Script of failure: CHECKING VPU: UNIT X(0):FAILED
(Note: Device passes and high yield)

>>>answer: device tested is 14x20 at 80/100 pins and does not require VPU because it 
           only for above 208pins above.

Script of Failure:TESTING POWER SUPPLIES:3OV supply is out of tolerance (30.72)
                        Power Supplies FAILED
                        MOTHER BOARD ANALOG:Passed
                        PIN DRIVER BOARDS:Passed
                        MOTHER BOARD:Failed
                        SYSTEM SELF TEST:Failed
                        1 Error Detected
 
Status during Programming:Programmed Device Failing with a very LOW YIELD  

>>>>answer:Here is another way to calibrate the power supply;
- Go to the Diagnostic Test
- Go to Device.
- Under Device, select PS (power supply). Make sure under Device/Option must be set 
  to the site you want to view. It will show you all the power supply rating for this
  site. If the power supply is out of spec. there is an astrick sign. Below is the 
  steps if it is out of spec.
- In the front of the machine panel left side unscrew all the screw.
- You will see there is 11 units of PS in there.
- You will need to see which site is for which PS. I believe David 
  had make some marking previously. 
- On the PS there is a Blue color trim pot which you can turn left or right. 
  Turn it slowly and view the changes on the screen. This trim pot is only adjusting 
  the 5Vdc and will affect the rest of the voltage. The usual rating for the 5Vdc is 
  5.14Vdc on automated system. If after adjusting this and you still can't get the 30V 
  astrick to disappear then the only way is to use software.
 
The only way to calibrate the site and power supply is to use a service software. 
This software is only for BP service usage and we are not in a position to release
this as we had signed NDA with BP.

MAJOR DOWN ENCOUNTERED ON BP4100 LAST JULY 19 TO 20, 2002

Problem: Cannot communicate with the PC(Demo Mode)
Action Done:Check programmer PC and found that parallel port card is faulty.
                  :Found that site 11 cable connecting to PC was connected reversed.

Remedy: Connect parallel cable to the PC parallel printer port(on mother board)
             : Re connect site 11 cable to the correct orientation.
             : Re teach all 11 sites for board name: ASM80PQR_TRAY_TRAY
             : Test run with the above board name with the device TMS370F16BIAPH
             : Monitor for two hours and programming is good.

      
 






BP PROGRAMMER BASICS

Operational Requirements:
1. Vacuum- 20-25psi

Directory assigning ;
Job Database Directory -  C:\JOBS             Job Database Directory – A:\
Use Categories : DISABLE                         Use Categories : ENABLE
Config: BP-2200/240/ASM80PQR AFS JM LPT2

ONE POINT LESSON ENCOUNTERED:

1.	PICKS UP AT NO SITE
SOLUTION: Stop handler press at HHT [ goto ] [runstep][2] [9] [Enter].
2.	ALIGNMENT OF HEAD / EDITING/ AT HHT TO ALIGN HEAD 
PLACEMENT OR PICK-UP.
Command: [FUNCTION] [3] [ENTER]
                  [PLACE] TYPE IN NUMBER OF SITE TO BE MODIFIED [ENTER]. [ENTER]
SAMPLE WINDOW WILL APPEAR X:11111:[ TYPE IN IF YOU WANT TO MODIFY] [ENTER].
X Y T Z  are all in mils.
     3. PASSWORD FOR BP PROGRAMMER : MICE AT POWER-UP
     4. IMPORTANT POINTS ON BP PROGRAMMER
         [4.1] Check programmer if its on version 3.47
                 [a] If version is not the same
                 [b] Go to C Drive [TYPE] C:>CD\BP_47
        [4.2] First device to program should be good if not reload program then change 
                device at first unit of tray.
        [4.3]At power down BP defaults to only submenu after AFS BUFFER DEVICE…ETC.
          <> QUIT then GOTO configure then choose from operator ( between Manual or Operator Choice)
       [4.4] If device needs a diskette, at power down remove diskette
       [4.5] Hand Held Terminal console initialization. X/Y/Z/T . Lastly “ V ENTER COMMAND” – This time you can press run for production.   
     5. ENABLE SITES WITH LOADBOARD
       [5.1] Escape program from production
                [a] Goto Eng. menu by pressing ESC
                [b] You will be ask of password : Upper Case “ STEP”
                [c] Press ALT + D
                [d] To add a site, install loadboard, then vision teach-press enter to open/ enter to go down.
               [e] Test diagnostics of site added if passed then it can go for production else replace loadboard.

