user`s manual - EWD Solutions
Contents
1. from the rails A Medium lubricant such as Way Oil should be applied to the X Y and Z rails linear bearing rails once every three months At the factory we use Mobil Vactra 2 ISO 68 Medium Way Oil Bottom Heater A IMPORTANT NEVER TOUCH THE HEATER LAMPS WITH BARE HANDS The bottom heater should be cleaned of dust and debris as needed If large amounts of dust and debris accumulate inside the bottom heater remove the top cover and collimator grille vacuum the interior and clean the reflectors and bulbs with isopropyl alcohol and a wipe Prism amp Mirror A IMPORTANT NEVER TOUCH THE PRISM OR MIRROR WITH BARE HANDS Natural oils from your skin may cause permanent damage to the surfaces or bond interfaces The prism and mirror should be cleaned once 1 a month with a non abrasive tissue Lens cleaner preferred or isopropyl alcohol can be added to the tissue to remove difficult or heavy deposits If alcohol is used however a second pass with a dry non abrasive tissue is recommended to remove any haze At the factory we use Bausch amp Lomb Sight Savers 8566 A IMPORTANT NEVER LEAVE THE COMPONENT BOARD LIGHTING ON FOR AN EXTENDED PERIOD OF TIME OR WHILE THE SYSTEM IS UNATTENDED Excessive heat from the halogen lighting system can damage the bond interfaces of the prism Vision Calibration The vision system on the machine should be verified and or calibrated annually This is completed using the Calibration Kit included wit2. A Operation and Maintenance Manual Rev 2005 08 HAKOFR 1418 Section 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 TABLE OF CONTENTS Item System Overview Unpacking amp Installation Rework Process Overview Operation Options Maintenance amp Troubleshooting HMI Software Guide Advanced Rework Profiling and Control Software Page l 12 14 16 19 21 29 39 1 0 System Overview Figure 1 FR 1418 ITEM NO DESCRIPTION e Pccpu oPrionaly e _ NOZZLE SETSTANDARD o CANERAZOOM LENS ASSY The previous picture and table are meant to familiarize the user with the terminology used to describe the major components of an FR 1418 BGA Rework System The figures below describe the specific features and controls found on the FR 1418 BGA Rework Systems Not all features and controls will be found on all systems as they vary according to the specific model and options purchased The items described in the following figures will be referred to throughout the rest of this manual Front Panel Figure 2 Front Panel Controls Item Description Spare Thermocouple Input TC2 Bottom Board Lighting Intensity Control Oo 6 Vacuum Switch and Indicator Lamp Note Some systems may have a footswitch or no switch when controlled by a Host PC Model FR 1418 Figure 3 FR 1418 HMI Panel Details Item Description 6 menu Up Buton or lt i gt e Menu Down Buton orse o
3. com Cancel Full Speed IFS Slow Speed IPS 0 250 Seek Speed IPS 0125 Jog Speed IPS foso Nest Clearance 0500 Apply Curent Z Optics Clearance 1 000 Apply Curent Z The settings are as follows Controller 1 WRD COM This is the Windows COM port that is connected to the port labeled Host PC or Controller 1 on the rear of the unit Controller 2 TriPLC COM This is the Windows COM port that is connected to the port labeled Option or Controller 2 on the rear of the unit 48 Z Axis CPI Full Speed IPS Slow Speed IPS Seek Speed IPS Default Jog Speed Nest Clearance Set Optics Clearance This stands for Counts Per Inch and represents the number of stepper counts per inch of travel on the Z Axis This is determined by hardware and must not be changed This is the speed in Inches Per Second the Z Axis moves during full speed motions This is the speed the Z Axis moves during slow speed motions The speed the Z Axis moves during seek motions picking and placing The speed the Z Axis moves by default during Jog operations The actually jog speed can be adjusted using the Jog Speed slider in the Jog Panel This is the height at which the Z Axis clears the top of the nest plate If the Z Axis is below this height then the software will prevent the nest from extending and colliding with it Likewise if the nest is already extended and the Z Axis is commanded
4. Figure 2A Recipe Setup Screen with standard Manual Z Axis Temperature G Board Heater Power o o Start Preheat at C 0 Time min sec f0 00 D l 20 30 40 50 Minutes Board Heater Power 20 Air Flow Rate Med High Board Heater Power 50 Air Flow Rate Low f Mea High Board Heater Power 50 Air Flow Rate Air Flow Rate Low Mea High 43 6 0 70 80 Recipe Setup Screen Continued File File Name sample Description Part Detect Board Heater Heat ones a A Heat 1 Preheat Part TC Target C 140 Heater Temp CN 300 Time min s c 2 23 Heat 2 Soak Part TG Target C 175 Heater Temp C 350 Time min s c 125 Heat 3 Reflow Part TG Target C 205 Heater Temp C aso Time min sec 0 30 Cooling Time min s c l 00 Board Heater Power 100 Start Preheat at C 50 Time min sec 0 24 Board Heater Power 95 fi 00 Air Flow Rate Low Med High Board Heater Power l1 00 Air Flow Rate High Board Heater Power 9 I 00 Air Flow Rate Low Med High Air Flow Rate Low Mea High Z Move Table Current 2 Focus Nest Nest Place Preheat Soak Reflow Board Board Place 2 0 3 0 Minutes i b Te Saj iri un e B tn E wn Z e un E AAA Figure 2B Recipe Setup Screen with optional Automatic Z Axis The following is a description of the v
