3-Service and Maintenance Instructions v1.6

Service and Maintenance Instructions
JTF2 JEDEC Tray Feeder
Fig 1 JTF2 JEDEC Tray Feeder

Table of Contents
Section 1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section 2 - Interfaces and Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 About Communications with the Host Machine . . . . . . . . . . . . . . . 2-1
2.2 Identifying the Communications Mode on a Particular Feeder . . . . 2-2
2.3 Simple Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Identifying the Communications Mode on a Particular Feeder . . . . 2-4
2.5 Advanced Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 RS-232 Serial Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.7 Siemens Serial Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Section 3 - Maintenance Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Maintenance Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Section 4 - Maintenance and Replacement Procedures . . . . . . . . . . . . . . . . . .4-1

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Cleaning and Replacing Short Pawls . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Checking Freedom of Movement for Long Pawls . . . . . . . . . . . . . . 4-6
4.5 Conveyor Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 Belt Guide Block Installation and Adjustment . . . . . . . . . . . . . . . . . 4-11
4.7 Tray Clamp Dowel Pin Replacement Procedure . . . . . . . . . . . . . . .4-13
4.8 Shaft Clamp Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . .4-18
4.9 Worm Gear Drive Assembly Replacement Procedure . . . . . . . . . . 4-24
Section 5 - Setup and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Conveyor Speed Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Main Air Regulator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5 Tray Clamp Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.6 Belt Guide Block Replacement and Adjustment . . . . . . . . . . . . . . . 5-13
JTF2 Service & Maintenance Instructions Rev 1.6 August 2011
5.7 Checking Pawl Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.8 Lift Cylinder Shock Absorber Adjustment . . . . . . . . . . . . . . . . . . . . 5-16
5.9 Elevator Bar Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.10 Slow-Down Delay Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
5.11 Lift Cylinder Flow Control Adjustments . . . . . . . . . . . . . . . . . . . . . . 5-29
5.12 Tray Clamp Pneumatic Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5.13 Return Pusher Pneumatic Adjustment . . . . . . . . . . . . . . . . . . . . . . 5-34
5.14 Feed Pusher Pneumatic Adjustment . . . . . . . . . . . . . . . . . . . . . . . 5-37
Section 6 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
5.4 Main Air Regulator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5 Tray Clamp Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6 Belt Guide Block Replacement and Adjustment. . . . . . . . . . . . . . . 5-13
Section 7 - Schematics / Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . .7

4037154 System Schematic
4036229 Control Circuit Schematic
9036231 Control Circuit Assy
4036236 Interface PCB Schematic
9039388 Return Slow Sensor Assembly
9037734 Elevator High Limit Sensor Assembly
9037735 Elevator Low Limit Sensor Assembly
9037736 Door Interlock Switch Assembly
9037737 Interface Cable Assembly
9037738 Tray Lift Sensor Assembly
9037739 Tray Position Selector Switch Assembly Bottom Up
9038305 Motor Assembly Conveyor
9038306 Motor Assembly Elevator
9039390 Tray Position Selector Switch Assembly
9042992 Tray Position Left/Right Sensor Assembly
9037490 Host Cable Generic
9043987 Serial Host Cable Generic
9041760 Host Cable Generic Advanced
Section 8 - Assembly Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9038378-T2-10 Core Assembly
9041745-T2-10 Core Assembly, Low Torque
9041770-T2-10 Core Assembly, High Torque
9041300-T3-30 Access Door Assembly
9041746-T3-10 Feed Pusher Assembly (Standard)
9039240-T2-20 Tray Clamp Assembly (Standard)
9039240-T2-30 Conveyor End Assembly (Standard)
9039240-T2-40 Conveyor Roller Shaft Assembly
9039240-T2-50 Tray Return Pusher Assembly
9039245-T2-60 Conveyor Assembly, 25" (Standard)
9039386-T1-50 Left Panel Assembly
9041748-T1-30 Bottom Up Lift Rod Assembly
9039386-T1-60 Right Panel Assembly
9041744-T1-20 Operator Interface Assembly
Long Belt Option Assembly Drawings

9047147 Feed Pusher Assy Extended Stroke
9041739 Conveyor Base, Long Belt 25”
9047140 Conveyor Assembly, Long Belt 25” JTF2

List of Figures
Fig. 1-1 JTF2 JEDEC TrayStak Feeder

Fig. 2-1 Configuration Table
Fig. 2-2 Simple Communications Mode
Fig. 2-3 Intermediate Communications Mode
Fig. 2-4 Advanced Communications Mode
Fig. 2-5 Light Tower and Error Messages - Advanced Mode
Fig. 2-6 HyperTerminal RS-232 setup
Fig. 2-7 RS232 Error Codes
Fig. 4-1 Remove the Side Cover
Fig. 4-2 Removing the Pawl Lift Rods
Fig. 4-3 Replacing the Dowel Pins or Spring
Fig. 4-4 Checking Pawl for Free Movement
Fig. 4-5 Reinstalling the Side Covers
Fig. 4-6 Checking the Long Pawls
Fig. 4-7 Disconnecting Cables and Air Lines
Fig. 4-8 Disconnecting Conveyor from Base
Fig. 4-9 Disconnecting Wiring Connectors
Fig. 4-10 Removing the Conveyor
Fig. 4-11 Removing the Conveyor Rail
Fig. 4-12 Old Guide Blocks
Fig. 4-13 New Guide Blocks
Fig. 4-14 Remove These Parts
Fig. 4-15 Remove These Screws
Fig. 4-16 Remove These Mounting Screws
Fig. 4-17 Remove the Assembly
Fig. 4-18 Disconnect the Air Lines
Fig. 4-19 Press Out the Dowel Pin
Fig. 4-20 Install the New Dowel Pin
Fig. 4-21 Remove the Bottom Plate
Fig. 4-22 Loosen the Shaft Clamp Screw
Fig. 4-23 Disassembling the Shaft Clamp
Fig. 4-24 Pry Out the Hub
Fig. 4-25 Shaft Clamp Disassembled
Fig. 4-26 Assembling the Coupling
Fig. 4-27 Worm Gear Assembly
Fig. 4-28 Checking the Elevator Lift Bars
Fig. 4-29 Rest the Elevator Lift Bar Against the pins
Fig. 5-1 Thick/Thin Switch
Fig. 5-2 Removing Front Cover Screws
Fig. 5-3 Location of Pressure Regulator
Fig. 5-4 Checking Air Pressure
Fig. 5-5 Maintenance Kit
Fig. 5-6 Tray Clamp Assembly
Fig. 5-7 Adjusting the Shaft Length on the Pneumatic Cylinder
Fig. 5-8 Engagement Lever
Fig. 5-9 Old-Style Guide Block
Fig. 5-10 Setting Conveyor Belt Height
Fig. 5-11 Checking Pawl Movement
Fig. 5-12 Lift Mechanism Cover
Fig. 5-13 Shock Absorber Adjustment
Fig. 5-14 Details of Shock Absorber
Fig. 5-15 Shock Absorber Gap Setting
Fig. 5-16 Manual Activation Buttons
Fig. 5-17 Location of Alignment Holes
Fig. 5-18 Bottom Plate and Mounting Screws
Fig. 5-19 Alignment Pins
Fig. 5-20 Slip Clutch
Fig. 5-21 Alignment Pins - Correct Alignment
Fig. 5-22 Incorrect - Elevator Bars Not at Same Level
Fig. 5-23 Incorrect - Elevator Bar is Not Level
Fig. 5-24 Adjusting New-Style Couplings
Fig. 5-25 Adjusting Old-Style Couplings
Fig. 5-26 Adjusting Chain Tension
Fig. 5-27 Conveyor and Stack Slow Down Adjustments
Fig. 5-28 Correct - Tray Starts Slow Down After Passing Sensor
Fig. 5-29 Incorrect - Tray Starts Slow Down Before Passing Sensor
Fig. 5-30 Lift Cylinder Cover
Fig. 5-31 Lift Cylinder Flow Controls

Fig. 5-32 Flow Control Locations - Lift Cylinders
Fig. 5-33 Flow Control Locations - Tray Clamp
Fig. 5-34 Flow Control Locations - Return Pusher
Fig. 5-35 Cover Screw Locations
Fig. 5-36 Forward Push Flow Control
Fig. 5-37 Removing Front Cover Access
Fig. 5-38 Feed Pusher Flow Control Valve - Older Feeders
Fig. 5-39 Feed Pusher Flow Control Valve - Newer Feeders
Fig. 5-40 Feed Pusher Assembly
Fig. 6-1 Component Locations on the Motherboard
Fig. 6-2 Indicator LEDs on Solenoids and Pneumatc Tube Connections
Fig. 6-3 Interface Cable for Simple and Intermediate Modes
Fig. 6-4 Interface Cable for Advanced Mode
Fig. 6-5 Interface Cable for Serial Mode
Fig. 6-6 Sensor Locations - Top of Feeder
Fig. 6-7 Sensor Locations - Bottom of Feeder
Fig. 6-8 Sensor Locations - Conveyor

1 Introduction
1.1 Introduction
This manual was written for the service technician who needs to set up or troubleshoot a JTF2 Feeder.
We have tried to include all of the information you might need, and arranged it in an easy-to-use form.
The manual includes these sections:
Section 2 - Communications Modes

Different versions of the feeder handle inputs and outputs in different ways, depending on the
communications modes they use. For example, the Simple communications mode uses just two outputs,
and only has one signal line to indicate all of the possible error conditions. The Advanced mode has more
outputs, and can indicate several separate error conditions. Before you can troubleshoot a feeder, you
need to know which communications mode it is using.
Section 3 - Maintenance Tools

This includes a list of the special tools used to maintain and repair the unit.
Section 4 - Scheduled Maintenance

The feeder will have the most reliable operation if you maintain it regularly.
Section 5 - Adjustments
This section includes detailed instructions for the most important adjustments on the machine. Some
troubleshooting problems can be cleared by re adjusting the feeder.
Section 6 - Troubleshooting
The first part of this section includes some general notes about the troubleshooting process on this
Feeder. The feeder has some functions that may not be obvious at first. You really have to understand
some of these points before you begin troubleshooting.
The second part includes some troubleshooting charts. We have based these on input from actual field-
service technicians, so they should be accurate and helpful.
Timing Diagrams -
The next section of the manual includes some detailed timing diagrams for a feeder operating in the
Advanced mode. This shows how the inputs from the sensors interact with the control program.
Electrical Diagrams -
We have included schematic diagrams of the most important electrical parts on the feeder.
Assembly Diagrams -
The final part of the manual includes prints for the important mechanical assemblies. These prints list part
numbers, in case you have to order replacements.
Additional Questions:
If there is anything in this manual that is unclear, or if you need more information, please send an email to
feeder@quasys.ch or call +41 41 740 20 60.

