) SHCSs that secure the gripper
to the Y axis casting and rotate the gripper until both wear plates are in
contact with the gauge.
• If jam errors are indicated when indexer is being dry cycled (run without
material), check:
• Mechanical interference - between the tucker arm or index pin and any
part of the workholder or output magazine handler. Make sure that the
tucker blade is centered between the front workholder rail and the front
boat support blade when the tucker arm is down. Make sure tucker
blade is not bent or otherwise damaged.
CLAMP VACUUM NOT PRESENT
• Error Recovery
• Vacuum sensor (optional) has detected low vacuum at bond site after a
device was clamped. Check:
• Device defect. Make sure underside of device has no defect that pre-
vents a good vacuum seal with the top surface of the heat block insert.
• Heat block condition. Make sure top of heat block insert is clean so that
device can seat properly on the insert.
• Vaccum hoses - make sure that there are no blocked, cracked, or
kinked hoses.
• False vacuum error indications. Adjust vacuum sensor. (Refer to
Section 2 for vacuum sensor setup procedure).
CARRIER CANNOT BE PULLED IN - ONE ALREADY PRESENT
INDEXER AXIS LIMIT ERROR
EMPTY INPUT MAGAZINE SLOT
• Error Recovery
• No carrier was found in a magazine slot when an attempt was made to
inject a carrier into the workholder. Select CONTINUE. If the error is
repeated, use the Magazine Handler Utilities to load a new input magazine.
5-26 Maintenance 98888-0000-JB3-01

WORKHOLDER DETECTED SLOT SENSOR BLOCKED
• Error Recovery
• Check whether there is a boat between the workholder and the input or
output magazine. If so, move the boat into the magazine and select CON-
TINUE. If there is no boat under the slot sensor fiber optic, set up the input
or output slot sensor amplifier (refer to Section 4 for procedure.)
RAIL INDEX MOTION ERROR

RAIL CORRECTION MOTION ERROR
DEVICE CLAMPED IN WORKHOLDER
• Error Recovery
MHS MOTOR DRIVER ERROR
• Error Recovery
• Fault reported in driver circuit board that operates one of the stepper
motors in the magazine handler or workholder. Make sure no MHS motor is
stalled. If motors are good, then driver circuit board should be replaced.
Refer to Section 4 for circuit board locations and replacement procedure.
5.5.2.7 Initialization Errors

MHS INITIALIZATION FAILED
• Error Recovery
• Press [MOTOR STOP]. Select OK in the Standby Mode dialog box to restart
the initialization. If the error is repeated, check:
• Workholder and magazine handler home sensors and workholder rail
jam sensors. Make sure there are no cuts in the insulation of the rail jam
sensor wires that may allow a short to ground through the workholder.
• Workholder and magazine handler motion axes. Make sure there is no
mechanical interference in any axis of motion.
• Electrical connections at indexer flex cable boards and at indexer inter-
face board. Electrical connections at magazine handler wiring har-
nesses and interface board.
• Operation of stepper motors.
MH MAGAZINE WILL BE DROPPED
• Error Recovery
• Grasp magazine held by the gripper, then select CONTINUE. Gripper will
release magazine.
CLEAR MAGAZINE HANDLER TRAYS OF ANY MAGAZINES
• Error Recovery
• Remove all magazines from unload and load trays of the magazine han-
dlers, then select CONTINUE.
98888-0000-JB3-01 Maintenance 5-27

MAGAZINE HANDLER SETUP ERROR
• Error Recovery
• Perform tray and slot calibrations for both magazine handlers.
5.5.2.8 Program Execution Errors

UNDEFINED MHS COMMAND
DISABLED OR ACTIVE MHS COMMAND
RESOURCES FOR EXECUTION OF MHS COMMAND ARE UNAVAILABLE
WORKHOLDER SOFTWARE RESET REQUEST
CANNOT CREATE SEMAPHORE
CANNOT OPEN CHANNEL
MAGAZINE HANDLER SOFTWARE LOGIC ERROR
MAGAZINE HANDLER SOFTWARE CREATION ERROR
MAGAZINE HANDLER ERROR SENDING MESSAGE
MAGAZINE HANDLER ERROR RECEIVING MESSAGE
UNDEFINED LEADFRAME LOCKING STATUS
UNDEFINED INDEX TYPE
UNDEFINED INDEX STATUS
UNDEFINED CORRECTION STATUS
UNDEFINED INDEXING CYCLE
UNDEFINED WORKHOLDER STATE
UNDEFINED PULLER STATE
UNDEFINED PULL TYPE REQUESTED
JAM DETECTION CONTROLLER’S COMMAND FAILED
JAM DETECTION CONTROLLER’S DIAGNOSTIC FAILED
• Error Recovery
• If a program execution error is indicated, always select CONTINUE or
RECOVER in the dialog box. If the error is repeated, select ABORT and then
perform an MHS initialization. If the error is repeated when operation is
resumed, press [MOTOR STOP], then shut down and restart the machine.
This will reload machine operating code.
5-28 Maintenance 98888-0000-JB3-01

5.6 MHS–Related Bonding Problems
Some problems seen in the bonding process or in general machine operation
may be caused by errors in operation, calibration, or setup of the MHS. Flow dia-
grams in the paragraphs that follow were prepared to help correct common MHS–
related problems:
• EYE POINT FIND FAILURES - See paragraph 5.6.1

• NON–STICK ON PAD ERRORS - See paragraph 5.6.2
• NON–STICK ON LEAD ERRORS - See paragraph 5.6.3
98888-0000-JB3-01 Maintenance 5-29

5.6.1 Eye Point Find Failures
Test bond several

leadframes. Observe
MHS operation. In- START
spect leadframes.
PRS or optics NO
problems?
YES
Leadframe clamping NO
problem?
Check optics focus.