5. Section 7 0 Adjust the head Z height down to pick up the component and then up away from the nest Fig 15 Retract the nest and extend the optics train under the nozzle with the component Fig 19 Using the video image and X Y Theta adjustments align the leads balls on the component to the pads on the PCB Fig 8 12 17 18 27 Section 4 0 Retract the optics train move the head DOWN to the board Fig 19 13 15 Adjust the Z height so the component is just touching the board Fig 15 Press the VAC button or footswitch to release the component and continue the cycle Fig 3 Adjust the Z height so the nozzle is approximately 1 8 inch above the top of the component Fig 15 The cycle continues heating through Preheat PH Soak SK and Reflow RF steps Section 7 0 The cycle progresses to the Cooling CL step while air flows through the heater nozzle to freeze the solder joints The cycle is complete Section 7 0 When the board has cooled sufficiently remove it from the board fixture Fig 7 Proceed to electrical test visual inspection or x ray inspection of the reworked assembly as required F F j r lt 7 s i ve 7 E F Fi Soy Fs a i Figure 24 Removing Excess Solder Figure 25 Leveling Pads using Solder Wick amp Flux 15 a A bh bh kh ea Oo 8 6 6 6 o oeo o eee opacereesce0e8e G6 6 ooo T o 2 oo 6 oO 8 oo over es evo e 0 070 eteo o e o o o o E n o a o o 00
6. to increment decrement the recipe Push the lt SET gt key to accept the choice Note The unit holds 100 00 99 recipes in non volatile memory ENTERING THE PASSWORD Use the SET UP SET DN keys to enter the Ist digit of the password and push lt SET gt Repeat until all 6 password digits are entered Note The system default password is 123 You must push lt SET gt 3 times to serve as the last 3 digits 30 If the Password was incorrect push the lt MENU gt key to try again If the Password was correct push the MENU DN key to begin EDITING A RECIPE From MAIN MENU select EDIT TEACH SETTINGS and enter the password When the password is entered amp accepted see ENTERING THE PASSWORD the unit asks if you want to Edit Settings Push the lt MENU gt key to say yes When Editing a recipe use the MENU UP and MENU DN keys to skip fields you don t want to change When changing a field use SET UP and SET DN to change the value then push the lt SET gt key to enter the value Edit the recipe name using SET UP SET DN keys to change the Ist digit then push lt SET gt Repeat process to enter all 16 digits All 16 digits must be entered with the lt SET gt key 31 EDIT HEAT 1 SETTINGS Note Manual displays default values Note PH Preheat Edit HEAT Top Temp using SET UP and SET DN Push lt SET gt to enter the value Edit HEAT 1 Air Flow using SET UP a
7. Set Data Up Buton or lt SI gt OOO Note When the unit is controlled by an optional PC with the Thermal Analysis and Control Software installed the display will read UNDER HOST CONTROL and all keypad actions are ignored All functions are accessible through the PC software Figure 4 Lighting Intensity Control Turn clockwise to increase intensity and counterclockwise to decrease intensity The TOP lighting left hand knob affects the brightness of the video camera image in the UP direction This is the COMPONENT or NOZZLE image The BTM lighting right hand knob affects the image brightness in the DOWN direction This is the BOARD image By varying the intensity in both directions the operator can view a superimposed image of the COMPONENT or NOZZLE and BOARD for installation or removal of SMT components Figure 5 Vacuum Control Vacuum can be manually controlled by a front panel pushbutton footswitch or PC software At any time the machine is in a normal RUN mode actuating the vacuum switch will toggle the vacuum from OFF to ON or from ON to OFF The vacuum switch is also used during semi automatic operation to release the COMPONENT from the vacuum tip when placing a component on the BOARD or when placing a component in the NEST to indicate to the operator that it is time to continue the cycle after a manual operation Figure 6 Thermocouple Inputs TCH Shown The FR 1418 has 2 Thermocouple T C i