2 Interfaces and Communications
2.1 Communications with the Host Machine

The JEDEC feeder can be interfaced to many different kinds of machines. In some installations, the
communication setup with the host machine is very simple - there is one input and two outputs. The
host machine can call for a tray, and the JEDEC feeder can indicate whether it is busy or ready, or if it
is full or has an error condition. This last signal has some limitations, because the host machine does
not know whether the JEDEC feeder is full, or has an error. Quasys added some more complex
communications modes so that more complex signals can flow between the host and the JEDEC
feeder.
There are several communications options:
Discrete IO Serial communication
• Simple mode • Siemens serial mode

• Intermediate mode • RS-232
• Advanced mode
2.2 Identifying the Communications Mode on a Particular Feeder

If you're given a feeder, and you do not know which communications mode is used, how do you
determine this? Here are the steps in the process:
On the mother board for the feeder, there should be a label on the EPROM which identifies the
software version. (This should be a combination of letters and numbers similar to this: A25-02-4.0.3)
Refer to print #9044023, "Configuration Settings, Control PCB Assembly." (There is a copy of this
print included with this manual.) Check the table in the upper left-hand corner. We have included a
copy of this table here. See Fig. 2-1.
Fig. 2.1 Configuration Table

The software version number is listed on a label on the microprocessor chip (U3). On the table in Fig.
2-1, locate the line that has the correct software number. The middle two digits indicate the type of
communication:
01 Simple
02 Intermediate
03 Advanced
04 Customer specific configuration 1
06 RS-232 (serial)
Any other numbers than that indicate special customer software.
Reading across the correct line in the table, you can also find some other information about the
feeder:
Some feeders have a smaller daughter board which provides extra input/output capability.
On most feeders, the 24V DC is supplied from the host machine to the mother board. On units made
for Siemens, the daughter board is supplied with 30V, and steps it down to the mother board at 24V.
There are six DIP switches (S1 through S6) which determine whether each input and output line
operates as a "sink" or "source." On a feeder having the optional 9038875 daughter board, there are
two more DIP switches (S1 and S2). The table shows how each of these switches should be set for
each input or output function.
2.3 Simple Mode

The Simple communications mode uses just one input and two outputs. See the table below. Notice
that the signal on Output 2 can have several different meanings: error, stopped, inhibit, full, and
empty.
The Simple communications mode uses just one input and two outputs. See the table below.
Notice that the signal on Output 2 can have several different meanings: error, stopped, inhibit, full,
and empty.
Description Input 1
Nothing 0
Tray Exchange Request 1
Description Output 1
Busy 0
Ready 1
Description Output2
Normal 0
Error/Stopped/Inhibit/Full/Empty 1
Fig. 2-2 Simple Communications Mode

2.4 Intermediate Mode
The Intermediate mode is similar, except it includes an additional output line. This allows the JEDEC
feeder to communicate several different full and error conditions. See the table below:
Description Input 1
Nothing 0
Tray Exchange Request 1
Description Output 2 Output 3

Normal/Tray Exchange 0 0
Full || Inhibit 1 0
Empty 0 1
Error || Stopped 1 1

Description Output 1
Busy 0
Ready 1
Fig. 2-3 Intermediate Communications Mode
2.5 Advanced Mode

When using the Advanced mode, the JEDEC feeder has five output lines. Output lines
4 and 5 are provided by the daughter board. The source/sink settings for these lines are controlled by
S1 and S2 on the daughter board. When you are looking at the control board, the yellow LED on the
right of the daughter board indicates that output 4 is on, and the one on the left indicates that output 5 is
on.
See the table below.
State # Description Input 1 Input 2

1 Maintenance 0 0
2 Slow Index 0 1
3 Fast Index 1 0
4 Production 1 1
State # Description Output 1 Output 2 Output 3 Output 4 Output 5

1 Door Open 0 0 1 0 1
2 Elevator Moving 0 0 1 0 0
3 Empty 0 1 1 1 0
4 Empty+Door Open 0 1 0 1 0
5 Empty+Full 0 0 0 1 0
6 Empty+Full+Door Open 0 1 0 1 1
7 Empty+Inhibit 0 0 0 1 1
8 Error 0 0 0 0 1
9 Full 0 1 1 0 0
10 Full+Door Open 0 0 1 1 0
11 Inhibit 0 1 1 0 1
12 Normal 0 0 0 0 0
13 Ready 1 0 0 0 0
14 Ready+Door Open 1 0 1 0 1
15 Ready+Elevator Moving 1 0 1 0 0
16 Ready+Empty 1 1 1 1 0
17 Ready+Empty+Door Open 1 1 0 1 0
18 Ready+Empty+Full 1 0 0 1 0
19 Ready+Empty+Full+Door 1 1 0 1 1
Open
20 Ready+Empty+Inhibit 1 0 0 1 1
21 Ready+Full 1 1 1 0 0
22 Ready+Full+Door Open 1 0 1 1 0
23 Ready+Inhibit 1 1 1 0 1
24 Stopped 0 1 0 0 1
25 Tray Exchange 0 1 0 0 0
Fig. 2-4 Advanced Mode
The feeder with advanced mode configuration has two operating modes:
• When the "production" mode is selected, the feeder is controlled by the host machine. The
index buttons on the front of the feeder do not have any effect.
In order to automatically index a tray, "production" mode must first be set. This is accomplished by
turning inputs 1 and 2 on. After both inputs are on, automatic indexes are possible according to the
table on the previous page - in other words, by turning one of the two signals off, and then on
again.
• When the "maintenance" mode is selected, the feeder is controlled using the control buttons on
the front of the unit. If the host machine calls for a tray feed, this will have no effect. To exit from
the "production" mode, inputs 1 and 2 must be turned off. Manual index will only work when both
inputs are turned off.
Advanced Mode - Signal Description:
READY -- This is always output 1 on the JTF2. ON means ready, OFF means busy.
Error lines 1-4 (Outputs 2-5 respectively) -- These follow the truth table, based on the current state
of the feeder.
Signal 1 and Signal 2 -- The feeder has two operation modes when using Advanced communication:
Production and Maintenance. In order to automatically index a tray, the feeder must first be put in
Production mode. This is done by turning both Signal 1 and Signal 2 on.
After these are held on for ~10 ms, Production mode is set and automatic indexing can occur. From this
point, turning Signal 1 off causes the feeder to execute or queue (if in inhibit) one slow tray exchange.
This signal should be turned off for a minimum of 50 ms and maximum of 100 ms, and then turned on
again to maintain Production mode. Turning Signal 2 off causes the feeder to execute or queue (if in
inhibit) one fast tray exchange. This signal should be turned off for a minimum of 50 ms and maximum
of 100 ms, and then turned on again to maintain Production mode.
Manual tray exchange (using the Index 1 button and Index 2 buttons) is not possible while the
feeder is in Production mode.
To enter the Maintenance mode, both Signal 1 and Signal 2 must be turned off for ~10ms. From this
point, pushing both the Index 1 button and Index 2 buttons simultaneously for a minimum of 50 ms will
cause the feeder to execute or queue (if in inhibit) one tray exchange.
Upon exiting Production mode, the feeder will execute all following manual tray exchanges at the
slow speed. Automatic tray exchanges are not possible when the feeder is in Maintenance mode
(inputs 1 & 2 off).
Upon power up and before entering Production mode for the first time, the feeder will only execute
manual tray exchange at the slow speed.

The table below shows the signals on the User Interface panel, and also the error messages produced
by the feeder. To compare this with the output signals listed in the last table, note the "state number"
for each condition (first column).

Message 1 JTF elevator access door is open
Message 2 JTF has no more empty trays.
Message 3 JTF capacity of full trays reached.
Message 4 JTF is in Inhibit mode.
Message 5 JTF has experienced error during tray exchange.
Message 6 JTF is stopped.
Fig. 2-5 User Interface and Error Messages
2.6 RS-232 Serial Mode

Serial communication via RS232 offers the highest level of control and error handling for the
JTF2. The discrete IO signals (Intermediate mode) are available in addition to serial
communication. To set up the board for RS-232 operation, a MAX233 chip is installed inU8. Due
to space constraints the Advanced mode daughter board cannot be installed, so advanced mode
cannot be used in conjunction with serial communication. The voltage levels on the signal lines
are ±12V.
The system uses standard serial settings:
Set up so the characters you type will not be echoed on the screen, as the feeder echoes each
character. To set this up, select Properties, which you find under the File menu. This will bring
up the Connection Name properties box. Select the Settings tab and then select ASCII Setup.
This will bring up the ASCII Setup dialog box (Figure 2-6). Uncheck the box to Echo typed
characters locally (as shown). Then click on OK twice, and the connection will be set up to
display only the text that is echoed by the feeder. Test the connection by typing a Simple
command such as ? <Enter>. The screen should only show one question mark.

Fig. 2-6 HyperTerminal RS-232 setup
Signals can travel in both directions. The serial cable has a transmit line, a receive line and a
ground.

The system can recognize these commands:
Index F<cr> (Index at fast speed)

I<cr> (Index at last or default speed)
S<cr> (Index at slow speed)
(If ready or ok, begins a tray exchange)
E<cr> (End of Line, speed according to last index)
optionally available
If successful, sends: Ready<cr>

Otherwise sends: Error<cr>
D<cr> (Elevator down)
Status T<cr> (Tray status, ready for production?)
Sends current status Ready<cr>

code:
Error<cr>
?<cr> (Index Status, ok to index new tray?)
Sends current error/status code:

(Error/status codes are prioritized. Only the highest code active is sent.)
Priority is:
Door open<cr> (Tray replacement in progress)

Stopped<cr> (Stop button is activated, manual reset required)
Full<cr> (No more room for used trays)
Empty<cr> (No more fresh trays available)
Error<cr> (Error or timeout occurred during indexing)
Inhibit<cr> (Unit has been placed in Inhibit mode)
Ok<cr> (Unit is ready to index a tray)
Reset R<cr> (Clears any errors)
Reboot B<cr> Reboots the feeder
*If the STOP button is pressed, a manual RESET is required.
NOTES:
- Letters are not case sensitive.
- U8 needs to have a Maxim MAX233 chip installed, not a daughter board.
- The “End-Of-Lot” command E<cr> is available in version A25-06-5.1.1 or higher. It will unload the current
tray on the conveyor without feeding a new one and then lower the elevator down.

RS232 Error Codes:
Error # Error Codes Description

Error_1 DOOR_OPEN JEDEC ONLY: Elevator loading door is open
Error_2 FULL_ERROR The output stack is full of trays
Error_3 STOP_ERROR Stop button pushed
Error_4 FAILED_TO_RECLAMP Tray Reclamp during initialization or reset failed
Error_5 TRAY_IN_STACK Tray Exchange initiated w/ tray partially in stack
Error_6 LIFT_NOT_DOWN The lift mechanism did not reach bottom dead center
Error_7 TRAY_NOT_CLEAR The tray returning from the pick position did not clear the
return slow down sensor
Error_8 TRAY_NOT_IN The tray returning from the pick position did not reach the
Stop @ Stack sensor
Error_9 LIFT_NOT_UP Tried to unload tray into occupied position
Error_10 TRAY_NOT_FED The lift mechanism did not reach top dead center
Error_11 TRAY_NOT_AT_END The tray being conveyed to the pick position did not reach
the stop @ end sensor
Fig 2-7 RS232 Error Codes
2.7 Siemens Serial Mode

This is a proprietary serial signalling system used only by Siemens. The voltage levels on the
signal lines are 0 - 30V. The system exchanges ASCII characters. For more details, contact the
Quasys factory.
3 Maintenance Tool List
3.1 Maintenance Tools (Kit P/N 9043900)

Quasys recommends you carry the following tools when servicing the JEDEC feeder:
Qty Description Used for

1 Tool, Allen wrench, .050 -5/16 Gearbox and couplings
1 Fitting, straight union, 5/32 To extend existing air ling tubing
1 Screwdriver, Vishay Spectrol Potentiometer adjustment
1 Tubing, poly 4mm x 2.5 mm, 1m length To extend existing air tubing
1 JTF2 maintenance CD ROM Maintenance instructions, troubleshooting
1 Power supply, 24V DC, 60W, enclosed Power to feeder on bench
2 Pin, elevator locating, JTF2 Check alignment of elevator bars
2 Shim, elevator bar assembly When assembling elevator bars
1 Shim, guide block alignment Set height of conveyor belt
1 Maintenance kit, air pressure gauge Checking input air pressure

4 Maintenance and Replacement Procedures
4.1 Introduction
This feeder requires a minimum of maintenance. However, these few required maintenance steps
are important. If they are ignored, performance may suffer and the feeder may wear out
prematurely.
All bearings used in the feeder are sealed, and do not require lubrication. The feeder uses dry-
run chains, and these should not be lubricated.
NOTICE
Any lubrication applied to mechanical parts in the feeder could potentially migrate and/or outgas,
which could contaminate the components being fed. Use only the specified lubricants.
The first part of this section lists the scheduled maintenance steps. The second part includes
instructions for replacing specific parts.

4.2 Scheduled Maintenance
Weekly Maintenance:
Section/Mechanism Check this Correction

All Sections of feeder Check for loose, damaged Tighten or replace
or broken parts
Conveyor belts Check for damage, dirt Clean with isopropyl alco-
hol. Replace if necessary.
See section 4.5 for replace-
ment instructions.
Short and long pawls Check for free motion. See Clean only. Do not lubri-
sections 4.3 and 4.4 for cate these parts!
instructions
Monthly Maintenance:
Section/Mechanism Check this Correction

Conveyor belts Clean Clean with isopropyl alco-
hol.
Tray platform Clean Clean with isopropyl alco-
hol.
Urethane pinch roller on Check for wear or damage Replace if necessary.
tray clamp mechanism
Rodless cylinder on tray Check for lubrication and If dry or moving unevenly,
clamp mechanism smooth motion wipe down the shaft with
isopropyl alcohol.