Adjust if necessary. YES
Check device thick-

ness. Enter correct
thickness if incorrect.
Increase diffuser
air pressure.
Check for vacuum

at top of heat block.
Reteach eyepoint. Check pneumatic
Change lighting or system if no vacu-
eyepoint scene area. um.
Perform clamp cal-

Perform PRS ibration.
Calibration.
NO
Problem corrected?
YES
DONE
5-30 Maintenance 98888-0000-JB3-01

5.6.2 Non–Stick on Pad (NSOP) Errors
NO
Transducer working START
Properly?
YES
Check Transducer
cable service
loop. Loosen
cable any tighten
cable.
YES
Device thickness
correct?
NO
Bond plane YES
height correctly
calibrated?
Enter correct value

for device thick- NO
Preheat and YES
ness parameter.
bond site tem-
perature cor-
rect?
Perform Transduc- NO
Correct clamp
er Alignment cal- and heat block YES
ibration to set bond insert for L/F
plane height. used?
Check bond site
Check and preheat tem-
Transducer perature set points. NO
and USG Change set points
Board if necessary. Verify that correct
Adjust workholder p-parts for L/F
rail height to OPTI- installed. Replace
MAL setting in rela- p-parts if incorrect.
tion to bond plane
height.
Check actual bond
and preheat tem-
perature. Enter Check if tie bar
temperature offsets seated correctly
as needed.
If p-parts are re-

placed, teach MHS
before continuing
production.
There may be a bonder or

NO material problem. Check
Problem corrected?
bond parameters, device,
and wire.
YES
DONE
98888-0000-JB3-01 Maintenance 5-31

5.6.3 Non–Stick on Lead (NSOL) Errors
NO
Transducer working START
Properly?
YES
Check Transducer
cable service
loop. Loosen
cable any tighten
cable.
YES
Device thickness
correct?
NO
Bond plane YES
height correctly
calibrated?
NO
Enter correct value
for device thickness YES
Preheat and bond
parameter. site temperature
correct?
NO
Perform Transducer Correct clamp YES
Alignment calibration and heat block
to set bond plane insert for L/F
height. used?
NO
Check
Transducer Adjust workholder rail Verify that correct
and USG height to OPTIMAL p-parts for L/F
Board setting in relation to installed. Replace
bond plane height. p-parts if incorrect.
Check bond site

and preheat tem- Check Lead finger
perature set points. vibration, if yes do
Set correct set clamp calibration.
points if necessary. -- Adjust clamp
force offset
Check Heat block
perpendicular
Check actual
bond and preheat
temperature. En- If p-parts are re-
ter temperature placed, teach
offsets as needed. MHS before con-
tinuing production.
There may be a bonder

NO or material problem.
Problem corrected?
Check bond parame-
ters, device, and wire.
YES
DONE
5-32 Maintenance 98888-0000-JB3-01

A Glossary of Terms & Abbreviations

-A-
ALIAS: Area or feature on a die or leadframe which may be mistaken by the PRS for a valid eye point.
ALIGNMENT: Material alignment is the positioning of the material at the bondsite. This positioning may be
accomplished by the use of the Pattern Recognition System or by the operator depending on the
parameters and settings in the bond program.
ALIGNMENT TOLERANCE: Maximum allowable deviation from the programmed distance between the two oper-
ator points of a reference system. Valid only for 2-point reference systems. Suggested tolerance
should be 10% of the smallest bond pad dimension. For outer leads, it should be referenced to
the lead with tolerance and may be somewhat greater to allow for the potentially larger expan-
sion.
ALTERNATE EYE POINT: An eye point for an alternate reference. For example: if there are two possible vendors
of a particular die that the manufacture uses where the two die are not identical, the program
would call out an alternate reference system/eye point. See also "Backup Eye point".
AXIS POSITION INDICATORS: X, Y and Z values at the upper right of the monitor screen. X and Y values of the
crosshair are relative to the previously entered X-Y zero. Z refers to the bondhead height, again
with reference to a previously entered zero location.
-B-
BACKUP EYE POINT: Another eye point on the same die in a different location. Its purpose is to give the vision
system a second chance to find an eye point for alignment purposes.
BITS: Bond Integrity Test System. Used to detect non-stick bonds at the die (NSOP), non-stick bonds at
the leadframe, or short tails (SHTL) during auto bonding.
BIMODAL: Only two primary brightness levels are present.
BOND FORCE: The force applied to promote a good bond (capable of providing an electrical connection). It is
the contact force, in grams, exerted on the wire during bonding.
BOND HEIGHT: The height at which the bonding tool touches the work surface.
BOND OFF: A process for forming a gold ball once the wire is loaded through the capillary (with a fraction of
an inch extended beyond the capillary). Used when repairing a broken wire or replacing a wire
spool.
BOND POWER: The ultrasonic energy exerted by the USG during bond time.
BOND PROGRAM: see Process Program.
BOND TIME: The length of time that the USG is turned ON for each bond. This affects the strength of the
bond. If bond time is too low or too high, the bonds will be relatively weak. Experimentation
using shear tests will reveal the optimum setting.
BONDING: Bonding requires the calculation of bond locations based on the alignment data and the control of
all the subsystems necessary to accomplish the bonding.
BOOT/BOOTING: The initial activity of the machine after a reset or power up to re-load the machine’s software
and prepare it for processing.
BUTTON: A button may be square, rectangular, or triangular in shape. When clicked on, it starts a process,
brings up a dialog box, steps through a list of choices, increases/decreases a value, or opens an
edit field.
98888-0000-JB3-01 Glossary of Terms & Abbreviations A-1