     6. TO REPLACE STEPPER MOTOR
        [6.1] At the BP Programmer ( A-Select )
        [6.2] Quit BP programmer , or goto drive C
        [6.3] Then  power off
        [6.4] Replace motor
     7. CONVERT FROM 80PIN TO 100PIN OR VICE VERSA
        [7.1] Power off programmer
     8.BP PROGRAMMER BIOS VERSION UPGRADE
        [8.1] Make sure all sites are connected and the PC is interfaced with the programmer 
        [8.2] Select  BP DIAGNOSTICS MODE .
        [8.3] In DEVICE / OPTIONS make sure Master site is # 1.
        [8.4] Go to DEVICE/ FLASH.
        [8.5] It will prompt you where is the file . Type in a:\118.bin
        [8.6] Screen will prompt you to type in UPGRADE. key this in.
        [8.7] It will automatically erase and reprogram the BIOS.
        [8.8] It may or may not broadcast the data to the rest of the site.
        [8.9] After it is complete , it will show cycle system power to be powered off
        [8.10] Turn off programmer.
        [8.11] Then turn on the programmer again.
        [ 8.12] Follow steps 2 to 11 but this time the master site is # 2 as you want to upgrade , if it does not broadcast to the rest of the sites.
      
    9. HOW TO LOAD PROGRAMS ON A EPROM FOR SW UPGRADE
    At the window for BP Programmer 
       Config: BP-1148 LPT1 Blank-Check Verify –Twice Check ID’s
       Device: AMD Am27C512
       Buffer: f:\sw\latest\ATLATU.203
   1. Buffer a. Load                2. Device  a. program       3. Select     4. Select        5. Quit

    Script of  failure : checking VPU : Unit X ( 0 ): FAILED   note: ( Device Passes and it is HIGH Yield ).
    >>>answer: device tested is 14 x 20 at 80/100 pins and does not require VPU because it prefers only for above 208 pins.
     Script of  failure : TESTING POWER SUPPLIES : 30V supply is out of tolerance ( 30.72 )
   >>>power supplies FAILED  / MOTHER BOARD ANALOG : Passed
                                   PIN DRIVER BOARDS : Passed
                                   MOTHER BOARD: Failed
                                   SYSTEM SELF TEST: Failed , 1 Error Detected
    Status during Programming: Programmed  Device Failing with a very LOW YIELD
  >>>answer: Here is another way to calibrate the power supply :
-	Go to the Diagnostic Test
-	Go to Device
-	Under Device, select PS ( power supply ). Make sure under Device /Option must be set to the site you want to view. It will show you all the power supply rating for this site. If the power supply is out of  spec., there is an astrick sign. Below is the steps if it is out of spec.
-	In front of the machine panel left side unscrew all the screw.
-	You will see there is 11 units of PS in there
-	You will need to see which site is for which PS. I believe David had made markings previously
-	On the PS there is Blue color trim pot which you can turn left or right. Turn it slowly and view the changes on the screen . This trim pot is only adjusting the 5V dc and will affect the rest of the voltage . The usual rating for the 5V dc is 5.14 dc on automated system. If after adjusting this and you  still cant get the 30V astrick to disappear then the only way is to use software.
The only way to calibrate the site and power supply is to use a service software.
This service software is only for BP service usage and we are not in the position to release this as we had signed NDA with BP.

MAJOR DOWN ENCOUNTERED ON BP4100 LAST JULY 19-20,2002

Problem : Cannot communicate with the PC ( Demo Mode )
Action done : Check programmer PC and found that the parallel port is faulty. Found that site 11 cable connecting to PC was connected reversed.
Remedy: Connect parallel cable to the PC parallel printer port ( on the mother board )
             : Re connect site 11 cable to the correct orientation .
             : Re teach all 11 sites for board name : ASM80PQR_TRAY_TRAY
             : Test run with the above board name with the device TMS370F16BIAPH
             : Monitor for two hours and programming is good