4.3 Cleaning and Replacing Short Pawls
The following procedure outlines how to remove, clean and replace a short pawl from the pawl lift
rod.
1. Remove the side cover as shown in Fig. 4-1.
Remove the Side Cover

(12 sunk screws)
Fig. 4-1 Remove the Side Cover
2. Remove the pawl lift rod as shown in Fig. 4-2.

3. Remove the short pawl by pushing the dowel pin out of the pawl lift rod as shown in
Fig. 4-3.
4. Clean the dowel pin and short pawl with alcohol. Be certain the pawl moves freely on the
dowel pin before assembling the pawl on the lift rod.(See Fig. 4-4.)
5. Replace the short pawl and reinstall the dowel pin. NOTE: Be sure the dowel pin
does not protrude from the pawl lift rod. (See Fig. 4-3.) Be sure the short pawl moves freely.
(See Fig. 4-4.)
6. Reinstall the pawl lift rod and attach the side cover. NOTE: Be certain the retracted short
pawls on both lift rods move freely when installing the side cover. (See Fig. 4-5) Double
check short pawl movement after mounting side panels.

Pawl Lift Rods
Remove this two

screws to remove
the Pawel Lift Rod
Fig. 4-2 Removing the Pawl Lift Rods
Before reinstalling the

When reinstalling the pawl lift rod, be sure
dowel pin, be sure the the pawl moves nicely
pin is flush with the side
Push out the dowel pin

to remove the pawl
Fig. 4-3 Replacing the Dowel Pins or Spring

Fig. 4-4 Checking Pawl for Free Movement
Lift up the lower pawel

before tight the side
cover screws in order
not to pinch the lower
pawel with the notch of
the inner side plate as
marked above!
Fig. 4-5 Reinstalling the Side Cover

4.4 Checking Freedom of Movement for long Pawls
The long pawl should always fall down in place by gravity.
1. Push the long pawl to one side, and test the upward movement as shown below.
2. Push the long pawl to the other side and test the upward movement again.
Move the pawl to the up position ,

release it and make sure it is
falling down all the way to the
down position
Fig. 4-6 Checking the Long Pawls 1

Test for freedom of
movement in both
directions
Fig. 4-6 Checking the Long Pawls
Fig. 4-6 Checking the Long Pawls 2

4.5 Conveyor Belt replacement
The following procedure outlines the steps necessary to replace the flat urethane convey- or belts
on a JTF2 feeder.
1. Disconnect all cables and pneumatic air lines shown in Fig. 4-7. Cut cable ties where needed.
Disconnect pneumatic air lines H7, Unplug connectors J1, J2, J3 and
H8, H9, H10 from the solenoid J18.
valve bank and the main air line on
the air regulator.
Main Air Regulator Customers using advanced

mode software must disconnect
J9 underneath the tube.
Fig. 4-7 Disconnecting Cables and Air Lines

2. Remove the screws holding the conveyor to feeder base. See Fig. 4-8.
After removing the

screws, slide the
conveyor in this
direction
To disconnect the conveyor from the

base, remove these screws on both sides
of the base.
Fig. 4-8 Disconnecting Conveyor from Base
3. Remove the conveyor from the base and place it on the bench. For additional reference
on what is removed with the conveyor, refer to Fig. 4-9.

J2 J18 J1 J3
Fig. 4-9 Disconnecting Wiring Connectors
4. Remove the four screws holding the conveyor rail. See Fig. 4-10.
Remove these four screws

5. Remove conveyor rail. See Fig. 4-11.
NOTE: When removing the rail, be aware that the conveyor roller shaft sits inside the rail.
Conveyor roller shaft
CAUTION: Sensor wiring is tie wrapped inside

the conveyor rail. After removing the rail, lay
the rail to the side as shown above.
6. Replace the belt. Reinstall the rail.

7. For the other belt, repeat steps 4 through 6.

4.6 Belt Guide Block Installation and Adjustment
The following instructions explain how to install and adjust the belt guide blocks on the
JTF2 feeder.
A change was made to the belt guide blocks to aid warped trays (out of specification) in
successfully reaching the stop @ end switch. The original guide block was held to a fixed
location by two flat head screws as shown in Fig. 4-12.
Old guide blocks using

flat head screws
Fig. 4-12 Old Guide Blocks

The new guide blocks are attached to the rail by M4 x 16 button head cap screws as shown
in Fig. 4-13. The size of the mounting holes in the new guide block was increased from 4.5
millimetres (.177 inch value) to 5.56 millimetres (.219 inch value) allowing the block to be
positioned higher. This height increase allows warped trays to remain in contact with the belt
for a longer distance as the tray transitions from the conveyor to the pick position.
Set the conveyor belt height by Conveyor rail

placing a .015 shim between
the belt and conveyor rail, then
tighten the M4 mounting
screws.
Belt New guide blocks with

M4 x 16 button head
Fig. 4-13 New Guide Blocks
1. To set the guide block position height, place a .38 millimetres (.015 inch value) shim between
the belt and rail, then tighten the guide block mounting screws. See Fig. 4-13.
NOTE: Customers with the older type of guide blocks can modify these blocks by increasing
the size of the mounting hole to 5.56 mm, reversing the block and installing using the
instructions above.

4.7 Tray Clamp Dowel Pin Replacement Procedure
The following procedure documents how to replace the pivot roller dowel pin.
1. Remove the retaining ring, pivot roller and nylon washers as shown in Fig. 4-14.
Retaining Ring Pivot roller Nylon washer
Pivot roller dowel pin
Fig. 4-14 Remove These Parts

2. Remove the four screws from the conveyor rail. See Fig. 4-15
Remove the four side rail mounting screws
Fig. 4-15 Remove these screws
3. Disconnect the side rail from the conveyor assembly. Refer to Fig. 4-16.
Side Rail Remove the two mounting screws
Fig. 4-16 Remove these mounting screws

4. Remove two screws holding the tray clamp assembly as shown in Fig. 4-16.
5. Remove the assembly by pulling it back toward the cut-out in the rail and pivot the
assembly as shown in Fig. 4-17
Pull the assembly

back in this
direction.
Side rail cut-out
Fig. 4-17 Remove the Assembly
6. Disconnect the air lines as shown in Fig. 4-18.
Disconnect the two air lines
Fig. 4-18 Disconnect the Air Lines

7. Press out the dowel pin as shown in Fig. 4-19
Press out the dowel pin
Fig. 4-19 Press Out the Dowel Pin
8. Insert a new pin. Assemble the nylon washers, pivot roller and retaining ring.
9. Press the pin into pivot arm until the retaining ring is close to the pivot roller.
See Fig. 4-20. NOTE: Leave minimal up and down play between the pivot roller and the
nylon washers. The pivot roller must rotate freely.
Press the dowel pin until the retaining ring is as close as possible to the pivot roller. The
pivot roller must move freely.
Retaining Ring
Pivot roller
Nylon Washers
Fig. 4-20 Install the New Dowel Pin

4.8 Shaft Clamp Replacement Procedure
The following procedure outlines the steps necessary to replace the shaft clamps that hold the
flex coupling against the coupling adaptor on the elevator drive train.
1. To access the drive train, remove the bottom plate by removing the four M4 socket
head screws labelled as “A” in Fig. 4-21.
Remove these screws
Bottom plate
Remove these screws
Fig. 4-21 Remove the Bottom Plate

2. Loosen the shaft clamp setscrews. See Fig. 4-22.
Flex coupling Shaft clamp setscrews - Use

wrench: 3/32” hex key driver
Fig. 4-22 Loosen the Shaft Clamp Screw (picture show low torque couplings)
3. Pull the shaft clamp and flex coupling back to the gearbox. See Fig. 4-2
Shaft Clamp Coupling Adapter
Gearbox Flex Coupling 90 º opposed
Fig. 4-23 Disassembling the Shaft Clamp (picture show high torque couplings)

4. In order to remove the shaft clamp, it is necessary to disassemble the flex coupling.
Using a screwdriver, pry the hub out of the urethane sleeve as shown in Fig. 4-24.
Fig. 4-24 Pry Out the Hub
5. Remove flex coupling and shaft clamp from the gearbox shaft. See Fig. 4-25.
Urethane Sleeve Hub
Fig. 4-25 Shaft Clamp Disassembled

6. Install a new shaft clamp and flex coupling (with one hub attached). Attach the second
hub to the urethane sleeve, positioning the hubs 90 degrees apart. See Fig. 4-23.
7. Push the shaft clamp and flex coupling firmly into the coupling adaptor and tighten the
shaft clamp screw. See Fig. 4-2
Push the flex coupling hub firmly

into the coupling adaptor before
tightening the shaft clamp. Coupling adaptor
Flex Coupling
Fig. 4-26 Assembling the Coupling
8. Repeat the procedure for the other side.

4.9 Worm Gear Drive Assembly Replacement Procedure
1. After installing the new worm gear drive, snug the four mounting screws holding the gearbox in
place. The screws must be snug enough to position the gearbox against the mounting bracket
while allowing a limited freedom of motion for the gearbox. Check that the motor drive shaft
coupling screws and both shaft collar screws are loose. See Fig. 4-27.
Worm gear mounting screws Motor drive shaft coupling screw use
use wrench: 7/64” hex key Slip clutch wrench: 3/32 hex key driver
driver
Coupling Shaft collar screws use

Coupling adaptor
wrench: 3/32” hex key
driver
Fig . 4-27 Worm Gear Assembly

2. Verify that both of the elevator lift bars have full and equal freedom of motion. (Any significant
drag can result in gearbox failure). This is a two-step process:
• Verify that the coupling is completely disconnected from the coupling adaptor. See Fig. 4-27.
To verify freedom of motion, move the elevator lift bar through its range of motion.
See Fig. 4-8.
• Push the coupling and shaft collar firmly into the coupling adaptor. Move the elevator lift bar
through its range of motion. If any resistance or binding is felt, rotate the worm gearbox
slightly to align the gearbox shaft with the coupling. Loosen the shaft collar screw and repeat
these steps for the other elevator lift bar assembly.
Elevator bar range of

motion
Elevator lift bar
Fig. 4-8 Checking the Elevator Lift Bars

3. Verify that both shaft collar screws are loose. See Fig. 4-27. Put the whole feeder upside-
down. Place the two dowel pins, provided in maintenance kit, into the holes in the left and right
side plates as shown in Fig. 4-30 (If pins are not available use four 1⁄4 -20 socket head cap
screws or 6mm socket head cap screws). Position the elevator lift bar so it rests firmly against
the alignment pins.
Elevator lift bar
Use alignment pins, part number 8045528
Fig. 4-30 Rest the Elevator Lift Bar Against the 2 alignment Pins
4. While maintaining pressure on the elevator lift bar, tighten the left shaft collar screw while making
sure the coupling is extended all the way toward the outer walls. Repeat steps 3 and 4 to align the
right elevator bar.
5. Tighten the worm gear mounting screws. See Fig. 4-27.
6. Tighten the motor drive shaft coupling screw. See Fig. 4-27.
7. Before turning on the power to the unit, check the assembly for freedom of movement by turning
the motor shaft by hand using the slip clutch assembly.

5 Setup and Adjustments
5.1 Introduction
For reliable operation, it is very important to set up this feeder correctly. The JEDEC feeder
has to handle parts which may be small, delicate, light-weight, and often expensive. If the tray
moves too quickly, small or lightweight parts may move out of position. In this section, we will
tell you how to set up the JEDEC feeder correctly.
The unit may be set up to operate in three ways. There are differences in the setup procedure,
so you must identify the application for your particular feeder.
• Unload application - full trays loaded at bottom of feeder, parts supplied to host ma-
chine, empty trays unloaded at top.
• Load application - empty trays loaded at bottom of feeder, parts taken from host ma-
chine, full trays unloaded at top.
• Handling application - full trays loaded at bottom of feeder, parts supplied to host
machine, parts returned from host machine, full trays unloaded at top.
5.2 Conveyor Speed Settings
Most of the settings on the feeder are not particularly critical. These are set up at the factory.
Unless they are radically changed, they should not cause performance problems. In case you
have to reset the feeder to the original settings, we have detailed these adjustments in this
section.
The lift mechanism must handle a wide range of load conditions. There could be one tray on the
lift, or 30. The trays could be loaded or empty. The lift mechanism is set up at
the factory to handle a condition where it is holding just one unloaded tray - the lightest possible
load. As more trays are added, the operating speed of the lift mechanism simply slows down a
bit.
The more critical settings control the motion of the conveyor. Performance problems may appear
if the type of die is changed. The operating speed of the conveyor is fixed. The motion of the
trays is affected by the slow-down delays at each end of the travel. Let's say that the feeder has
been set up to handle relatively heavy die, and then begins to process die which are very light,
with a large surface area. If the conveyor mechanisms are set up to move too quickly at the end
ends of travel, the lighter die might tend to lift
or "fly." At the factory, the feeder is set up to provide the best compromise performance for a
wide range of die types. However, customers sometimes change the factory settings, with
unpredictable results.
There are seven different stages in the process:
Tray moving out:

1. The out feed pusher moves the tray from the elevator onto the conveyor. The tray must
lift up a bit to reach the level of the conveyor. The pusher speed is controlled by a
pneumatic adjustment.
2. The conveyor operates at full speed.
3. As the tray reaches the far end of the conveyor, it goes through a "slow-down" delay.
This speed is controlled by a potentiometer.