-C-
C/V: see Constant Velocity Value.
CALIBRATION MODE: A mode of the machine that allows the operator to calibrate parameters of the machine
to ensure valid measurements. For example: to set the distance between the tool and the optics
(crosshair offset),find limits, set the pixels to pulse ratio in the PRS.
CAMERA IMAGE: The window that displays the image from the camera on the machine’s screen.
CAMERA LINEARITY: Alignment of the video camera CCD image element with the machine axes of motion.
This is accomplished by rotating the camera body.
CHESSING: Moving the work table (in the X and Y directions) corresponding to manual controls by using the
mouse and mouse button [B2]. Holding the Arrow button down will cause the auto repeat function
to take effect and the image will move at a continuous rate. Chessing only applies to the graphics
and video image window. There are three forms of chessing available to the operator:
• JUMPING - Position the cursor at the desired location and press B2.
• DRAGGING - Press and hold B2 then drag the image.
• INCHING - Use the cursor keys on the keyboard to move a single pixel at a time
(depending upon the zoom factor).
COMPONENT FILES: The other files used with the Process Program File to create a process program. The
process program file has the .BND extension and may have a filename of up to 80 characters. A
component file has a REF., .PRM, OPR, .CHG, .WIR, .PDL, or a .EYE extension and may have a
filename of up to 40 characters.
CONFIGURE MODE: A mode of the machine that allows the operator to configure or style the machine to meet
the factory’s needs.
CONSTANT VELOCITY VALUE (C/V): The speed of the capillary descending to the work surface after TIP and,
therefore, the constant velocity of the capillary against the work. If set too high, bonds may be
squashed. If set too low, the operating times may be unacceptably high. Value is expressed in
microns/msec or mmps.
CROSSHAIR: On-screen horizontal and vertical cross image which are used with the X, Y, and Z directional
buttons to locate eye points, operator points, etc. for the process program. The large yellow
crosshair appears initially in the center of the graphics and the video image windows. The two
windows and their crosshair are handled slightly differently. The crosshair on the video image
window is always centered. Selecting a new position causes the video image to shift and the
crosshair is automatically recentered. Hence, it is possible to "work your way" across the bond
site. The graphics image crosshair can be moved to any position in the graphics window and
depending upon the zoom factor this may include the entire work area or only a very small portion
of it. Manipulation of either window will cause an appropriate change in the other window.
CROSSHAIR OFFSET: A taught distance which compensates for the fact that the objective lens and the capil-
lary are not in line above a device. This adjustment is necessary when the crosshair is being used
to represent the location of the bond tool over the device.
CURSOR: The on-screen "+" used to point to and click on menus, menu items, and buttons and to grab and
adjust slide bars.
A-2 Glossary of Terms & Abbreviations 98888-0000-JB3-01

-D-
DE-SELECT:To close or turn off a menu, menu item, function, or state by positioning the cursor on top of the
desired item and clicking the B1 (left) mouse button. If a state is de-selected, the highlighting will
be turned off to show that the state is no longer active.
DEFAULT BUTTON: A square button with a “D” in the center of it. Clicking on this button will set a parameter
value to its pre-determined default value.
DEFAULT BUTTON
DIALOG BOX:A window that appears temporarily to request information or to allow adjustment or selection of
settings/parameters.
DOUBLE-CLICK: To rapidly press and release the mouse button [B1] twice without moving the cursor.
DRAG: To move an item on the screen by first positioning the cursor over the item and then pressing and
holding the mouse button [B1] while manipulating the mouse to move the cursor.
DRY CYCLE: Cycle the MHS workholder with or without material present in the workholder, without bonding
wire.
-E-
EFO: see Electronic Flame-Off.
EFO GAP: The vertical distance between the EFO electrode and the tip of the wire on the capillary when the
bond head is at its reset position.
EFO OPEN: Refers to an error condition that occurs when the wire tail is too short or no wire is at the tip of the
capillary or the EFO Gap is too great.
EFO TIME: The time that the EFO is turned on.
EJECT: This refers to the activity of transferring materials from one mechanical sub-system to another.
For example: eject a leadframe refers to the process of moving a leadframe from the output side
of the workholder to the output magazine in the output elevator. To eject a magazine means to
move it from the elevator to the output platform.
ELECTRONIC FLAME-OFF: The hardware that produces the electronic spark to make the gold ball form at the
end of the wire exposed at the tip of the capillary.
ENTER: Using the MMI keypad or the keyboard to enter and edit information.
EYE POINT: A human and machine identifiable feature of the material. The number of eye points and their
location can be specified in process program. This reference point is learned by the PRS during
the teach sequence. For each reference system, the number of eye points must equal the num-
ber of operator points. Die eye points make use of the fine detail typically found on die reference
systems. Lead eye point looks for long straight edges such as those normally found in an outer
lead reference system.
EXCEPTION: Failure, fault, or unusual occurrence.

-F-
FACTORY AUTOMATION SERVER/SYSTEM: A computer which can supervise the wire bonder through a commu-
nications link using the SEMI SECS protocol.
FAS: Factory Automation Server/System.
FORCE: see Bond Force.
FUNCTION BUTTONS: Two rows each containing 10 buttons at the bottom of the screen. These buttons are
used to begin or end an action. The function associated with a button may change when certain
types of operations are performed.
FUNCTION KEYS: The row of 10 keys at the top of the keypad located on the MMI. These keys perform the
same functions as the bottom row of Function buttons. The function associated with a key may
change when certain types of operations are performed.
-G-
GUI: An abbreviation for the term Graphical User Interface.
-H-
HOST: A remote computer that can gather or issue process information from/to the machine, select pro-
cess programs for the equipment, and control the machine.
HOST INTERFACE: A technique to exchange information between a host computer and the machine. The host
computer may also exert control over the machine using this interface.
HOT KEY: The numeric character associated with an item in a menu or dialog box. When working in menus
or dialog boxes, pressing the item’s Hot Key selects the that item. By selecting the item, a data
entry field may open, an operation may be performed or another menu or dialog box may appear.
HOT
KEY
-I-
IC: A device with two reference systems: the outer leads or substrate and the die.
ICON: A symbol that represents a window or action/s.
INDEXING: Indexing moves new material into position for bonding. Indexing may occur after an entire unit
has been processed or after a partial unit has been processed. The index may present an entirely
new unit to the bond location or a new part of the same unit.
INJECT: Generally this term refers to leadframes and usually means a leadframe will be moved from the
input magazine into the workholder.
-J-
J WIRE: A Kulicke and Soffa technique to lay designed bent wires. This technique puts a J-shape into the
bonding wire by using a parameter called lateral motion.
JOG: A term to indicate a vertical index of a mag handler’s gripper assembly.