8. Z Move Table or for maintenance or manual operating reasons Inputs Z Axis Z Axis Contro o zy Position 0 000_ i i seek VAC SENSOR Jog Up Home C Slow Move To 0 Jog HOME CRASH Jog Down Full Figure 4 Z Axis Manual Controls The Z Axis Jog Panel has the following elements Position Display the current position of the Z Axis Move To Clicking this button will move the Z Axis to the position entered into the adjacent text box Speed This controls the speed of the Z Axis when jogging Up Down Jogs the Z Axis up or down at the speed set by the Jog Speed control 47 Manual Control Fig 5 This panel is used for toggling several of the machine s outputs such as Vacuum and heaters The machine can be manually operated by using these controls Some fields shown may depend upon optional equipment Outputs Top Heater Air Flow Low Alr Setpoint gi Low Medium Air Set Medium C High Bottom Heaters zones powe a oe Figure 5 Manual Control Panel Options Panel Figure 6 The Options Panel is accessed by clicking on the View menu in the Main Screen and selecting Options From here several configurable options are shown Itis recommended that you consult PMT or your local representative before changing any of these settings as improper values could allow the machine to damage itself Fan Lz Configuration x Controller 1 AD COM EE Controller 2 TriPLC COM
9. rework system to be controlled by a Pentium class PC with its serial port connected to the HOST PC connector Fig 20 on the machine s rear panel This software also allows the recipes to be created and stored on the PC Thermocouple data can be plotted real time stored and analyzed using software tools for measuring ramp rates time above melting temperature and more The customer can purchase software only and provide their own PC or the software can be preinstalled on a PC witha frame grabber card for viewing the video camera images using a 15 inch or 17 inch PC monitor This option may not currently be available for all models Automatic Motorized Z Axis This option is only available if option 2 above is installed It is only available as a factory installed option The Heater head is driven by a motorized lead screw making the Z Axis of the machine automatic This allows more automated rework cycle operation with the pick and place operations programmed into the recipes and controlled by the PC software This option may not currently be available for all models 19 Figure 29 Automatic Motorized Z Axis Option 20 6 0 Maintenance and Troubleshooting d Important Always disconnect the unit from the electrical and pneumatic supplies before servicing or performing maintenance Maintenance Linear Bearing Rails All linear bearing rails should be cleaned once a month with a tack rag to remove debris dust and dirt
10. tested using the LCD readout by pushing lt MENU gt at this screen This is the last diagnostic choice If you push MENU DN again it starts over with inputs TESTING THE INPUTS The LCD shows the state of the inputs Push lt STOP gt to stop the input testing TESTING THE OUTPUTS Use the SET UP amp SET DN to move the cursor to the four outputs shown on the LCD Push lt MENU gt to toggle the output state Push lt STOP gt to stop the input testing 36 TESTING THE THERMOCOUPLES The LCD shows the thermocouple temps Push lt STOP gt to stop the thermocouple testing MANUAL MODE Note Manual Mode is a bottom heat only mode Manual mode runs the bottom heaters manually Push lt MENU gt to manually change bottom heat parameters Push lt STOP gt to stop Manual Mode Edit bottom heat zones using SET UP and SET DN Push lt SET gt to enter the value Repeat for all zones Edit bottom heat percent using SET UP and SET DN Push lt SET gt to enter the value RAMP amp HOLD MODE Note Ramp amp Hold Mode is a bottom heat only mode Ramp amp Hold Mode runs the bottom heaters according to a temperature set point and TCH actual Push lt MENU gt to adjust the set point as well as the bottom heat parameters Push lt STOP gt to stop Ramp amp Hold Mode Alternate display in Ramp amp Hold Mode Edit bottom heat Zones using SET UP and SET DN Push lt SET gt to enter the
11. value Repeat for all zones Edit bottom heat percent using SET UP and SET DN Push lt SET gt to enter the value this is the highest percent used Edit bottom heat set point using SET UP and SET DN Push lt SET gt to enter the value 37 FAULT MODE If you run the machine with no air pressure you will receive this error message Push lt MENU gt to clear the message and try again abies 90 ete Fata 38 8 0 Appendix B Thermal Analysis and Control Software FR 1418 Software Operation Note This Appendix is a supplement to the FR 1418 Operation and Maintenance Manual Read about and understand the general machine operation before proceeding This operator manual supplement is a guide for operating the FR 1418 Rework Systems using the Thermal Analysis and Control Software Package This software is available as an option on the FR 1418 Rework Systems Some features and functions may not be enabled or available depending on the rework system hardware configuration purchased Important functions of the software are Notes Virtually unlimited recipe storage and retrieval using the PC hard disk drive or a remote network Multi point thermocouple data acquisition profiling and analysis to accurately measure temperature vs time curves used in the soldering process This includes convenient tools to measure ramp rates time above temperature and other key indicators relevant to the solderi