4. At the end of travel, the tray is held in place by a clamp.
Tray moving in:

5. The clamp releases, and the tray moves back along the conveyor. Again, the conveyor
operates at full speed.
6. As the tray reaches the near end of the conveyor, it goes through another "slowdown"
delay. This speed is also controlled by a potentiometer.
7. The in feed pusher moves the tray from the conveyor back onto the elevator. The
pusher speed is controlled by a pneumatic adjustment.
Awe said, there are three ways the feeder can be used (load, unload, and handling). Let's
see how these seven mechanisms or settings are affected.
When operating in "unload" mode - (trays are full going out, empty on return)
Tray moving out:

1. Out feed pusher - The tray is heavy, because it is holding the die or parts. This means
the pusher must provide some extra "push" to get moving and lift a bit onto the conveyor.
Adjust to get a smooth motion, without "snapping" or moving the tray too suddenly.
2. Conveyor speed - Operates at full speed.
3. Slow-down delay - The tray is still loaded at this point, so it should not stop too suddenly.
Adjust to get the fastest cycle speed, while still providing a smooth motion. The die must
remain in place on the tray.
4. End clamp - Should hold the tray firmly.
Tray moving in:

6. Slow-down delay - The tray is empty at this point. Adjust to get the fastest cycle speed.
7. In feed pusher - The tray is empty. Adjust to get the fastest cycle speed.
When operating in "load" mode -(trays are empty going out, full on return)
Tray moving out:

1. Out feed pusher - The tray is empty. Adjust to get the fastest cycle speed.
3. Slow-down delay - The tray is empty. Adjust to get the fastest cycle speed.
4. End clamp - Should hold the tray firmly.

Tray moving in:
6. Slow-down delay - The tray is loaded, so it should not stop too suddenly. Adjust
to get the fastest cycle speed, while still providing a smooth motion. The die must remain
in place on the tray.
7. In feed pusher - The tray is loaded. Adjust to get a smooth motion, without "snapping" or
moving the tray too suddenly.
When operating in "handling" mode - (trays are full going out, full on return)
Tray moving out:

1. Out feed pusher - The tray is heavy, because it is holding the die or parts. This means
the pusher must provide some extra "push" to get moving and lift a bit onto the conveyor.
Adjust to get a smooth motion, without "snapping" or moving the tray too suddenly.
3. Slow-down delay - The tray is still loaded at this point, so it should not stop too suddenly.
Adjust to get the fastest cycle speed, while still providing a smooth motion. The die must
remain in place on the tray.
4. End clamp - Should hold the tray firmly.
Tray moving in:

6. Slow-down delay - The tray is loaded, so it should not stop too suddenly. Adjust to get the
fastest cycle speed, while still providing a smooth motion. The die must remain in place
on the tray.
7. In feed pusher - The tray is loaded. Adjust to get a smooth motion, without "snapping" or
moving the tray too suddenly.
5.3 Setup Procedure
This procedure will set up the feeder to the original or default factory settings. The feeder can
operate in one of three modes - the load, unload, and handling modes. The conveyor speed
settings may be different for these modes. For details, see Section 5.2.
1. Check the supply voltage to the feeder. This should be 24V DC.
2. Check that the air pressure reaching the JEDEC feeder is 60 psi. (For instructions, see
Section 5.4.)
3. Check the tray clamp assembly adjustments. (For instructions, see Section 5.5.)
• Check the condition of the pinch roller. It should not be dented, worn, or softened.
• Check that the pinch roller can turn freely.
• Check that the air cylinder stroke is properly adjusted.
• Check that the lock nut on the end of the tray clamp air cylinder is tight.
• Check that the engagement lever is properly adjusted.
• Check that the set screw on the engagement lever is held in place by Loctite 222.

4. Check that the conveyor guide block is properly adjusted. (For instructions, see Section
5.6.)
5. The short and long pawls are located inside the feeder, and support the trays above
the level of the conveyor belt. Be sure that both the short and long pawls can move freely.
(For instructions, see Section 5.7.)
6. Check that the lift cylinder shock absorbers are adjusted correctly. (For instructions, see
Section 5.8.)
7. The elevator bars support the trays as they are lifted by the elevator. Check that the
elevator bars are level, and move evenly. (For instructions, see Section 5.10.)
8. Check that the slowdown potentiometers are adjusted properly. (For instructions, see Section
5.11.)
9. Check the flow adjustments:
• Lift cylinder flow controls - see Section 5.12.
• Tray clamp pneumatic adjustment - see Section 5.13.
• Return pusher flow controls - see Section 5.14.
• Out feed pusher flow control - see Section 5.15.
10. Check that the Thick / Thin Switch is set to match the tray size. See Fig. 5-1.
Thin / Thick switch
Fig. 5-1Thick/Thin Switch

5.4 Main Air Regulator Adjustment
1. Check the air pressure reaching the feeder. This should be 60 psi (4.1 bars).
• Newer feeders which are prepared to work with the air pressure gauge (air
pressure maintenance kit - P/N 9043931). See Fig. 5-5. This kit allows you to
check the pressure actually reaching the feeder. Connect the pressure gauge to
the micro coupler (see Fig. 5-5) and check that the output pressure is 60 psi (4.1
bars). If adjustment is required, remove the front cover (step 2), then perform
steps 7, 8, 9 and 11.
• On older feeders it is necessary to disconnect air pressure to the feeder and
follow steps 2 thru 6. If adjustment is required follow steps 7 through 11.
2. Remove the front cover by loosening the two M4 screws. See Fig. 5-2 for screw
locations.
3. After removing the front cover, locate the main air pressure regulator. See Fig. 5-3.
4. Disconnect the output line tubing. See Fig. 5-3.
5. Connect the air pressure gauge to the output line. See Fig. 5-4.
6. Reconnect the air pressure to the feeder. The air pressure coming from the
pressure regulator should be 60 psi (4.1 bars).
7. If the output air pressure must be adjusted, unlock the regulator adjustment screw by
loosening the locking knob. See Fig. 5-3.
8. To increase the output air pressure, turn the adjustment screw counter clock wise.
See Fig. 5-3. To decrease the output air pressure, turn the adjustment screw
clockwise.
9. Lock the regulator adjustment knob once the desired air pressure is set.
10. Disconnect the air supply to the feeder. Remove the gauge and reconnect the
output line tubing.
11. Reconnect the air supply to the feeder. Check for air leaks and assemble the front.

Front cover
Front cover screws - (recessed into bottom cover)
Fig. 5-2 Removing Front Cover Screws
Regulator
Output Line H2
Main Air Pressure

Regulator
Locking Knob
Adjustment Screw
Fig. 5-3 Location of Pressure Regulator

Air pressure
gauge
Main air pressure

regulator
Fig. 5-4 Checking Air Pressure
Micro-coupler (on
newer feeders),
located under
conveyor rail
Maintenance kit
(P/N 9043931)
This kit is not included

with the feeder. It is
an option, sold
separately.
Fig. 5-5 Maintenance Kit

5.5 Tray Clamp Adjustments
The following adjustments apply to the tray clamp assembly on JTF2 feeders:
1. Check the condition of the pivot roller. Replace it if necessary.
2. Be sure the pivot roller rotates freely.
3. The pivot roller should be in the proper location when unclamped. (See Fig. 5-6.) In the
unclamped state, the roller should not extend outside the side wall of the conveyor rail. If
adjustment is necessary, refer to step 4.
The tray clamp assembly shown in this photograph Pivot roller

is in the unclamped state.
Pneumatic cylinder Locking nut To avoid blocking the tray's forward

motion, the roller should not touch the
tray as it passes.
Fig. 5-6 Tray Clamp Assembly

4. Make the adjustment. Remove air pressure from the system. Manually pull the roller
assembly toward the pneumatic cylinder (in the clamped position) until the cylinder rod stops
as shown in Fig. 5-7. Loosen the locking nut and turn the cylinder shaft with pliers. NOTE:
Grasp the shaft as close to the end as possible and use care not to damage it. After the
adjustment is complete, tighten the locking nut and turn on the air pressure to the system.
5. Check the engagement lever alignment. (See Fig. 5-8.) NOTE: Older systems may not
have the engagement lever set screw.
Pneumatic cylinder Pneumatic cylinder

shaft lock nut
Pneumatic Clamped position

cylinder
Fig. 5-7 Adjusting the Shaft Length on the Pneumatic Cylinder

The engagement lever
must be parallel to the
slot in the conveyor rail.
Engagement lever
Conveyor rail
Engagement lever set screw - Note:

This adjustment is set at the factory. If
further adjustment is required, apply
Loctite 222 to the set screw after
adjustment. Use a hex wrench size
1.27 mm or .050 inch.
Fig 5-8 Engagement Lever

5.6 Belt Guide Block Replacement and Adjustment
The following instructions explain how to install and adjust belt guide blocks on the JTF2
feeder.
A change was made to the belt guide blocks to aid warped trays (out of specification) in
successfully reaching the "stop at end" switch. The original guide block was held to a
fixed location by two flat head screws as shown in Fig. 5-9.
The new guide blocks are attached to the rail by M4 x 16 button head cap screws as
shown in Fig. 5-10. The size of the mounting holes in the new guide block was increased
from 4.5 millimetres (.177 inch value) to 5.56 millimetres (.219 inch value), allowing
the block to be positioned higher. This height increase allows warped trays to remain in
contact with the belt for a longer distance as the tray transitions from the conveyor to the
pick position.
1. To set the guide block position height, place a .38 millimetres (.015 inch value) shim
between the belt and rail. See Fig. 5-10.
2. Tighten the guide block mounting screws.
NOTE: Customers with older revision guide blocks can modify these blocks by increasing
the size of the mounting hole to .219, reversing the block, and installing using the
instructions above.
Old guide blocks have flat-head screws
Fig. 5-9 New-Style Guide Block

Belt Set the conveyor belt height by placing the .015" (0,38 mm) shim
between the belt and conveyor rail, then tighten the M4 mounting screws.
Conveyor
rail
New guide
blocks have
M4 x 16
button head
screws
Fig. 5-10 Setting Conveyor Belt Height
5.7 Checking Pawl Movement
Both the short pawls and long pawls are located in the tower area of the feeder, near
the level of the conveyor. See Fig. 5-11. If the pawls do not move freely, the motion
of the trays may become unreliable.
1. To test a short pawl, move each one with your finger. Each short pawl should
move easily.
2. To test a long pawl, push the long pawl to one side. Check to see that the long
pawl can move freely in the up-and-down direction. Push the long pawl to the
other side, and test again.
If the pawls are sticking, do not lubricate them! The lubrication will cause the
pawls to stick, and increase the problem. Instead, disassemble the mechanism and
clean the parts using alcohol.