-K-
KEYBOARD:A QWERTY keyboard (keypad) located on the MMI (see MMI).
KINK HEIGHT:The vertical distance between the first bond and the position above the first bond where the XY
table starts the Reverse Motion.
-L-
L/F: LeadFrame.
LEADFRAME:Carrier for IC devices incorporating metal leads to which wires from IC bond pads are attached
LIGHT TOWER:A post on which a number of signal lights are mounted to indicate the machine’s state (Motors
stopped, operating automatically, error, etc.).
LINEARITY: Camera rotation. See Camera Linearity.
LOT: A grouping of materials for tracking purposes.
LOT ID: A name or number associated with a lot for identification purposes.
LOT TRACKING:A technique to monitor the process and collect data for historical purposes.
LOW LOOPING:The Kulicke and Soffa process for making very low wire loops.
LOWER CONSOLE:The machine’s main card rack, electronics(cards), power supplies, amps for the servos and
steppers, the disk drives, the chassis, and the fans.
LTOL: An abbreviation for the term “line tolerance”. Line tolerance is used to ensure that the placement
of operator points and eye points are valid.
-M-
M/C: Machine.
MACHINE DEPENDENT PARAMETER: A bonder or machine specific parameter.
MAN MACHINE INTERFACE (MMI): Means through which the machine operator communicates with the control
system. Operator controls via the mouse, buttons, function keys, and keypad on the lower con-
sole.
MANUAL: Depending upon context this term may refer to the Manual Mode of the machine’s operation or
indicate human intervention is required to complete a process.
MANUAL MODE: A machine mode that allows the operator to bond wires in a manual fashion. That is, desig-
nate the location of bond sites and lay a single wire.
MATERIAL HANDLING SYSTEM: The Material Handling System consists of the electronics, mechanics, and
controlling software that is used to move material through the machine. The Material Handling
System may be considered as part of the process if the heating elements are controlled by the
Material Handling System.
MATRIX: An array of chips, devices or device groups that are arranged in columns and rows.
MBD: Missing Ball Detector.
MDP: see Machine Dependent Parameter
MENU: A list of available commands in a window. Menu titles may appear in the banner at the top of the
window. The illustration shows the MANUAL mode menu.
MODE
BAR
MENU
MHS: see Material Handling System.

MMI: see Man Machine Interface.
MODE: A logical grouping of related tasks or functions usually accessed by selecting the “mode” of oper-
ation in a dialog box or menu (e.g., “Add” mode when teaching operator points). This term could
also be used to refer to an operating state of the machine such as Auto mode, Manual mode, Pro-
gram mode, etc.
MODE BAR: The horizontal bar that contains the names of the program’s major sections or modes. The mode
bar is at the top of the display screen. The illustration above shows the leftmost modes in the
mode bar. MANUAL mode is the active mode
MOTORIZED WIRE SPOOL: Activated by a sensor indicating the wire loop is getting taunt and deactivated by a
sensor indicating the wire loop is getting slack.
MOUSE: Input device with three buttons and a ball used to position an on-screen cursor and make selec-
tions or adjustments (see illustration).
MOUSE BUTTONS: The three mouse buttons are located on the mouse and are referred to as B1, B2, and B3
on the screen. The function of each button changes depending on the operations being per-
formed on the screen. Refer to the screen for the current button functions. Some of the possible
functions for the three buttons are listed below.
Mouse Buttons
B1, B2, B3
Mouse
• B1 = Left Button: Select, Add/Learn, Unselect, Next, Step

• B2 = Center Button: Chess
• B3 = Right Button: Delete, Unselect, Auto Learn, Relearn, Assign, Disassoci-
ate, Reverse
MTBA: Mean Time Between Assists. Average length of time between bonder-detected errors.
MTBF: Mean Time Between Failures. Average length of time between events that require actual repair
by a technician.
MTTA: Mean Time To Assist. Average amount of time to fix a bonder program.
MTTR: Mean Time To Repair. Average amount of time needed for a technician to complete the repair.
MWS: see Motorized Wire Spool
MULTI-CHIP: A device with more than 2 reference systems: one for outer leads or substrate and one for each
die on the device.
-N-
NSOL: No Stick on Lead. BITS error message indicating wedge is lifted from the second bond.
NSOP: No Stick on Pad. BITS error message indicating ball is lifted from the first bond.
-O-
ON-LINE HELP:A window is displayed containing text that explains an indicated object for the machine opera-
tor. Note: once On-line Help is activated other topics are available for review.
ON-LINE PROCEDURE: A window with information for the machine operator that gives step by step instructions
for some procedure to be performed on the machine. For example: threading the wire.
OPEN: To display the contents of a file in a window or to enlarge an icon to a window.