MAJOR DOWN ENCOUNTERED ON QUAD ALIGN HANDLER , MARCH 21, 2005

        Problem at BP4100-02 SN: 3401 – LIMIT ERROR
        Recom: When a Limit Error appears on HHT , Press Enter one time to see / check which axis has the problem. ( Usually it is the Z axis ) . Example: Z = -16 This means that the Z axis overdrove 16 steps. I will assume that tried to re teach the Pickup 20 where the Limit error occurs. The Z axis does not use an encoder , but maybe the Z- axis is losing pulses . So the problem could be the Z motor ( CPICMOT03 ), Z driver board ( WPICBRD04 ), upper ribbon cable ( CPICCAB02 ), or lower ribbon cable ( CPICCAB01 ).
         Problem at BP4100-01 SN: 3396 – TEP Error # 01
         Recom: TEP Error 1 is displayed on the HHT because the Mod Codes have gone to a default state. Press Enter  on the HHT to continue the initialization . The cause of this is a dead battery  on the EPCU board – 3V Lithium battery ( CPICBAT01). This battery holds the Mod Codes and the current board is volatile memory. The solution is to replace the battery and restore the Mod Codes to the operational values. 
Normally we have a backup Mod Code board, and can download it using Utilities/ Database Utilities/ Download Mod Codes to assembler. If not , you have to manually key in total of 74 Mod Code values.
         
One Point Lesson taken : March 30 / 31,2005
1.	To view the actual location , if your not sure on what encoder will be changed at the sytem. ( Place 30/31 or Pickup 20/21.
        Command: press CTRL OUTPUT AT THE HHT, then if if you want to goto normal run- press STOP then do the same procedure.



Problem: Waiting for autohandler to start---October 11, 2006
RootCause: Defective ac adapter for the head supply.

DRIVER BOARD VOLTAGE OUPUT READINGS:


       1. ( X / Y ), 12 VDC, HIGHER Voltage    2. ( Z / T ), 5-6 VDC, Lower Voltage    
Note: all driver boards are interchangeable , don’t forget to put correct addressed.
        T- O.6 , Z-0.8, Y-2.5, X-2.5

WHEN REPLACING (30V) LITHIUM BATTERY AT THE EPCU BOARD,FOLLOW PROCEDURE:
1.	Off the Main Power.
2.	Replaced the 30v Lithium Battery of the EPCU Board
3.	Put back the EPCU Board, and power it ON.
4.	Initialize the Handler , then at the HHT 
a.	see Error : TEP ERROR
b.	press Enter  , until it initialized all motors.
5.	Go to handler monitor screen then type, Level 3 Password. ( KetecA)
a.	go to editor ,enter  b. pick and place , enter   c. select new board ( MODCODE 30-03-2005), enter
6.	Go to Utilities , enter  , then Go to Database Utilities, Enter , then under this
a.	Upload Mod Codes from assembler , after uploading go back to the original board name, 
b.	Then Download Mod Codes to Assembler., Enter

Command to load the MNUPASS.IDX
1.	Put the file in a diskette ( 31/2 Floppy Disc ). Insert the disc into the floppy drive of  Programmer CPU. 
Recheck the file into the disc, if it is present by typing A: DIR
Select the file ( MNUPASS.IDX ), Go back again to C> by typing C:
Then type C:\EDIT MNUPASS.IDX, enter
How to modify Mod Codes in the HHT manually, command: Press modify 1-74 then key the correct values which was listed  in your reference guide per handler.   

Passwords for the Quad Align Handler ( Select B )and BP4100- Programmer ( Select A).
1.	Quad Align level 1 Password – Enter key
                            Level 2 Password- 
                            Level 3 Password-      note: The same passwords for the 2 handlers.

2.	BP4100 Programmer 01 – Diagnostics Password – caps lock < STEP>
3.	BP4100 Programmer 02  - Diagnostics Password -  



Quad Iic Firmware Version 3.03					2-Apr-05
 BP Programmer 2  					
Modify Code list for Iic Firmware ( Version 3.03 )					