12. 506 0 oo io g D000 0 9 6 o p E ra oo o D a 7 A ee op 0 0 0 0 6 0050 2 C so Ki i eect c o G Syn S ee x a 2 A ps am K ofc gt fk ooo 6 6 ik D C 2 900 o o Figure 26 Printing BGA with Solder Paste Figure 27 Aligning the Component 4 0 Operation Note The operation and programming of the FR 1418 requires that the operator have reasonable proficiency with the features controls and processes described in Sections 1 0 3 0 7 0 and 8 0 if applicable of this manual Read and understand sections 1 0 3 0 7 0 and 8 0 if applicable before proceeding to operate and program the equipment as described in this section Note Consult the references in parentheses after each item for additional information or description relevant to each topic General Warnings 1 Keep in mind that the system is designed to melt solder joints on very dense boards The heaters are very powerful and can reach internal air temperatures exceeding 450 C 840 F Surfaces of the heater PCB nozzle and other components can be VERY HOT Always use caution to prevent accidental burns especially when changing nozzles unloading boards or components or when working around the heater head area 2 Never touch any glass optics components with bare hands 3 Never wipe any glass optics components with rags or paper towels Use an optical wipe camera lens tissue eye
13. REMOVE Heat Cycle Fig 3 Section 4 0 Section 7 0 5 When the heat cycle is complete the vacuum comes on Adjust Z height to pick up the component Fig 14 6 Raise heater head Fig 13 15 7 Move the component nest CPF under the hot component Fig 19 Lower the head near the component nest and press the VAC switch to drop the component and continue the cycle 9 After a timed cooling step the cycle is complete 10 Retract the component nest and raise the head Fig 19 14 Note See the items referenced after each step for additional information in this manual Rework Phase II Board and Component Preparation Practices vary widely but they may consist of the following steps 1 Remove excess solder and level the pads with solder wick and soldering iron Fig 24 amp 25 2 Print fresh solder paste onto BGA balls using CPF stencil Fig 26 Note In many cases for plastic BGA components with eutectic solder balls a thin coating of flux paste is applied to the board in lieu of adding additional solder paste 3 Load CPF with BGA into component nest Fig 19 14 Rework Phase III Component Installation typically consists of the following steps 10 11 12 13 14 Load PCB onto adjustable board fixture Fig 7 With the head UP load the component in the nest and slide it under the nozzle Fig 13 15 19 Press lt Start gt to initiate the RUN INSTALL cycle The vacuum turns on Fig 3 Section 4 0
14. ad to the rough DOWN position and then adjust the Z height so the calibration tip 2 is just above the blind hole 3 in the calibration plate 1 Align the calibration tip with the plate as shown in Figure 41 Use the video alignment system to view the superimposed image of the tip and the hole in the plate It is important not to allow the X and Y axes to move at this time If the tip and hole in the plate appear concentric then no adjustment of the prism is required If the tip and hole appear misaligned adjust the prism according to Figures 42 and 43 Replace the vacuum tip and any covers which have been removed Figure 39 Optics train stop adjustment Bring the head to its uppermost position Move the optics train to the right until it stops Fig 17 Adjust the Z height so the calibration or vacuum tip is just above the top lighting and visually check that the tip is centered left to right with respect to the prism Gauge the centering of the prism with a graduated scale if one is available If the optics train position requires adjusting adjust the stop screw 4 accordingly 26 Figure 40 Mirror adjustment Return the head to its uppermost position and turn on the LCD monitor Move the optics train 7 to its right most position Loosen the locking screw 5 on the mirror bracket very slightly and using the three set screws 6 adjust the mirror so the nozzle tip appears in the center of the video image Adj