OPERATOR POINT: A location on the die or outer lead that a machine operator can identify to
ensure the device is properly aligned. This reference point is taught by the operator. Used if the
PRS fails. Must be targeted before device can be bonded. Preferred location is on bond pad or
streets.
OPTICS OFFSET:The displacement between the center of the optical path and the bonding tool.
-P-
PAD FIND: This function uses the PRS to automatically center first bonds on bond pads.
PATTERN RECOGNITION SYSTEM (PRS): A part of the Vision System. This term usually refers to the electronics
and software that actually recognize patterns at the work site for alignment purposes. The PRS
allows the bonder to operate without attention by automatically finding eye points before each
device is bonded. Compensates for variations in die location from package to package.
PERFORMANCE LOGGING: Refers to statistical information that can be automatically gathered by the machine
and includes such information as MTBA, MTTA, MTBF, MTTR, and Utilization time.
PFR: see Power Failure Recovery.
PIXEL: The smallest graphic unit that can be displayed on the screen, usually a single dot.
POINT: Moving the cursor to a specific area on the screen.
POWER FAILURE RECOVERY: This routine provides resumption of automatic operation after power failure.
PREHEAT: Heating the device before it reaches the bond station.
PROCESS PROGRAM (PP): Made up of re-usable modules of ASCII text that can be read, modified, saved, and
restored. These modules contain the instructions and parametric information that the machine
will need to process materials.
PROCESS PROGRAM FILE:Main file of a process program. Component Files are the other files used with this
file to create a process program. The process program file has the .BND extension and may
have a filename of up to 80 characters.
PROCESS STATISTICS:Refers to information automatically gathered by the machine while the equipment is
automatically bonding. Included in this set of statistics would be: number of devices bonded, and
number of bonds since capillary was replaced.
PROGRAM MODE:A mode that allows the operator to load, edit or teach a process program.
PROMPT: A program initiated statement which indicates an operator action is needed. Prompts are normally
located in dialog boxes or in the monitor screen’s information boxes, below the Mode bar.
PRS: see Pattern Recognition System.
PRS CALIBRATION:A procedure to establish the relationship between the vision systems pixels and the
machines motion pulses particularly to ensure orthogonality between the two systems.
-Q-
-R-
RADIO BUTTON:A diamond shaped button. Radio buttons are grouped in sets of two or more. Only one radio
button per set can be active at a time. As shown in the example, “Normal Index” is selected.
RADIO
BUTTONS

REFERENCE SYSTEMS:A reference system is a logical grouping of bond sites, typically all the bond sites of a
particular object in the work area, always of the same height. Examples of reference systems are:
• all the bond sites on a die
• all the bond sites on the outer lead (lead shelf)
The goal of the reference system technique is to allow the mixing and matching of die and outer
lead without the necessity of re-teaching. A complete process program would contain the defini-
tion of all of the reference systems in the work area in addition to instructions regarding the wiring
of the device.
REFERENCE SYSTEM ORIGIN: The origin (0,0) of an instance of a reference system.
REVERSE BONDING: Refers to the reverse sequence of bonding. Where typically, when ball bonding, the first
(ball) bond is on the die and the second (wedge) bond is on the lead. In reverse bonding the first
bond is on the lead and the second bond is on the die pad.
REVERSE MOTION: The reverse motion causes the XY table to move a defined distance in the reverse direc-
tion (away from the second bond) after the bond head has risen to a preset height (Kink Height)
while still above the first bond to achieve a unique wire shape.
-S-
S ING: This term refers to unintentionally curved wires. When viewed from the overhead position these
wires take on a slight “S” shape.
SCAN CORRIDOR: The area and direction that the VLL will scan when searching for the lead.
SCREEN: The display area of the monitor.
SCROLL BAR: A horizontal or vertical bar within a dialog box containing a center button which can be moved
to show additional text or choices.
SELECT: To choose or turn on a menu, menu item, function, or state by positioning the cursor on top of the
desired item and clicking mouse button B1. If a state is selected, the selection will be highlighted
to show that it is active. Items in dialog boxes and menus may also be selected by pressing the
item’s “Hot Key” if a number is to the left of the item.
SEQUENCE STOP MODE: A mode the machine enters when the operator presses the sequence Stop Button
while the machine is in automatic mode. Its effect is to pause the action at the earliest safe place
in the process. For example: at the end of a wire or at the end of an index. While in Sequence
Stop mode the operator may operate the machine as if it were in Manual mode. While generally it
is assumed the operator will release the sequence stop button and continue processing materi-
als, it is possible to escape automatic operation entirely from this mode of the machine
SHTL: Short Tail. BITS error message indicating that the wire tail formed after the second bond is too
short.
SITE: Depending on context it can mean a bonding site (a die pad or lead bonding site), a die, a die and
outer lead, device group, or all the area accessible by the bond head.
SKIP: An index where the materials that will be moved away from the work site have not been pro-
cessed.
SLIDE BAR: A horizontal or vertical bar with a center button used to make sliding adjustments to a setting such
as illumination or focus. As shown, the illuminators can be increased by moving the center button
to the right or decreased by moving it to the left.
SLIDE BAR
SOIC: Small Outline IC.

SPC: see Statistical Process Control.