Number	Description	                                    Default  Minimum  Maximum  Current
1	Unused	                                               0	n/a	n/a	0
2	Unused	                                               0	n/a	n/a	0
3	Unused	                                               0	n/a	n/a	0
4	Unused	                                               1	n/a	n/a	1
5	Number of retries on vacuum verify                     3	1	255	3
6	Park/home after run	                               0	0	1	0
7	Placement vacuum delay	                               8	0	255	8
8	Pickup vacuum delay	                               0	255	8
9	This sets vacuum window	                               1000	0	65535	500
10	Max difference for vacuum readings	               7	0	65535	7
11	Max number of vacuum readings	                       16	0	255	16
12	Pre-vacuum cerify delay	                               0	0	255	0
13	Soft home for x mils from sensor ( open loop )	       50	0	25000	50
14	Soft home for y mils from sensor ( open loop )	       90	0	25000	90
15	Soft home for z mils from sensor	               50	0	1500	150
16	Unused	                                               0	n/a	n/a	0
17	Y Pickup Motion Setting Time	                       0	0	255	0
18	X Pickup Motion Setting Time	                       0	0	255	0
19	T Pickup Motion Setting Time	                       0	0	255	0
20	Y Placement Motion Setting Time	                       0	0	255	0
21	X Placement Motion Setting Time	                       0	0	255	0
22	T Placement Motion Setting Time	                       0	0	255	0
23	Sees Device ( Head Number )	                 Dip Swicth 1	0	255	1
24	Z Axis down limit 	                               1400	0	1500	1500
25	X Axis limit ( Value determined in limit find )	       0	1	65535	27263
26	Y Axis limit ( Value determined in limit find )	       0	1	65535	27038
27	X Steps Characterization value	                       25000	1	65535	25000
28	X Mils Characterization value	                       25000	1	65535	25000
29	Y Steps Characterization value	                       26500	1	65535	26500
30	Y Mils Characterization value	                       26500	1	65535	26500
31	Return to Pickup ( affects waffle tray lookahead       1	0	1	1
32	Host controlled run flag                               0	0	255	0
33	Alternate Pickup loop count	                       3	0	255	3
34	Transport Present Flag	                               1	0	1	0
35	Illluminator # 1 LED intensity level	               128	0	255	128
36	Illluminator # 2 LED intensity level	               0	0	255	0
37	Illluminator # 3 LED intensity level	               128	0	255	128
38	Illluminator # 4 LED intensity level	               0	0	255	0
39	X closed loop home	                               50	0	500	50
40	Y closed loop home	                               1200	0	2150	1200
41	Installed Link/ Step combination                       0	0	2	0
42	X axis Hold Gain                                       250	1	512	250
43	X axis Maximum Hold Velocity	                       2600	100	8000	2600
44	Y axis Hold Gain	                               450	1	512	450
45	Y axis Maximum Hold Velocity	                       3000	100	8000	3000
46	Theta home offset ( Signed word )	               0	-1024	1024	0
47	Unused                                                 0	n/a	n/a	0
48	Diasble Audible Hand Held Alarm / Yellow Flush	       0	0	3	0
49	Tep Offset                                             2930	0	65535	2930
50	X Camera offset to center of rotation	               -2100	-32767	32767	-2308
51	Y Camera offset to center of rotation	               -3000	-32767	32767	-3173
52	Unused                                                 0	n/a	n/a	0
53	Machine Speed setting	                               0	0	2	1
54	X Camera offset to center of nozzle	               -2100	-32767	32767	-2304
55	Y Camera offset to center of nozzle	               -3000	-32767	32767	-3175
56	Iic Dispenser Enable	                               0	0	3	0
57	X dispenser offset to center of nozzle	               554	-32767	32767	554
58	Y dispenser offset to center of nozzle	               -4069	-32767	32767	-4069
59	Z Dispense Position	                               700	0	1000	700
60	Infinite Repeat Retry	                               0	0	1	0
61	X Location to Dump Parts	                       0	n/a	n/a	0
62	Y Location to Dump Parts	                       0	n/a	n/a	0
63	Z Location to Dump Parts	                       900	n/a	n/a	900
64	Quad Align Debug Display	                       0	n/a	n/a	0
65	MCR Feeder Control	                               0	0	88	0
66	MCR Look Ahead Enable	                               0	0	1	0
67	Quad Align Calibration Angle	                       2333	0	65535	2333
68	 Z Height for Vision	                               185	0	500	185
69	Quad Align Illuminator Value	                       255	0	255	255
70	Enable Slow Vision Inspection Speed	               0	0	1	0
71	Offset From Final Placement Z Position 	               0	0	255	0
72	Z Axis Acceleration Limit	                       100	1	100	100
73	Electrical test enable flag	                       0	0	1	0
74	Transport (Tep) Homing disable flag	               0	0	1	0



Quad Iic Firmware Version 3.03					2-Apr-05
 BP Programmer 1      					
Modify Code list for Iic Firmware ( Version 3.03 )					