The long pawl should be able to move up and down freely
Short
pawl
Long
pawl
Fig. 5-11Checking Pawl Movement
5.8 Lift Cylinder Shock Absorber Adjustment
The lift cylinder shock absorbers are designed to slow the rod less cylinder body at the end of its
stroke. See Fig. 5-13. The shock absorber is not designed to be used as a stop. The rod less
cylinder body stop point is determined by the pawl lift rod stopping at its end of travel.
The following procedure outlines how to verify the shock absorbers are correctly adjusted, and
how to adjust if necessary.
1. Remove the cover on the lift mechanism. See Fig. 5-12.
2. Disconnect power to the feeder. (Leave the air pressure connected.)
3. Manually fire the lift cylinder down and measure the gap between the lift cylinder body and
the shock absorber. (See Fig. 5-16 to locate the lift cylinder manual activation solenoid
valves.)
The gap should be approx. 3/32." See Fig. 5-15. The body of the shock absorber must not
contact the body of the lift cylinder.
4. Manually fire the lift cylinder up and observe the gap between the lift cylinder body and the
shock absorber on the other end of the stroke. The gap should be approx.
3/32."
5. If adjustment is required, loosen the lock nut on the shock absorber and turn the shock
absorber until the proper gap is reached. Tighten the lock nut.
6. Manually fire the lift cylinder in the opposite direction then back again to verify proper
adjustment.
7. Attach the lift mechanism cover.

Lift mechanism cover
Fig. 5-12 Lift Mechanism Cover
Lift cylinder body
Shock absorber and lift

cylinder body gap setting
Shock absorber
Fig. 5-13 Shock Absorber Adjustment

Shock absorber
lock nut
Shock
absorber
body
Shock
absorber
plunger
Fig. 5-14 Details of Shock Absorber
Set gap to
approx. 3/32”
Do not allow
the lift cylinder
body to touch
the shock
absorber body”
Fig. 5-15 Shock Absorber Gap Setting

Lift cylinder up manual activation button Lift cylinder down manual activation button
Fig. 5-16 Manual Activation Buttons
5.9 Elevator Bar Alignment Procedure
For the tray separation and lift function of the JTF2 feeder to work properly, the elevator
bars must be aligned. The elevator bars must be parallel to each other, and each elevator
bar must be parallel to the alignment holes drilled in each feeder side panel. The following
procedure outlines the steps required to check the alignment, and if necessary, align the
bars.
1. Remove all trays from the feeder and close the door. The elevator bars
will move upward. The alignment holes are shown in Fig. 5-17. Once the elevator bars
are close to the alignment holes, open the door and disconnect power to the feeder.
2. Remove the bottom support plate as shown in Fig. 5-18 by removing the mounting
screws.
3. Insert the pins into the alignment holes (shown in Fig. 5-19). Manually move the bars by
turning the slip clutch (shown in Fig. 5-18) until the elevator bars contact the pins.
4. Observe all four points where the elevator bars touch the pins. If all four points touch the
pins (Fig. 5-21), the alignment is correct. If one bar touches both pins and the other
does not (shown in Fig. 5-22), see step 5. If one end of a bar touches a pin and the
other does not (shown in Fig. 5-23) , see step 6.

5. To align the elevator bars so that they are parallel to each other, loosen the screw on
the flex coupling on the side where the elevator bar does not touch the pins. See Fig.
5- 24 and Fig. 5-25. Manually move the elevator bar up
so it touches the pins, and then tighten the screw on the flex coupling.
NOTE: Maintain the tension of the elevator bar against the pins when tightening
the set screw on the flex coupling.
6. To align one elevator bar to the pins, remove the side cover on that side. On each side
of the feeder, there are two chain tensioning screws. See Fig. 5-
26. On the end where the pin touches the elevator bar, loosen the screw 1⁄2 turn .
Tighten the other chain tensioning screw 1⁄2 turn. Repeat this process until the
elevator bar touches the pins on both ends.
NOTE: By loosening one side and tightening the other equally, proper chain tension is
maintained.
7. After making the adjustments, remove the alignment pins. Apply power
to the feeder and close the door. Allow the elevator to reach the top sensor and start
moving downward. Open the door after the elevator bar clears the alignment holes.
Repeat steps 3 and 4 to verify the adjustments.
Alignment holes
Elevator bar
Fig. 5-17 Locations of Alignment Holes

Mounting screws
Bottom plate
Mounting screws
Fig. 5-18 Bottom Plate and Mounting Screws
Alignment pins
Fig. 5-19 Alignment Pins

Slip clutch
Fig. 5-20 Slip Clutch
Correct : The alignment pins contact four points on the elevator bars at the same time.
Fig. 5-21 Alignment Pins - Correct Alignment

The alignment Incorrect:
pins contact the The alignment pins
elevator bar on do not contact the
this side. elevator bar on this
side.
Fig. 5-22 Incorrect - Elevator Bars Not at Same Level
Alignment pin Incorrect :

contacts elevator Alignment pin
bar does not
contact
elevator bar
Fig. 5-23 Incorrect - Elevator Bar Is Not Level

New-style
couplings
Loosen coupling
with 2mm hex
wrench
Fig. 5-24 Adjusting New-Style Couplings
Old-style Loosen
couplings coupling with
3/32" hex
wrench
Fig. 5-25 Adjusting Old-Style Couplings

Chain tensioning
adjustment screws –
use 2.5 mm hex wrench
Fig. 5-26 Adjusting Chain Tension
5.10 Slow-Down Delay Adjustments
During a tray index, the "forward" slow down delay adjustment must slow the tray's forward
motion enough to prevent the tray from “bouncing” when it reaches the end of the conveyor. The
"return to stack" slow down delay adjustment must slow the tray's forward motion as it enters the
base. This delay adjustment is set so the back edge of the tray slows down just as it passes the
slowdown sensor. If there is too much delay time, the tray will be moving too fast as it enters the
base, possibly causing components in the tray to be “upset.” The return pusher may not have
time to assist the tray, causing uneven stacking of trays. If there is not enough delay time, the
tray will start slow speed before the back edge of the tray passes the slowdown sensor,
increasing the overall tray exchange cycle time.
Use the following procedures to set the correct slow down delays and get the maximum
efficiency from the feeder. Before adjusting, set the feeder to operate in fast mode.
"FORWARD" SLOW DOWN DELAY ADJUSTMENT:

1. Turn the "forward" slowdown delay potentiometer all the way clockwise (increase the delay) as
shown in Fig. 5-27. CAUTION: If you turn the potentiometer with too much force, it can be
“stripped” so that it will not work correctly. To avoid this problem, be careful when adjusting the
potentiometer.
2. Index a tray and observe the tray as it stops at the end of the conveyor. If the tray reaches
the end of conveyor and is clamped without “bouncing” off the end, the adjustment is set
correctly. If the tray does “bounce” off the end, turn the "forward" slowdown potentiometer
counter-clockwise (decrease the delay) until the tray does not “bounce. Make a small
adjustment, then test the setting.

"RETURN TO STACK" SLOW DOWN DELAY ADJUSTMENT:
1. With a tray at the end of the conveyor, initiate a tray index and observe the back edge of tray
in relation to the slowdown sensor. The tray should start the slowdown speed after the rear
edge of the tray passes by the "return" slow down sensor. If the tray slows down before the
rear edge passes the "return" slow down sensor, see step 2. If the tray slows down too far
after passing the "return" slow down sensor, see step 3.
2. If the slowdown speed begins with back edge of tray positioned before the "return" slow
down sensor, turn the "return to stack" potentiometer clockwise and repeat step
1. See Fig. 5-27. If necessary, make repeated small changes, and test after each
change until you reach the correct adjustment.
3. If the slowdown speed begins with the back edge of the tray positioned too far past the
"return" slow down sensor, turn the "return to stack" potentiometer counter clockwise and
repeat step 1. See Fig. 5-27. If necessary, make repeated small changes, and test after each
change until you reach the correct adjustment.
Return to stack conveyor slow

down delay adjustment - reverse
CW = increase delay time for slow

down
Conveyor forward slow down delay

adjustment - forward
CW = increase delay time for slow

down
Fig. 5-27 Conveyor and Stack Slow Down Adjustments

Return slow down
sensor
The rear edge of

the tray has
passed the return
slow down sensor
Tray Return
pusher
Fig. 5-28 Correct: Tray Starts Slow Down After Passing Sensor
When the sensor

sees the tray, the
orange LED
is lighted
The slowdown
period starts
before passing
the return slow
down sensor
Fig. 5-29 Incorrect: Tray Starts Slow Down Before Passing Sensor

5.11 Lift Cylinder Flow Control Adjustments
The speed settings for the lift cylinder must sometime be changed in relation to the weight of the
stack of trays. To maximize the throughput on the feeder, increase each flow control setting until
you find the fastest speed at which the entire stack of trays cycles in a smooth motion without
upsetting the components in the trays.
1. Before performing this adjustment, check that the input pressure to the feeder is 60 psi. See
Section 5.4.
2. Remove the lift cylinder cover. See Fig. 5-30.
Lift cylinder cover
Fig. 5-30 Lift Cylinder Cover

Lift cylinder Loading door
down flow side
control
Lift cylinder
up flow
control
Fig. 5-31 Lift Cylinder Flow Controls
3. Before making this adjustment, you must first unlock the flow control by turning the locking
knob counter clockwise. See Fig. 5-32
Flow control Flow control

adjustment knob locking knob
Fig. 5-32 Flow Control Locations – Lift Cylinders
4. To increase the airflow and increase the speed of the tray stack lift, turn the flow control adjustment
knob in a counter clockwise direction. To decrease the airflow and decrease the speed of the tray
stack lift, turn the flow control adjustment knob in a clockwise direction.
5. When you are satisfied with the lift cylinder adjustments, lock the flow controls and assemble the
lift cylinder cover.
NOTE: When locking a flow control, be certain the flow control adjustment knob does not
move when you are turning the flow control locking knob.

5.12 Tray Clamp Pneumatic Adjustment
The pneumatic tray clamp performs two functions. One function is to secure the tray at
the end of the conveyor (the "clamping" function). The flow control for this function must be set so
the clamping action does not dislodge components from the tray.
The second function pushes the tray back onto the conveyor to return a tray to the stack (the
"pushing" function). The flow control for this function must be set so the tray is pushed onto the
conveyor without dislodging components.
NOTE: Before adjusting the flow controls, be certain the tray clamp mechanical adjustments
are correct.
The following steps outline how to adjust the pneumatics for each function. Before performing
these adjustments, check that the input pressure to the feeder is 60 psi. See Section 5-4.
Tray Push function Pushing function

locking nut B adjustment screw B
Tray Clam function

adjustment screw A
Tray Clam function

locking nut A
Tray clamp direction

Tray push direction
Fig. 5-33Flow Control Locations - Tray Clamp
1. To adjust the speed of the clamping function, unlock the adjustment screw by loosening locking
nut A, shown in Fig. 5-33.
2. To increase the speed of the clamping function, turn adjustment screw A counter- clockwise. To
decrease the speed of the clamping function, turn adjustment screw A clockwise. Tighten
locking nut A when adjustment is complete.
3. To adjust the speed of the pushing function, unlock the adjustment screw by loosening locking
nut B, also shown in Fig. 5-33.
4. To increase the speed of the pushing function, turn adjustment screw B counter clockwise. To
decrease the speed of the pushing function, turn adjustment screw B clockwise. Tighten locking
nut B when adjustment is complete.

5.13 Return Pusher Pneumatic Adjustment
Two flow control valves control the speed of the return pusher function. The flow control at the
end of the return pusher assembly controls the "return to home" speed. See Fig. 5-34.
The "forward push" flow control valve is located next to the control board under the front cover.
See Fig. 5-36. The following procedure outlines adjustments for both functions.
NOTE: Be certain the internal air pressure is 60 psi before making these flow control
adjustments. See Section 5.4.
Slow down
spring
Forward push
direction "Return"
pusher
home
position
Locking
nut
"Return to
home position"
flow control
Fig. 5-34 Flow Control Locations - Return Pusher

Front cover
Front cover
screws NOTE:
screws are
recessed into
bottom cover
Fig. 5-35 Cover Screw Locations
Forward push speed flow control valve

Fig. 5-36 Forward Push Flow Control

When adjusting the "forward push" speed, set the speed fast enough to overcome the
slowdown spring tension, but slow enough not to dislodge components from the trays, if the
trays being returned will not be empty.
Adjust the "return to home position" speed so pusher returns to the home position without any
hesitation.
1. To adjust the "return to home position" speed, unlock the adjustment screw by loosening the
locking nut. See Fig. 5-34.
2. To increase the "return to home position" speed, turn the adjustment screw in a counter
clockwise direction. Decrease the "return to home position" speed by turning the adjustment
screw in a clockwise direction. When the adjustment is correct, tighten the locking nut.
3. To adjust the "forward push" speed, remove the front cover by loosening the two
screws shown in Fig. 5-35.
4. Locate the "forward push" speed flow control valve. See Fig. 5-36. Unlock the adjustment
screw by loosening the locking nut. (This is the same type of flow control valve as shown in
Fig. 5-34.)
5. To increase the "forward push" speed, turn the adjustment screw in a counter clock wise
direction. Decrease the "forward push" speed by turning the adjustment screw in a
clockwise direction. (This is the same type of flow control valve as shown in Fig.
5-34.) When the adjustment is complete, tighten the locking nut. Rinstall the front cover.