STANDBY: This mode is entered by pressing the [Motor Stop] control button on the MMI. In
Standby mode, power to the electric motors and solenoids is interrupted.
STATISTICAL PROCESS CONTROL: A technique to improve manufacturing yield by gathering and analyzing
data, and then altering the process while in progress to improve or keep the product consistent.
STEP AND REPEAT: A machine feature to process a number of identical devices (device groups) without an
index. For example, if several identical die are in the same work site instead of teaching each die
individually the operator would teach the process once and then teach only the locations of suc-
cessive die.
SWAP: To move the images in the screen’s display windows so that they change place (swap). The
image in the large window moves to the small window and the image in the small window moves
to the large window. Initiated by the pressing F1 function key.
-T-
[TAB]: A key used to move from one edit field or selection to the next.
TABLE MAPPING:A method of correcting any precision errors in the XY table positioning.
TABLE ORIGIN:The absolute origin (0,0) of the table. Reference System Origins are located within (mapped on
top of) this reference system.
TAIL LENGTH:Tail length is the length of the wire “tail” left hanging below the capillary after the second bond is
made. This parameter effects the size of the ball that will be formed by the EFO.
TIP: see Tool Inflection Point.
TIP HEIGHT: The height above the work surface to start search (or constant) velocity.
TOL CORRECTION: Top of Loop correction equalizes wire payout and adjusts trajectory during part of the cycle
to help loop height consistency in some applications.
TOOL INFLECTION POINT: The distance above the bond surface at which the speed of the descending capillary
changes from controlled deceleration to constant velocity. TIPs are learned for all wires. Sub-
tracting the programmed TIP offset value from the learned bonding height gives the TIP offset.
TRANSDUCER:A device that converts electrical into vibration energy to weld the wire.
-U-
ULTRASONICS GENERATOR: The mechanics and electronics that vibrate the transducer as part of the bonding
process.
UPPER CONSOLE: Bonder subassemblies including: monitor, man machine interface, keyboard, light tower,
audio alarm, wire feed, pneumatic controls and cabling.
UPH: UNITS PER HOUR. The number of units bonded per hour.
UPS: Uninterruptible Power Supply.
USG: see Ultrasonics Generator.
UTILITIES MODE: A mode of the machine that allows the operator to make adjustments that are typically not
related to the process. For example: copying disks, deleting files, etc.
-V-
VIDEO LEAD LOCATOR: Finds exact taught location of bond positions on the outer leads to each device to
ensure accurate placement. Maintains information about position, angle, width, and illumination
levels. Notifies bonder of any lead displacements to ensure correct bond placement. Takes video
image directly from the monitor.
VISION SYSTEM: There are two aspects of the vision system: the optics and the electronics. The Vision Sys-
tem provides information for the proper alignment of die bond sites and leads within the work site.
VLL: see Video Lead Locator.
VLL ASSOCIATION: A contiguous group of leads that can be viewed by the Vision System from one position of
the table.

-W-
W/C: Wire clamp.
W/H: Workholder.
WIRE FEED: A system for taking wire from a wire spool and delivering it to the bonding tool. A wire feed mech-
anism including: mechanics, electronics, sensors, and controlling software.
WIRE GROUP:A group of wires that reside in the same reference system that have the same bond parameters
applied to them.
WIRE PATH: The mechanics including: possibly compressed air, supports, etc. that is the bonding wire’s route
from the spool to the capillary.
WIRE SAG: Refers to a wire whose loop tends to dip down unintentionally.
-X-
X AXIS: The side to side motion of the bond head (see XY table).
X-Y ZERO: Primary alignment point for a package. Used as point from which all other X and Y coordinates
are calculated. Suggested location is at bottom left-hand corner of package on a lead.
XY TABLE: A positioning system for moving a load (a bond head in the case of wire bonders) in XY (horizon-
tal) space.
-Y-
Y AXIS: The front to back motion of the bond head (see XY table).
YIELD: The percentage of good bonded devices processed by the machine vs. the number of unbonded
devices that enter the machine.
-Z-
Z APEX: The highest point achieved by the Z axis between bonds of a single wire.
Z AXIS: The up and down motion of the bond head.

B IConn J Boat Wire Bonder MHS Wiring Diagrams

See below for IConn J Boat MHS Wiring Diagram.
98888-0000-JB3-01 IConn J Boat Wire Bonder MHS Wiring Diagrams B-1

B-2 IConn J Boat Wire Bonder MHS Wiring Diagrams 98888-0000-JB3-01

Index
A Signal Light 1-9

Video & Graphics Display 1-10
Abbreviations A-1 Video Monitor 1-9
Adjust Puller Gripper Jaw Gap 2-15
D
B Declaration of Exemption S-22
Belt Tension Setup, Magazine Tray 3-13, 3-15 Descriptions
Bond Site/Preheat Heat Block Assembly Replacement Carrier Injection 2-9
Bond Site Heat Block Assembly 2-80 Device Indexing 1-5
Bond Site Heater Assembly 2-76 General 1-3
Bond Site Motor 2-85 Magazine Handlers 1-5
Bond Site Thermocouple Assembly 2-78 Workholder 1-4
Compression Spring 2-71 Dictionary A-1
Preheat Heat Block Assembly 2-79
Preheat Heater Assembly 2-73
Preheat Linear Slide Assembly 2-86
Preheat Motor 2-82
E
Preheat Thermocouple Assembly 2-75 Electronics 4-1
Cable Assemblies 4-35
MHS Sensors 4-28
C Overview 4-2
Sensor Handling 4-5
Cable Assemblies 4-35 Stepper Drive 4-4
Calibration System Diagram 4-3
Access to Software Options 1-12 System Organization 4-2
General Descriptions 1-12 Replace Circuit Boards
Workholder 2-40 Replace Indexer Intermediate Board 4-26
Clamp 2-44, 2-50 Replacing the Input/Output Magazine Handler
Heat Block 2-51 Intermediate Board 4-24
Tucker Eject 2-52 Replace DMHS Card Rack Circuit Boards 4-23
Workholder Calibrations 2-53 Subsystem/Board Description 4-8
Circuit Boards Circuit Board Locations 4-8
Descriptions 4-8 DMHS Hex Half Stepper Driver Circuit Boards
Indexer Interface Board 4-18 4-15
Indexer Intermediate Board 4-21 DMHS Indexer/Solenoid Driver Board 4-14
Locations 4-8 DMHS Micro/Tri Half Stepper Driver Board
Replace Card Rack Circuit Cards 4-23 4-18
Replace Indexer Interface 4-26 DMHS Stepper Controller Board 4-17
Replace Input/Output Interface 4-24 Indexer Intermediate Board 4-21
Roller Jam Detect Board 4-20 Interconnect Boards 4-22
Stepper Controller 4-14 Magazine Handler Intermediate Board 4-20
Clamp Calibration 2-44, 2-50 Emergency Off Switch S-8
Clear Leadframes from Workholder 1-20 Other Safety Features S-9
Configuration Overview S-8
Boat/Device Dimensions Specifications S-8
Boat Dimensions 2-55 Testing Operation S-8
Bond Plane Offset 2-57 Equipment-Specific Warnings S-2
Device Dimensions 2-56
Configuration, MHS 2-54
Controls/Indicators 1-6
Alarm, Audible 1-9
F
Control Panel 1-6, 1-8 Fire Safety S-7
Emergency Off 1-6 Fire Suppression S-7
Locations 1-7 Maintenance S-7
98888-0000-JB3-01 Index INDEX-1