Number	Description	                                       Default	Minimum	Maximum	Current
1	Unused	                                               0	n/a	n/a	0
2	Unused	                                               0	n/a	n/a	0
3	Unused	                                               0	n/a	n/a	0
4	Unused	                                               1	n/a	n/a	1
5	Number of retries on vacuum verify	               3	1	255	1
6	Park/home after run	                               0	0	1	0
7	Placement vacuum delay	                               8	0	255	8
8	Pickup vacuum delay	                               8	0	255	8
9	This sets vacuum window	                               1000	0	65535	500
10	Max difference for vacuum readings	               7	0	65535	7
11	Max number of vacuum readings	                       16	0	255	16
12	Pre-vacuum cerify delay	                               0	0	255	0
13	Soft home for x mils from sensor ( open loop )	       50	0	25000	50
14	Soft home for y mils from sensor ( open loop )	       90	0	25000	90
15	Soft home for z mils from sensor	               50	0	1500	170
16	Unused	                                               0	n/a	n/a	0
17	Y Pickup Motion Setting Time	                       0	0	255	0
18	X Pickup Motion Setting Time	                       0	0	255	0
19	T Pickup Motion Setting Time	                       0	0	255	0
20	Y Placement Motion Setting Time	                       0	0	255	0
21	X Placement Motion Setting Time	                       0	0	255	0
22	T Placement Motion Setting Time	                       0	0	255	0
23	Sees Device ( Head Number )	                 Dip Swicth 1	0	255	1
24	Z Axis down limit 	                               1400	0	1500	1500
25	X Axis limit ( Value determined in limit find )	       0	1	65535	27260
26	Y Axis limit ( Value determined in limit find )	       0	1	65535	27024
27	X Steps Characterization value	                       25000	1	65535	25000
28	X Mils Characterization value	                       25000	1	65535	25000
29	Y Steps Characterization value	                       26500	1	65535	26500
30	Y Mils Characterization value	                       26500	1	65535	26500
31	Return to Pickup ( affects waffle tray lookahead       1	0	1	1
32	Host controlled run flag	                       0	0	255	0
33	Alternate Pickup loop count	                       3	0	255	3
34	Transport Present Flag	                               1	0	1	0
35	Illluminator # 1 LED intensity level	               128	0	255	128
36	Illluminator # 2 LED intensity level	               0	0	255	0
37	Illluminator # 3 LED intensity level	               128	0	255	128
38	Illluminator # 4 LED intensity level	               0	0	255	0
39	X closed loop home	                               50	0	500	50
40	Y closed loop home	                               1200	0	2150	1200
41	Installed Link/ Step combination	               0	0	2	0
42	X axis Hold Gain	                               250	1	512	250
43	X axis Maximum Hold Velocity	                       2600	100	8000	2600
44	Y axis Hold Gain	                               450	1	512	450
45	Y axis Maximum Hold Velocity	                       3000	100	8000	3000
46	Theta home offset ( Signed word )	               0	-1024	1024	0
47	Unused	                                               0	n/a	n/a	0
48	Diasble Audible Hand Held Alarm / Yellow Flush	       0	0	3	0
49	Tep Offset 	                                       2930	0	65535	2930
50	X Camera offset to center of rotation	               -2100	-32767	32767	-2311
51	Y Camera offset to center of rotation	               -3000	-32767	32767	-3138
52	Unused	                                               0	n/a	n/a	0
53	Machine Speed setting	                               0	0	2	1
54	X Camera offset to center of nozzle	               -2100	-32767	32767	-2311
55	Y Camera offset to center of nozzle	               -3000	-32767	32767	-3138
56	Iic Dispenser Enable	                               554	-32767	32767	554
58	Y dispenser offset to center of nozzle	               -4069	-32767	32767	-4069
59	Z Dispense Position	                               700	0	1000	700
60	Infinite Repeat Retry	                               0	0	1	0
61	X Location to Dump Parts	                       0	n/a	n/a	0
62	Y Location to Dump Parts	                       0	n/a	n/a	0
63	Z Location to Dump Parts	                       0	n/a	n/a	0
65	MCR Feeder Control	                               0	0	88	0
66	MCR Look Ahead Enable	                               2333	0	65535	2333
68	 Z Height for Vision	                               185	0	500	185
69	Quad Align Illuminator Value	                       255	0	255	255
70	Enable Slow Vision Inspection Speed	               0	0	1	0
71	Offset From Final Placement Z Position                 0	0	255	0
72	Z Axis Acceleration Limit	                       100	1	100	100
73	Electrical test enable flag	                       0	0	1	0
74	Transport (Tep) Homing disable flag	               0	0	1	0