5.14 Feed Pusher Pneumatic Adjustment
The feed pusher assembly moves the tray from a stationary position on the long pawls
onto the moving conveyor. A pneumatic flow control valve determines the speed of the
"push" function. The "pusher return to home" function is controlled by spring tension. The
following procedure outlines the feed pusher adjustments.
1. On older feeders, the feed pusher pneumatic flow control is located next to the solenoid
valve assembly located under the front cover. (See Fig. 5-38.) Remove the front cover to
access this area. (See Fig. 5-37.)
On newer feeders, the feed pusher pneumatic flow control is located under the bottom
plate. (See Fig. 5-39.) Remove the bottom plate to access the flow control valve. (See
Fig. 5-37.)
Front cover
Front cover
screws NOTE:
screws are
recessed into
bottom cover
Fig. 5-37 Removing Front Cover

2. To adjust the feed pusher speed; unlock the adjustment screw by loosening the locking
nut.
3. To increase the feed pusher speed; turn the adjustment screw in a counter clockwise
direction. To decrease the feed pusher speed, turn the adjustment screw in a clockwise
direction. Adjust pusher speed so trays reliably move onto conveyor without dislodging
components. When adjustment is completed, tighten the locking nut and reattach bottom
plate.
Flow control
valve
Fig. 5-39 Feed Pusher Flow Control Valve – Location shown in newer Feeder models.

Flow control valve
Fig. 5-38 Feed Pusher Flow Control Valve – location shown in older Feeder models.
Feed pusher
assembly
Fig. 5-40 Feed Pusher Assembly

6 Troubleshooting
6.1 Safety Notes
Safety Notes for the Operator -

• Parts inside the unit can move suddenly if it is serviced with the power on.
You could be hurt, or the feeder could be damaged. To avoid this problem,
before servicing the feeder, ensure turn off the power to the assembly equip-
ment, or disconnect the power to the feeder by unplugging the power cable
from the assembly machine.
• Before removing the feeder from the assembly equipment, ensure that the
assembly equipment is in a safe or E-Stop condition. Remove all trays from
the feeder.
• If the area near the feeder is obstructed, or the floor surface is slippery, you
may slip or fall near the feeder. You may be hurt, or the feeder may be
damaged. To avoid this problem, keep the area around the feeder clear.
Safety Notes for the Technician -

• Remember to remove your watch and any rings before you work inside the
feeder. Any metal jewelry could cause a short-circuit and injure you or
damage the feeder.
• For some types of troubleshooting, it may be helpful to check the LEDs on the
motherboard (locations U1 and U6). If the feeder is mounted on the host ma-
chine, the easiest way to do this is to use an inspection mirror. Be very careful
to keep the inspection mirror away from all of the electrical parts inside the
feeder. If you allow the metal frame of the inspection mirror to touch any
charged parts, this could cause a short-circuit and injure you or damage the
feeder.

NOTICE
Notes for the Operator:

• Do not use the manual index feature to index another tray if there is a tray being
processed in the assembly equipment.
• When removing trays, if the blue LED is not flashing, this indicates that the upper output
stack has room for more trays. Before removing the trays, press the Inhibit button and
wait to see the yellow LED. The inhibit mode will prevent the feeder from cycling a tray
while you are removing the trays.
• If the Thick/Thin switch is set incorrectly, the feed mechanism will jam, triggering an
error condition.
• Whenever the feeder detects an error, the operator should press the Stop button
immediately.
Note for the Technician:

• Work carefully when replacing the micro-controller (U3) or the motor driver IC (U9 -
SN75441). Wear an anti-static strap and use an IC puller to prevent any damage to the
parts or the motherboard.
• The lift mechanism includes shock absorbers at each end of the travel. These are not
designed to act as stops for the lift cylinder, and should not be used this way. If these
parts are set incorrectly, they will wear out quickly and the mechanism will not work
correctly. See Section 5.8 for the correct adjustment procedure.
Do not Over-Lubricate:
It is possible to prevent the feeder from operating correctly by over-lubricating some of the
parts. Be especially careful of two areas:
• The lifting pawls near the top of the feeder should not be lubricated at all. These are simple
metal parts with drilled holes which ride on metal pins, so the friction should be minimal. The
pawls must be able to move freely, and drop back into place using just the force of gravity. If
the pawls are sticking, do not lubricate them. In- stead, disassemble the mechanism and
clean the parts with alcohol. Use a thin rod to clean out the pivot hole in each pawl. Blow
the parts clean with compressed air and re-assemble.
• The sensor for the Stop At End or Ready sensor is activated by a small metal arm that swings
up and down. This part must be able to move freely, and should drop back into place using
just the force of gravity. If this arm is sticking, do not lubricate it. Instead, disassemble the
mechanism and clean the part with alcohol. Use a thin rod to clean out the pivot hole in the
part. Check for burrs or sharp edges. Blow the part clean with compressed air and
reassemble.

6.2 Troubleshooting Information
Important Note About This Feeder -

This is a small machine, but do not be fooled - it is complicated. There are a number of features
and relationships that are not obvious at first. If an untrained worker begins to tinker and make
adjustments without really understanding how it is supposed to work, he or she can leave the
feeder in a strange or non-working condition.
Identifying the Communications Mode -

Different versions of this kind of feeder communicate with the host machine in different ways. In
order to troubleshoot the feeder, you really have to know which communications mode is being
used. The main variations are the Simple, Intermediate, and Advanced communications modes.
The Simple mode is quite basic. The Intermediate mode adds a few features, and the Advanced
mode is more complicated. For complete details, see Section 2. At the start of Section 2, we
describe a simple way of identifying the communications mode.
We have included detailed timing diagrams for the Advanced mode at the end of this
manual.
Reset Procedures -
If the feeder is under local control (Simple or Intermediate mode), you may be able to re set the
unit using the Reset button on the front panel. This button is used to recover from either a stop or
an error condition (orange LED on or flashing).
• When the Reset button is pushed while the feeder is in a stop condition (orange
LED on continuously), power is restored to both motors and to the pneumatic
mechanisms.
• To recover from an error condition (orange LED flashing), first identify the cause of
the problem and correct it. Once the cause of the error has been corrected, press
the Reset button. The feeder will be able to operate normally.
In the case of a more serious problem, you may be able to reset by turning the power to the
feeder off, then on again. You can do this by turning off the power on the host machine, or by
disconnecting the interface cable between the feeder and the host machine.

About Production/Maintenance Mode -
If the feeder is under control of the host machine (Advanced mode), it will normally
operate in the Production mode. The control buttons on the front of the feeder will not
work as long as the feeder is in Production mode.
• The host machine sets the feeder for Production mode by turning on both of the
inputs. Once the feeder is set this way, it will respond to Index signals from the
host machine.
• For the feeder to operate in Maintenance mode, both of the inputs must be off. You
can accomplish this using the host machine, or by disconnecting the interface cable
between the host machine and the feeder. Press the Index 1 and Index 2 buttons at
the same time to index a tray. The tray will index at the speed last used during the
Production mode.
• If you start the feeder directly from power up, without going to Production mode, it
will only index trays at the slower speed. Checking the Indicator LEDs on
the Mainboard
Most of the switches and other inputs for the feeder have LED indicators on the
motherboard. The LEDs are mounted in U1 and U6 on the board. See Fig. 6-1. The
LEDs can be very helpful as you troubleshoot the feeder. You can use these LEDs to
check for two kinds of problems:
• Is there a switch or input that is not coming on at the correct time (switch not
being made, or input missing)?
• Is there a switch or input that is on at the wrong time (switch or input "stuck")?
In order to reach the motherboard and the LEDs, you remove the cover. While the
feeder is mounted on the host machine, the clearance here is very tight. It is possible to
see the LEDs, even while the feeder is mounted, by using an inspection mirror. If an
LED is lighted, it can be difficult to tell which function is being indicated. The LEDs are
close together, and if you are using a mirror you are seeing a mirror-image of the LED
bank.
If no visible, unscrew the feeder from mount and slide it back or remove it completely
and reconnect air and 24V on a bench for trouble shooting.
CAUTION
When using an inspection mirror, be very careful to keep it away from any charged parts
inside the feeder. The metal frame of the inspection mirror could cause a short-circuit.
This could injure you or damage the feeder.
JTF2 Service & Maintenance Instructions Rev 1.6 August

2011
U1 and U6 – U3 – Micro- J2 – Interface U9 – Motor driver J16 – Auxiliary
Feeder Input contoller to host chips power
banks (Green) connector
U12 – Feeder J9 - Serial R S 2 3 2

Output bank connection
(Yellow)
Fig. 6-1 Component Locations on the Mainboard
JTF2 Service & Maintenance Instructions Rev 1.6 August

2011
Here is a list of the functions indicated by the LEDs input banks U1 and U6:
Location Function
U1-1 Lift cylinder up
U1-2 Lift cylinder down
U1-3 Forward slow
U1-4 Stop at end
U1-5 Tray Position
U1-6 Reset
U1-7 Stop switch
U1-8 Spare
U1-9 Input 1
U1-10 Input 2
U6-1 Inhibit switch
U6-2 Elevator down
U6-3 Stack full
U6-4 Stop at stack
U6-5 Reverse slow
U6-6 Elevator high
U6-7 Elevator low
U6-8 Door
U6-9 Manual index
U6-10 Host index
U12-4 Full/Empty LED (blue) Constant on= Input stack is empty
Flashing = Output stack is full
U12-5 Inhibit LED (yellow) Constant on= Inhibit condition

Flashing = Inhibit condition, elevator
moving up.
U12-6 Stop/Error LED Constant on= Feeder stopped
(orange) Flashing = Error Condition
These LED status can be very helpful when trouble shoot any sensor or
communication issues.

Checking the Indicator LEDs on the Solenoid Bank:
The feeder includes a bank of at least five solenoids that control the pneumatic functions. See
Fig. 6-2. Each solenoid includes an LED that lights when that solenoid is active. These can
also be helpful as you troubleshoot the feeder.
1- Return pusher
2 - Tray clamp
3 - Out feed pusher
4 - Lift cylinder up
5 - Lift cylinder down

H9
H7
H10
H8
H5
H3
H4
Fig. 6-2 Indicator LEDs on Solenoids and Pneumatc Tube Connections

There are situations where it is not clear whether the feeder is actually communicating with the
host machine. In such a case, it is helpful to be able to verify the communication. As we said
before, the first step is to find out what kind of communications the feeder is using. For details,
see Section 2.
On feeders using the Simple or Intermediate mode, all of the signals flow through connector J2
(2036261) on the motherboard and then through a cable connected (Host cable). See Fig. 6-3.The
error signals appear on Pin 5/ Output 2 - the pink wire. The Ready signal appears on U12-1 and
on Pin 4 - the yellow wire. The feeder is getting his power through pin 1 (24V DC) and pin 2
(Common).
Fig. 6-3 Generic Interface Cable for Simple and Intermediate Modes
Note: Host cables on older feeders may have different wire colours.