G Calibration 3-7
Input/Output Slot 3-9
General Precautions S-3 Input/Output Tray 3-7
Glossary A-1 Components 3-2
Grippers Description 3-2
MHS utilities 5-18, 5-19 Magazine Handler Adjustments 3-13
Magazine Handler Configuration 3-13
Positions 3-3
H Removal and Installation 3-15
Input Magazine Handler 3-15
Heat Block Vacuum Sensor Adjustment 2-38
Output Magazine Handler 3-21
Heated Material and Equipment S-6
Setup 3-6
Servicing Heated Equipment S-6
Maintenance 5-1
User Responsibilities S-6
MHS Errors 5-21
MHS-Related Bonding Problems 5-30
Preventive Maintenance Schedule 5-2
I Special Tools and Gauges 5-5
Identification Label Descriptions S-18 Troubleshooting 5-5
EFO Box Odering Notice Label S-18 Manual Mode Utilities 5-16
Equipment Identification Label S-18 MHS Utilities 5-14
Index/Tucker Parts Replacement Motor Diagnostics 5-5
Index Arm and Pin 2-95 Re-Initialize MHS 5-10
Tucker 2-98 Sensor Diagnostics 5-10
Tucker Solenoid 2-99 MHS Errors 5-21
Indexer Flex Cable Assembly Replacement Error and Status Messages 5-22
Gripper Flex Cable Assembly 2-113 Error Indications 5-21
Puller Flex Cable Assembly 2-111 MHS Information in other Manuals 1-2
Indexer Intermediate Board 4-21 MHS Manual Contents 1-1
Indexer Pin/Tucker Eject Setup MHS Manual Mode Utilities
Indexer Pin Setup Sequence 2-20 Clamp Utilities 5-18
Tucker Eject Setup Sequence 2-22 Gripper Utilities 5-18
Initial Start-Up 1-18 Index Utilities 5-16
Introduction S-1 Pin Utilities 5-19
Descriptions 1-3 MHS Manual Scope 1-1
General Information 1-1 MHS-Related Bonding Problems 5-30
Operating Procedures 1-18 Eye Point Find Failures 5-31
Operator Controls 1-6 Non-Stick on Lead (NSOL) 5-33
Product Conversion 1-22 Non-Stick on Pad (NSOP) 5-32
Software Functions 1-12 Microscope Use S-6
Specifications 1-6
O
L Operating Procedures 1-18
Leadframe Present Sensor Setup 4-34 Bonder/Workholder System Shutdown 1-21
Load/Unload Magazines 1-20 Clear Leadframes from Workholder 1-20
Initial Start-Up 1-18
Load/Unload Magazines 1-20
M Remove Magazines from Magazine Handlers 1-20
Stop Auto Bonding 1-20
Machine Emissions S-9 Options
Gases,Vapor,Dust S-9 Heat Block Vacuum Sensor Adjustment 2-38
Ionizing and Non-Ionizing Radiation S-9
Noise S-9
Vibration S-9
Magazine Handler Adjustments
P
Belt Tension Setup 3-13 Parts Replacement 2-71
Tray Adjustment 3-15 Control System
Magazine Handlers 3-1 Card Rack Circuit Boards 4-23
INDEX-2 Index 98888-0000-JB3-01

Indexer Interface 4-26 Workholder Sensor Locations 4-29

Input/Output Interface 4-24 Servicing Electrical Equipment S-4
Workholder 2-71 Lockout/Tagout Procedure S-5
Bond Site/Preheat Heat Block Assembly 2-71 Servicing the Power Supply S-5
Index/Tucker 2-95 Types of Electrical Hazards S-4
Indexer Flax Cable Assembly 2-111 Shutdown and Start-up Procedures S-23
Puller 2-88 Shutdown Procedure S-23
Rails 2-101 Start-up Procedure S-23
Replace Heat Block Vacuum Solenoid Valve Shutdown Bonder/MHS 1-21
2-116 Software Functions 1-12
Sensor Assemblies 2-106 Auto Run Configuration 1-16
Preventive Maintenance Calibration 1-12
Schedule 5-2 MHS Configuration 1-12
Workholder 2-69 MHS Diagnostics 1-17
Product Conversion 1-22 MHS Magazine Utilities 1-14
Conversion Sequence 1-22 MHS Utilities 1-13
Enter/Edit MHS Parameters 1-24 MHS Workholder Utilities 1-15
Load Process Program 1-24 Specifications
MHS Operation Check 1-25 Carrier Dimensions 1-6
Replace Clamp/Heat Block Inserts 1-23 Magazine Dimensions 1-6
Required Tools/Parts 1-23 Other 1-6
Puller Parts Replacement Stop Auto Bonding 1-20
Puller Finger 2-88 Symbols and Messages S-1
Puller Motor 2-90 Caution S-1
Puller Rack 2-89 Note S-1
Puller Solenoid 2-93 Warning S-1
Puller Pin Setup
Puller Pin Setup Sequence 2-16
T
Terms and Conventions S-1
R Tools and Fixtures 5-5
Rail Calibration 2-40 Trained Operators and Service Technicians S-4
Rail Parts Replacement Troubleshooting 5-5
Indexer Motor 2-101 Error Indications 5-21
Leadscrew Bearing 2-105 Error Messages 5-22
X Axis Leadscrew Assembly 2-103 Initialize MHS 5-10
Record of Changes S-2 Maintenance Diagnostics 5-10
Remove Magazines from Magazine Handlers 1-20 MHS Manual Mode Utilities 5-16
Remove/Install Input Magazine Handler 3-15 MHS Related Bonding Problems 5-30
Remove/Install Workholder 2-61 MHS Toolbar Utility Menus 5-14
Roller Jam Detect Board 4-20 MHS Workholder and Motor Cycling Diagnostics 5-5
Temperature Controller Diagnostics 5-8
S
Safe Handling U
Heated Material and Equipment S-6 Use of This Manual S-1
Safety 1-2
Sensor Assemblies Replacement
J Boat Present Sensor Amplifier 2-109
Optical Switch Assemblies 2-107
V
X Registration Sensor 2-106 Video & Graphics Display 1-10
Sensors 4-28
Magazine Handler Sensor Locations 4-30
Reflective Sensor Setup 4-33 W
Leadframe Present Sensor 4-34 Warning and Safety Labels S-10
Sensor Types 4-28 Berylium Product Warning S-16
Status Display 4-34 Burn Hazard Warning S-14
98888-0000-JB3-01 Index INDEX-3