15. and styles They are generally low mass stainless steel shrouds with a machined top flange or hub which engages the lower heater housing To remove a nozzle 3 grasp the shroud and tilt the lower end of the nozzle slightly away from one of the spring loaded clips 2 while pulling straight down To insert a nozzle center the theta adjustment see note hold the nozzle by the shroud insert the vacuum tip through the opening in the top of the nozzle place the flange of the nozzle over two of the spring clips 2 at a slight angle and then push the nozzle straight up until the other side of the flange snaps past the third spring clip A CAUTION Nozzles may be VERY HOT Hot nozzles can cause severe burns Use adequate hand protection when changing a hot nozzle or wait for the nozzle to cool before changing Note The range of theta adjustment for the heater head is limited Attempting to force the theta adjustment beyond its intended travel will damage the assembly To minimize the possibility of this occurring observe the following Before installing each nozzle it is best to center the theta adjustment in its travel range and install the nozzle at the approximate rotation angle required for installation or removal of the SMT component usually 0 90 or 45 degrees Video Camera and Optical Alignment System Figures 17 amp 18 A video optical system aids the operator in aligning the nozzle or component to the board To use the alignmen
16. arious items on this screen File Name amp Description Reflow Part Detect This is the same information that appears on the Main Screen The Description can be edited from here The amount of time the Part Thermocouple spends above this temperature is displayed in the Above Reflow field on the Main Screen Auto Z equipped machines only This toggles whether or not the vacuum switch is used to detect when a component is on the tip when picking a component from the nest Install Mode or the board Remove Mode If Use Vacuum Switch is selected then the Z Axis will stop seeking as soon as the vacuum switch is triggered when picking up a component If Nest Board Place is selected the software will ignore the vacuum switch and use the Nest Place or the Board Place positions from the Z Move Table to determine how far to seek the Z Axis when picking up a component In either case the Nest Place and Board Place positions are always used when placing components 44 Board Heater Section Heat Zones 1 amp 2 Board Heater Power Start Preheat At Time Heat Stage Settings These buttons toggle which board heaters are active during the process Sets the power from Q off to 100 full power during the Board Preheat Stage When running in Teach Mode once the Board Thermocouple reaches this temperature the software will advance to the Heat Preheat stage The time required to reach this temperature will be recorded i
17. d recipe file A text field of the recipe that can be used to display additional information about the currently loaded recipe This will open the Recipe Setup Screen discussed below which is used to edit the currently loaded recipe or create new recipes Part Temp Board Temp Top Heater Temp Spare Temp Timers These fields show the current and target temperatures of each of the machine s thermocouples They can be checked or unchecked to toggle their display on the graph These fields show timer values for each of the process stages the total time and the time above reflow temperature 42 Recipe Setup Screen Figure 2A Figure 2B This screen is accessed by clicking on the Edit Recipe button on the Main Screen This screen allows the operator to set the thermal process requirements and the Z Axis locations for the recipe The thermal cycle starts with the Board Heater settings and runs through the heating and cooling steps to the end of the process The small chart in the top right corner shows a graphical approximation of the Target Profile as determined by the various settings Board Heater Heat Zones a F Heat 1 Preheat Part TG Target C lo Heater Temp C lo Time min sec 0 00 Heat 2 Soak Part TG Target Gi lo Heater Temp C lo Time min s c 0 00 Heat 3 Reflow Part TG Target C lo Heater Temp C lo Time min s c 0 00 Cooling Time min s c 0 30
18. e heater nozzle Fig 19 13 15 6 Press lt Start gt The vacuum turns on 7 Adjust the head down to pick up the component and then raise the head away from the nest Fig 10 11 2 15 Align the leads on the component to the pads on the board using the video alignment optics Fig 17 18 Lower the head to the rough DOWN position and then adjust the nozzle height to place the component on the board The component should touch but not push on the board Press the VAC button or footswitch The heaters will turn on and the cycle will continue with the PH step after a short delay which allows the vacuum to dissipate Immediately adjust the nozzle Z height to approximately 1 8 inch above the component The nozzle should NOT be touching the component Fig 13 15 The system will progress through Preheat PH Soak SK and Reflow RF steps at the programmed top and bottom heater settings When in INSTALL RUN mode the system will run at the programmed heater settings for the step times programmed in the recipe This is a time driven cycle When in INSTALL TCH mode the system will heat at the programmed step heater settings until the TGT temperature is reached by the TCH T C This is a temperature driven cycle and is dependent on T C feedback Make sure the T C is securely in contact with the solder joint to ensure accurate temperature readings An L E D bar graph progressively illuminates from bottom to top ind