On feeders using the Advanced mode, two extra wires are added to handle two more outputs.
See Fig. 6-4.This allows the feeder to report a wider range of error conditions. (Output 5 - violet wire)
Fig. 6-4 Interface Cable for Advanced Mode
Feeder which run with RS-232 or Serial mode, the serial communication cable plugs into the
same connector that would be used for Output 4 and Output 5 in Advanced mode. You can read
these signals using a laptop. You will need an adapter to connect between J9 on the
motherboard and the DB-9 serial connector on the laptop. You can monitor the signals using the
"HyperTerminal" utility supplied as an accessory with the Windows operating system.
Fig. 6-5 Interface Cable for Serial Mode

Changing the Firmware
The large IC in the centre of the board (U3) holds the micro-controller which includes the
EEPROM memory which records the control program for the feeder. If it is necessary to
change or update the firmware, there are two ways to do this:
• Remove the existing IC and replace it with an IC which has already been
programmed by Quasys. Verify Pin1 orientation before install.
• Download a new program to the existing IC.
CAUTION
Work carefully if you replace the micro-controller. To avoid possible damage to the part or the
motherboard, wear an anti-static wrist strap and use and IC puller.
In order to download a program directly, you will need a laptop computer, some programmer
software, and an interface box. The software and interface box are available from Quasys.
See the instructions supplied with the interface box.
Once the interface is connected and the software is running, you can use it to download
a new version of the control software supplied by Quasys. If there is a problem with the new
program, this arrangement also allows you to re-load the earlier program.
Operating the Feeder on the Bench

For testing, the feeder can be removed from the host machine and "bench-tested" or operated
on a countertop. This allows you to enter your own test inputs, without any chance of
interference from the host machine.
• Disconnect the feeder from the host machine and place it on a firm nonconductive
supporting surface.
• Use the 24V power supply (Quasys No. 2037830) to supply power to the mother-
board. The smaller cable on the unit connects to J16 on the motherboard. See Fig.
6-1.
• Connect the factory air supply to the normal air input for the feeder. The air should be
supplied at 60 psi - 5 bar or higher. More recent feeders include a maintenance internal
test connection, shown in Fig. 6-7. On a feeder with this line, you can connect the
maintenance air pressure gauge (Quasys No. 9043931).
After you make these connections, you can supply your own inputs for testing. Operate the
unit using the manual controls on the front panel. On a feeder which uses the Serial or RS-
232 mode, you can send control signals over the serial link.
Start-Up Functions
Different versions of the feeder behave differently on start-up. This depends mainly on the
communications mode and firmware version. For a complete explanation of the
communications modes, see Section 2.
There are two points where the start-up functions may be different:
• Power-up and initialization
• First index

In order to troubleshoot a feeder, you need to understand these differences. Begin by referring
to Section 2 to identify the communications mode. Next, check the table below to identify the
start-up functions for the unit you are working on.
On power-up, manual On power- After Feeder Feeder stops

initialization is up, feeder initialization, automaticall and waits for
required. Set conveyor initializes tray elevator y indexes index signal
speed manually. (Elev automatically automatically first tray for host
button for fast- or the moves up
two Index Buttons
together for slow
speed)
Simple X x x
Intermediate x x x
Advanced x x x
Siemens x x x
Fuji x x x
Error Conditions Reported to Host Machine
In the current version of the feeder, there is only one output signal or line for Error. However,
there could be eight separate conditions that might trigger the Error output. If the feeder
reports an Error to the host, the cause could be any of the following:
STOP ERROR SYMTHOME ACTION NEEDED

FAILED TO RECLAMP Re-clamp failed during Press Reset to continue
initialization or reset. Stop
button pushed.
TRAY IN STACK Tray exchange was initiated Remove the tray from the
with a tray partially in the "stop at stack" sensor.
stack.
LIFT NOT DOWN The tray lift mechanism did Check for a jammed tray or
not go down all of the way. other obstacle. Press
Reset to continue.
TRAY NOT CLEAR The tray returning from the Check for a jammed tray or
pick position did not clear other obstacle. Press
the "return slow-down" Reset to continue.
sensor.
TRAY NOT IN The tray returning from the Check for a jammed tray or
pick position did not reach other obstacle. Press
the "stop at stack" sensor. Reset to continue.
LIFT NOT UP The tray lift mechanism did Check for a jammed tray or
not come up all of the way. other obstacle. Press
Reset to continue.
TRAY NOT FED The tray being conveyed to Check for a jammed tray or
the pick position did not other obstacle. Press
reach the "forward slow- Reset to continue.
down" sensor.
TRAY NOT AT END The tray being conveyed to Check for a jammed tray or
the pick position did not other obstacle. Press Reset
reach the "stop at end" to continue.
sensor.

Sensor Locations
The following drawings show the approximate locations of the sensors used to control the
feeder:
"Stack Full" sensor
"Stop at
Stack" sensor
"Thick" Tray sensor
"Thin" Tray
sensor
Fig. 6-6 Sensor Locations - Top of Feeder

"Elevator Up” sensor “Door lock” sensor (Behind the side panel)
"Elevator Down” sensor
"Lift Cylinder up" sensor

(Under the cover and “tray
stack cyclinder”)
"Lift Cylinder Down"

sensor (Under the cover
and “tray stack cyclinder”)
“Tray Thin – Thick” switch
Fig. 6-7 Sensor Locations - Bottom of Feeder

"Forward Slow- Down" sensor "Return Slow- Down" sensor
"Stop at End" sensor
Normal dry air input Maintenance internal pressure

test connection
Fig. 6-8 Sensor Locations – Conveyor

6.3 Troubleshooting Charts
General Problems:
To recover from a tray exchange error:
1. Identify the cause of the error, warped or clamped trays. Check the blinking pattern on the orange
LED and compare with the list below and Troubleshooting chart.
2. Correct the problem (In most cases this means removing the tray from the conveyor).
3. Press the Stop followed by the Reset button.
4. The orange LED should stop flashing. If it does not, repeat steps 1-3. If the error persists, continue
trouble shooting usig the charts on next pages. If error still there, contact wendor.
5. When the orange LED stops flashing, the feeder is ready to resume normal operation.
Error Name Blink Description

Code Pattern
1 DOOR_IS_OPEN ..._ Elevator door is open
2 FULL_ERROR .._. The output stack is full of trays
3 STOP_ERROR ..__ Stop button pushed
4 FAILED_TO_RECLAMP ._.. Re-clamp during initialization or reset failed
5 TRAY_IN_STACK ._._ Tray Exchange initiated w/ tray partially in
stack
6 LIFT_NOT_DOWN .__. The lift mechanism did not reach bottom
dead center
7 TRAY_NOT_CLEAR .___ The tray returning from the pick position did
not clear the return slow down sensor
8 TRAY_NOT_IN _... The tray returning from the pick position did
not reach the Stop @ Stack sensor
9 LIFT_NOT_UP _.._ The lift mechanism did not reach top dead
center
10 TRAY_NOT_FED _._. The tray being conveyed to the pick position
did not reach the forward slow down sensor
11 TRAY_NOT_AT_END _.__ The tray being conveyed to the pick position
did not reach the stop @ end sensor
These Error codes are sent out to the RS232 serial port (e.g. “Error 7”)

General Problems (continued):
Problem Possible Cause Solution
On power-up, the feeder will not The feeder may not be getting • Be sure the feeder is plugged into the
operate. There are no lights on power. assembly machine.
the panels or sensors. • Is the host machine providing power?
U nplug the cable and check for 24V DC on
pins 1 and 2.
• Be sure the host machine is on and not in an
E-Stop condition.
• Check the voltage reaching the feeder. See
Section 6.2.
• The motherboard in the feeder may be bad.
Try operating the feeder on the bench. See
the instructions at the beginning of this
section.
Simple or Intermediate The feeder must be initialized For Fast conveyor speed, press the Elevator
communications mode – manually. button. For Slow s p e e d , press Index 1 and
The feeder will not initialize (all Index 2 bottons together.
operator LEDs on) The EPROM (U3) may be bad. Replace the microcontroller. Use an IC puller
and an antistatic strap.
The motherboard may be bad. Replace the motherboard.
The feeder powers up, but does The Stop button on the feeder Press the Reset button.
not operate. may have been hit.
The host machine may not be • Be sure that the air feed line is connected to
supplying enough compressed the assembly machine.
air. • Be sure that the air supply on the assembly
machine is on.
• Be sure the assembly machine is supplying
about 60 psi or 5 Bar. See Section 6.2.
One of the user interface LEDs The interface cable may be bad. Check the signals through the cable. See Fig.
remains on. 6-3 or 6-4.
All of the pneumatic f unctions The host machine may not be • Be sure the host machine is supplying about
seem slow or sluggish. supplying enough compressed 60 psi or 5 Bar. See Section 6.2.
air. • Be sure that the air feed line is not pinched.
• Check for variations in air supply from the
host machine.
The main air regulator on the Set this to provide 60 psi or 5 bar.
feeder may be set up incorrectly.
One pneumatic function is slow The mechanism may be blocked Check for a mechanical problem.
or sluggish. or jammed.
The flow control(s) for that • Lift cylinder – see Section 5.12.
function may need adjustment. • Tray clamp – see Section 5.13.
The valve block for that function • Feed and
Check pusher – seeif Section
replace 5.14.
necessary.
may be bad. • Return pusher – see Section 5.15.
The cylinder for that function may Check and replace if necessary.
be bad.
The air pressure from the host • Be sure the host machine is supplying about
machine may be too high. 60 psi or 5 Bar. See Section 6.2.
• Check for variations in air supply from the
host machine.

General Problems (continued):
All of the pneumatic functions The main air regulator on the Readjust this to provide 60 psi or 4.2 bar.
seem too fast. feeder may be set up incorrectly.
The flow control(s) for that • Lift cylinder – see Section 5.12.
function may need a djustment. • Tray clamp – see Section 5.13.
• Feed pusher – see Section 5.14.
• Return pusher – see Section 5.15.
Logic and Communications Problems:

STOP ERROR • Stop button pushed. Press
Error on feeder (blinking orange Reset to continue.
LED), error signal sent to host • Stop button stuck. Check U1-7 and the
machine switch.
FAILED TO RECLAMP Reclamp of the tray in the Ready position failed
during initialization or reset. Press Reset to
continue.
TRAY IN STACK Tray exchange initiated with tray partially in
stack. Remove tray from “stop at stack”
sensor. Press Reset to continue.
LIFT NOT DOWN The tray elevator did not go down all of the way.
See “Elevator Will Not Go Down.”
TRAY NOT CLEAR The tray returning from the pick position did
not clear the “return slow-down” sensor. See
“Conveyor and Sensor Problems
– Return Cycle.”
TRAY NOT IN The tray returning from the pick position did
not reach the “stop at stack” sensor. See
“Conveyor and Sensor Problems – Return
Cycle.”
LIFT NOT UP The lift mechanism did not go all of the way
up. See “Elevator and Tray Exchange
Problems.”
TRAY NOT FED The tray being conveyed to the pick position
did not reach the “forward slow-down” sensor
before timeout. See “Elevator and Tray
Exchange Problems.”
TRAY NOT AT END The tray being conveyed to the pick position
did not reach the “stop at end” sensor before
timeout. See “Conveyor and Sensor Problems
– Outgoing Cycle.

Logic and Communications Problems (continued):
Error on feeder (blinking orange) The cable to the host machine Check the cable.
LED), no error signal sent to host There may
may not bebe a bad
connected. • Feeder using Simple or Intermediate mode –
machine. connection in the cable or Check brown wire (Output 2). See Fig. 6-3.
connector. • Feeder using Advanced mode – Check grey
wire (Output 5). See Fig. 6-4.
• Replace the cable.
The DIP switches not set to See the table in Sect. 2.2 and check the DIP
sink or source correctly. switches.
Ready signal sent to host, but no The arm for the “stop at end” Check for free movement of the arm. Is U1-4
green LED on feeder, no tray at sensor may be stuck. on?
ready position, feeder times out. The cable to the host machine Check the cable.
may not be connected.
The DIP switches may not be See the table in Sect. 2.2 and check the DIP
set correctly for sink or switches.
The feeder indexes before the source.
The micro-controller may be Reset by turning the power off, then on again.
tray is ready. lost in a program loop.
One of the button inputs may Check the LEDs on U1 and U6. See Fig. 6-1.
be
“stuck.”

