Applies to

• Trendsetter Autoloader with a version 2 picker

Causes and Solutions

Cause 1: Threshold level set too low.

Solution:
Check the vacuum levels and thresholds:
PICKER UP
PICKER IN
PICKER VAC ON with no plate.
PICKER. Make a note of the vac level.
Pick the smallest plate and make a note of the vac level. The value for SET AL PVT should be half-way between the readings for no plate and a small plate. If it isn't, set it to the half-way value.

Cause 2: The picker does not move close enough to the plates to get all of the suction cups on the plate (i.e., the bottom of the picker head does not press the vacuum cups against the plates).

1. Open the Operator door. Use an Omron key (Creo Part number 59-3450) to override the safety switch on the lower Operator door, or turn the laser safety key in the power box to mechanical hazards. Enter >>SET AL PCS 0
2. Enter >>PICKER IN to pick a plate (use 32x44" or the largest customer size).
3. When the picker head moves in, push the picker toward the plate.
4. Enter >>PICKER, and check to see if the picker vacuum reaches the threshold value (250 units).
5. If so, check that the air regulator for the picker head is set to 30psi. (The air regulator is directly in front of the Autoloader manifold.) The bottom cups should now contact the plate and the vacuum level should exceed 200 units.
6. If the bottom of the picker head still does not contact the plate, contact an Output Device Systems Engineer: a minor adjustment of the Load Table may be required.

Cause 3: Load table support brackets are not installed on the Autoloader.

Install the load table support brackets on the Autoloader. See ECO C443.

Cause 4: Broken valves in the suction cups

Solution:
Check for broken valves in suction cups.

Cause 5: Small plates that do not cover as many of the suction cups.

Solution:
Decrease the vacuum threshold slightly to no less than 180 units.

Cause 6: A plate does not completely cover the vacuum cup on one edge (for a picker with valved vacuum cups). This can cause the valve to partially open, and result in a vacuum leak and a threshold error.

Solution:
Shift the plates slightly to one side to prevent contact with the offending cup.

Cause 7: Leaks or obstructions in the vacuum circuit tubing.

Solution:
Check the vacuum circuit tubing for leaks and obstructions. Replace the cable harness if it is too tight and presses the picker tubing.