Disconnect Power Label S-15 2-61

Electrical Hazard Warning S-15 J Boat Slider Assembly Removal and Installation 2-66
Emergency Off S-14 Preventive Maintenance 2-69
Equipment Grounding IEC S-16 Setup & Adjustments 2-13
General Hazard Warning S-15 Preheat Heat Block/Bond Site Alignment 2-32
Hard Stop Caution S-17 Puller Rack Backlash Adjustment 2-36
Operator ESD Connection S-16 Subsystems 2-5
Pinch Point Hazard Warning S-14 Bond Site Heat Block Assembly 2-7
Workholder 2-1 Front/Rear Rail Assemblies 2-6
Boat Indexing and Ejection Sequence 2-11 Index/Tucker Assembly 2-7
Boat Injection Sequence 2-9 Indexer Intermediate Board 2-8
Boat Transfer Sequence 2-11 J Boat MHS Pneumatic System 2-8
Calibration 2-40 Preheat Heat Block Assembly 2-6
Heat Block Calibration 2-51 Puller Assembly 2-5
Workholder 2-40 Workholder Calibrations 2-53
Workholder Calibration 2-53 Workholder Setup & Adjustments 2-13
Components 2-2 Bond Site Heat Block Alignment 2-24
Configuration 2-54 Heat Block Vacuum Sensor Setup 2-38
Boat/Device Dimensions 2-55 Index Pin/Tucker Eject Setup 2-20
Indexing Options 2-59 Puller Pin Setup 2-15
Indexing Parameters 2-57 Rail Parallelism Adjustment 2-27
Workholder Configuration 2-59 Setup Sequence 2-13
General Description 2-2 Workholder Gauge 2-15
J Boat Indexer Assembly Removal and Installation
INDEX-4 Index 98888-0000-JB3-01

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Kulicke & Soffa Pte Ltd

Use of This Manual

Select Selection is initiated by:

Drag Repositioning or resizing of an item on the display. This is done by using

Index Initiating workholder motion.

Change Description Affected Revised

00 Launch Release ALL 12/2009

98888-0000-JB3-01 Safety Information S-1

S.3 Equipment-Specific Warnings

S-2 Safety Information 98888-0000-JB3-01

S.4 General Precautions

98888-0000-JB3-01 Safety Information S-3

S.5 Trained Operators and Service Technicians

• Read through section S.6.1 Types of Electrical Hazards thoroughly

S-4 Safety Information 98888-0000-JB3-01

A Safety LED Location

98888-0000-JB3-01 Safety Information S-5

S.7 Safe Use of Heated Material and Equipment

S.8.1 Servicing Heated Equipment

S-6 Safety Information 98888-0000-JB3-01

98888-0000-JB3-01 Safety Information S-7

S.10 Emergency Off Switch

S.10.1 Emergency Off Switch Specifications

S-8 Safety Information 98888-0000-JB3-01

98888-0000-JB3-01 Safety Information S-9

S.13 Warning and Safety Labels

A: S.13.2 Burn Hazard Warning

S.13.3 Pinch Point

S.13.3 Pinch Point

S.13.8 Operator ESD

Figure S-2 Machine Front and MHS Safety Label Tags

S-10 Safety Information 98888-0000-JB3-01

Machine Rear View With Covers

S.13.4 Electrical Hazard S.13.5 General

Lower Console Rear View Without Cover

Figure S-3 Machine Rear Safety Label Tags

98888-0000-JB3-01 Safety Information S-11

S.14.3 FDA Explanatory/

S.13.6 Disconnect Power Label

Lower Console Front View

S.13.4 Electrical Hazard

Card Cage Front View

Figure S-4 Lower Console Front Safety Label Tags

S-12 Safety Information 98888-0000-JB3-01

S.14.1 EFO Box Ordering Notice Label

S.13.4 Electrical Hazard Warning

S.13.3 Pinch Point Hazard Warning

Upper Console Rear View

S.13.9 Beryllium Product Warning

Bond Head Link Bottom View

Figure S-5 Bond Head, EFO, and MHS Safety Labels

98888-0000-JB3-01 Safety Information S-13

S.13.1 Emergency Off

Figure S-6 Emergency Off Label

Figure S-7 Burn Hazard Warning Label

• Label: Burn Hazard Warning

Figure S-8 Pinch Point Warning Label

S-14 Safety Information 98888-0000-JB3-01

Figure S-9 Electrical Hazard Warning Label

Figure S-10 General Hazard Warning Label

Figure S-11 Disconnect Power Before Servicing Label

98888-0000-JB3-01 Safety Information S-15

S.13.7 Equipment Grounding IEC