Elevator and Tray Exchange Problems:
The elevator does not move up or The door may be open. Close the door.
down (motor not moving). The door switch may be stuck. Check U6-8 and the door switch.
The gears in the gearbox may Replace the gearbox.
be stripped.
The elevator does not move up or The motor driver IC may be Replace the motor driver IC (U9 – SN75441).
down (motor moving). bad.
The elevator motor may be Replace the motor.
bad.
The elevator does not move up. The elevator may be out of Add more trays and close the elevator access
trays door.
(blueelevator
The LED on).access door may Close the elevator access door.
be open.
The door switch may be stuck. Check U6-8 and the door switch. Replace the
switch if necessary.
The “elevator high” switch Check the sensor (Fig. 6-5) and U6-6. Replace
sensor may have been made the sensor if necessary.
prematurely.
The elevator does not move There may be trays stuck Remove the trays. To prevent this in the
down. under the elevator. future, install the “tray block” accessory.
The “elevator high” sensor Check the sensor (Fig. 6-5) and U6-6.
may not have been made. Replace the sensor if necessary.
The “elevator low” sensor may Check the sensor (Fig. 6-6) and U6-7. Replace
have been made prematurely. the sensor if necessary.
As the elevator lowers, the top The pawls may be sticking. Check the action of the pawls. If the pawls are
tray catches. sticky, disassemble the mechanism and clean
them with alcohol. Do not lubricate these
parts!
The bottom o f t h e t h r e e Install four new pawl lift rods
(small) pawls may be (Quasys No. 8038060).
extending past the side plate.
The feeder indexes before the The microcontroller may be Reset by turning the power off, then on again.
tray is ready. lost in a program loop.
One of the button inputs may Check the LEDs on U1 and U6. See Fig. 6-1.
be
“stuck.”
The feeding mechanism jams. The Tr ay Thick/Thin switch Set the Thick/Thin switch correctly.
may be set for the wrong type
of tray.

Elevator and Tray Exchange Problems (continued):
During tray exchange, the lift The mechanism may have Check for a mechanical problem, then press
cylinder does not make it to the jammed. the Reset button.
top of its stroke.
The air pressure to the feeder Check the air pressure. This should be 60 psi
may be low. or 5 Bar. See the instructions at the beginning
of this section.
The lift cylinder may not be Remove the bottom plate inside the feeder
moving freely. a nd check for free motion of the cylinder.
The flow controls for the lift Check the pneumatic adjustments for the lift
cylinder may be out of cylinder. See Section
adjustment. 5.11.
The “lift cylinder up” sensor • Check LED U1-1 and the sensor.
may not be made. • If the sensor is not made, check that the
shock absorbers are properly adjusted. See
Section 5.8.
The valve block for the lift Check the valve block and replace it if
cylinder “up” function may be necessary.
bad.
The lift cylinder may be bad. Check the cylinder and replace it if necessary.
During tray exchange, the lift The door may be open, or the Check U6-8 and the door switch. Replace the
cylinder does not make it to the door switch may be stuck. switch if necessary.
bottom of its stroke.
The mechanism may have Check for a mechanical problem, then press
jammed. the Reset button.
The air pressure to the feeder Check the air pressure. This should be 60 psi
may be low. or 5 Bar. See the instructions at the beginning
of this section.
The lift cylinder may not be Remove the bottom plate inside the feeder and
moving freely. check for free motion of the cylinder.
The flow controls for the lift Check the pneumatic adjustments for the lift
cylinder may be out of cylinder. See Section 5.11.
adjustment.
The “lift cylinder down” sensor • Check LED U1-2 and the sensor.
may not be made. • If the sensor is not made, check that the
shock absorbers are properly adjusted. See
Section 5.8.
The valve block for the lift Check the valve block and replace it if
cylinder “down” function may necessary.
be bad.
The lift cylinder may be bad. Check the cylinder and replace it if necessary.

Conveyor and Sensor Problems - Outgoing Cycle:
The conveyor does not move. The feeder may be in an inhibit Press the Inhibit button again to cancel the
condition (yellow LED). condition.
The elevator access door may be Close the elevator access door. Check U6-8
open, or the door switch may be and the door switch.
stuck.
There may be an Error or Stop Press the Reset button. For information on
condition (orange LED blinking or the Error condition, see the first part of this
on). section.
Two trays move at the same time. The “thick/thin” switch may be Set the switch to the “thin”
incorrectly set to “thick.” position.
A tray exchange starts with a tray A tray may be improperly located Remove the tray and push the
underneath the separation in the feeder. Reset button.
mechanism.
The feeder indexes before the The “stop at end” or “ready” Check U1-4 and the sensor. Check for free
tray is ready. sensor may be stuck. movement of the sensor arm, and clean it if
necessary.
The micro-controller may be lost Reset by turning the power off, then on again.
in a program loop.
The micro-controller or the Replace the micro-controller or the

motherboard may be bad. motherboard.
The feeder stops before the index The “stop” button has been Press Reset to clear the feeder. Check U1-7
cycle is complete (solid orange pressed, or is sticking. and the stop switch.
LED).
The separated tray does not reach The conveyor belts may be dirty Clean the conveyor belts with alcohol.
the “conveyor slow down” sensor and slipping.
before timeout. The out feed pusher may not have Check the pneumatic adjustments for the tray
The separated tray does not reach extended properly. feed pusher. See Section 5.15.
the “conveyor slow down” sensor
before timeout. The valve block for the out feed Check the valve block and replace it if
pusher cylinder may be bad. necessary.
The out feed pusher cylinder may Check the cylinder and replace it if necessary.
be bad.
A tray on the conveyor does not A tray may be improperly located Remove the tray and push the
reach the “stop at end” or “ready” in the feeder. Reset button.
sensor. (You should see a green Something may be blocking the Remove the tray and any obstruction, then
LED on the sensor.) free motion of the tray on the push the Reset button.
conveyor.
The conveyor belts may be dirty Clean the conveyor belts with alcohol.
and slipping.
The “stop at end” or “ready” The flag on the “ready” sensor Check U1-4 and free up the mechanism.
sensor is made before the may be sticking.
“conveyor slow down” sensor.
The separated tray does not There may be an obstruction on • Check for warped trays.
reach the “stop at end” or “ready” the conveyor. • Check for anything blocking the motion of the
sensor before timeout (2 seconds trays.
after making the “conveyor slow Remove the obstruction and press the Reset
down” sensor”). button.
The conveyor belts may be Clean the belts with alcohol.
slipping.

Conveyor and Sensor Problems - Outgoing Cycle (continued):
Possible Cause Solution Possible Cause
The die are knocked out of the The action of the out feed Check the settings of the flow controls.
tray as the tray is pushed onto the pusher may be too quick. See Section 5.2 and Section 5.15.
conveyor.
The die are knocked out of the The tray may be slowing down too Check the setting for the forward slow down
tray as the tray reaches the end of quickly during the “forward slow delay. See Section
the conveyor. down” delay. 5.2 and 5.11.
The forward slow-down sensor Check U1-3 and the sensor.
may not be working.
The tray clamp may be moving Check the setting of the flow controls.
too quickly. See Section 5.2 and 5.13.
The belt guides may be out of Check the alignment. See Section 5.6.
alignment, causing the trays to
bounce.
Conveyor and Sensor Problems - Return Cycle:

The conveyor does not move A tray may be sitting at the “tray Manually remove the tray from the “tray
(blinking orange LED). home” or “stop at stack” position home” position, then press the Reset button.
during the index cycle, blocking
the path of a new tray.
There may be a problem with the Check U1-4 and the sensor.
“stop at end” or “ready” sensor.
The returning tray does not reach The conveyor belts may be dirty Clean the conveyor belts with alcohol.
the “stack slow down” sensor and slipping.
before timeout. There may be an obstruction on Remove the obstruction and press the
the conveyor. Reset button.
The tray clamp cylinder may not • Check the pneumatic adjustments for
have retracted properly. When the the tray clamp cylinder. See Section
tray returns, the tray clamp 5.13.
mechanism is supposed to provide • Check the valve block for the cylinder.
some “push” to get the tray • Check the cylinder itself.
moving.
The returning tray does not reach There may be an obstruction on Remove the obstruction and press the
the “tray home” or “stop at stack” the conveyor. Reset button.
sensor before timeout. The return slow-down delay may Check the setting. See Section 5.11.
not be set correctly.
The return pusher does not There may be an obstruction on Remove the obstruction and press the
successfully push a tray into the the conveyor. Reset button.
feeder base. The return cylinder may not have • Check to see if the return pusher is firing.
operated properly. • Check to see if the return pusher is
extending all of the way.
• Check the pneumatic adjustments for
the return cylinder. See Section 5.14.
• Check the valve block for the cylinder.
• Check the cylinder itself.
The spring in the return Check the spring, and replace it if necessary.
mechanism may be worn out.
The die are knocked out of the The tray may be slowing down too Check the return slow-down delay setting.
tray as it returns to the stack. quickly during the “return slow- See Section 5.2 and 5.11.
down” delay.
The return pusher may be Check the pneumatic adjustments for the
operating too quickly. return cylinder. See Section 5.14.

7 Schematics / Electrical Drawings
4037154 System Schematic
4036229 Control Circuit Schematic
9036231 Control Circuit Assy
4036236 Interface PCB Schematic
9039388 Return Slow Sensor Assembly
9037734 Elevator High Limit Sensor Assembly
9037735 Elevator Low Limit Sensor Assembly
9037736 Door Interlock Switch Assembly
9037737 Interface Cable Assembly
9037738 Tray Lift Sensor Assembly
9037739 Tray Position Selector Switch Assembly Bottom Up
9038305 Motor Assembly Conveyor
9038306 Motor Assembly Elevator
9039390 Tray Position Selector Switch Assembly
9042992 Tray Position Left/Right Sensor Assembly
9037490 Host Cable Generic
9043987 Serial Host Cable Generic
9041760 Host Cable Generic Advanced

8 Assembly Drawings
9038378-T2-10 Core Assembly

9041745-T2-10 Core Assembly, Low Torque
9041770-T2-10 Core Assembly, High Torque
9041300-T3-30 Access Door Assembly
9041746-T3-10 Feed Pusher Assembly (Standard)
9039240-T2-20 Tray Clamp Assembly (Standard)
9039240-T2-30 Conveyor End Assembly
9039240-T2-40 Conveyor Roller Shaft Assembly
9039240-T2-50 Tray Return Pusher Assembly
9039245-T2-60 Conveyor Assembly, 25" (Standard)
9039386-T1-50 Left Panel Assembly
9041748-T1-30 Bottom Up Lift Rod Assembly
9039386-T1-60 Right Panel Assembly
9041744-T1-20 Operator Interface Assembly
Long Belt Option Assembly Drawings
9047147 Feed Pusher Assy Extended Stroke

9041739 Conveyor Base, Long Belt 25”
9047140 Conveyor Assembly, Long Belt 25” JTF2

Replaced with P/N 1046772

3-Service and Maintenance Instructions v1.6

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Service and Maintenance Instructions

JTF2 JEDEC Tray Feeder

Fig 1 JTF2 JEDEC Tray Feeder

Section 1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section 2 - Interfaces and Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Section 3 - Maintenance Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Section 4 - Maintenance and Replacement Procedures . . . . . . . . . . . . . . . . . .4-1

Section 5 - Setup and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Section 6 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Section 7 - Schematics / Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . .7

Long Belt Option Assembly Drawings

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

Fig. 1-1 JTF2 JEDEC TrayStak Feeder

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

Section 2 - Communications Modes

Section 3 - Maintenance Tools

Section 4 - Scheduled Maintenance

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

2.1 Communications with the Host Machine

There are several communications options:

Discrete IO Serial communication

• Simple mode • Siemens serial mode

2.2 Identifying the Communications Mode on a Particular Feeder

Fig. 2.1 Configuration Table

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

Any other numbers than that indicate special customer software.

2.3 Simple Mode

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

Description Output 2 Output 3

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

2.5 Advanced Mode

State # Description Input 1 Input 2

State # Description Output 1 Output 2 Output 3 Output 4 Output 5

Advanced Mode - Signal Description:

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

2.6 RS-232 Serial Mode

The system uses standard serial settings:

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

Index F<cr> (Index at fast speed)

If successful, sends: Ready<cr>

D<cr> (Elevator down)

Status T<cr> (Tray status, ready for production?)

Sends current status Ready<cr>

?<cr> (Index Status, ok to index new tray?)

Sends current error/status code:

Door open<cr> (Tray replacement in progress)

Reset R<cr> (Clears any errors)

Reboot B<cr> Reboots the feeder

*If the STOP button is pressed, a manual RESET is required.

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

Error # Error Codes Description

Fig 2-7 RS232 Error Codes

2.7 Siemens Serial Mode

3 Maintenance Tool List

3.1 Maintenance Tools (Kit P/N 9043900)

Qty Description Used for

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

JTF2 Service & Maintenance Instructions Rev 1.6 August 2011

Section/Mechanism Check this Correction

Section/Mechanism Check this Correction