19. e pin engages when the adjust handle is released The Z Axis Fine Adjust Knob 2 rotates a pinion gear 6 which moves the rack assembly up or down This provides additional up and down adjustment of the head when it is in either the UP or DOWN rough position During general use the rack assembly should always be adjusted UP using the knob unless the operator is in the process of picking placing or soldering a component This ensures that there will be adequate clearance between the heater nozzle and the board or nest when a rapid move 1s made between the UP and DOWN rough positions Heater Head and Nozzle Installation Figure 16 Lower Heater Head Details The lower heater head assembly is supported by the theta adjustment bearings which are mounted to the heater plate 7 The lower heater housing 1 rotates using the theta adjust 8 The heat path from the upper heater head to the lower heater head is closed by a spring loaded bronze seal 4 Vacuum is generated by a venturi in the rear head enclosure The vacuum tip 6 not visible in Fig 16 receives vacuum through a Teflon tube connected to the vacuum transfer pipe 5 The vacuum tips are interchangeable for placing and removing different size and weight SMT components Interchangeable nozzles 3 are held into the lower heater housing 1 by three spring loaded clips 2 ragi Changing Nozzles Heater nozzles are available in different sizes end shapes
20. embly as shown Do not touch the bulbs with bare hands Be sure to observe the handling warning stated at the beginning of this section Insert the new lamp in the reverse manner Figure 34 Checking the bottom heater lamp contacts Grasp the lamp 1 near the center Push the lamp slightly toward one contact block 2 then the other You should feel some movement in each direction as the contact springs flex The lamp should not rattle or feel loose The lamp should be supported only by the pins in the contact blocks Rotate the lamp a small amount in both directions about its long axis to feel that the bulb is securely seated on the contact pins 24 Table for Figures 35 and 36 Item Description Description Power distribution board le Main power connections to from power switch I O board 9 Thermocouple input terminals Fuses Individually identified on board CPU board plugs into I O board 6 Power control module electrical connections 25 Optical Calibration and Adjustments Figure 37 Calibration Plate Figure 38 Calibration Tip Calibration Procedure l Remove the covers from the camera lens and light housing Fig 17 and install the calibration plate 1 onto the board support Remove the nozzle and vacuum tip Fig 29 and install the calibration tip 2 Adjust the optics train stop according to Figure 39 if necessary 3 Adjust the mirror according to Figure 40 if necessary Move the he
21. en with optional Automatic Z AXIS fog vt ao rag 1 i20 1g Figure 1B FR 1418 Thermal Anal The following menus are available in the Main Screen File gt Open Displays a dialog box for opening recipe files File gt Save Saves any changes made to the current recipe File gt Save As Saves the current recipe to a new file name File gt Exit Exits the program View gt Options Displays the Options Screen discussed below Help gt Contents Displays the software s help file Along the left hand side are the following buttons Home Z Axis Button Moves the Z axis to its home position and resets its zero location Start Button Starts the currently loaded recipe Stop Button Stops a running recipe Install Remove Buttons Toggles between these two modes of operation 4 Run Teach Buttons Camera View Button Jog Button Manual Control Button File Name Description Edit Recipe Button Toggles between these two modes of operation In Run mode the software will use recorded times for stage control In Teach mode the software will monitor the machine s thermocouples for stage control and will record the times between stages to be used in Run mode Opens the Camera View window discussed below Opens the Jog window for moving the Z Axis discussed below Displays buttons and parameters for manually controlling several of the machine s outputs discussed below The file name of the currently loade
22. glass wipe or other material which will not scratch the glass 4 Never touch the sides unpolished faces of the prism The oil from your hands can penetrate the bonded seam and adversely affect the image quality 5 Never touch the halogen bulbs for the component board lighting or the bottom heater quartz lamps with bare hands The oils from your skin can cause hot spots on the bulbs quartz lamps resulting in cracking or coating failure 6 Maintain good ESD prevention procedures when handling electronic components and boards Always disconnect the unit from the electrical and pneumatic supplies before servicing or maintenance 16 Powering the System l 2 3 4 Check that air N2 and power are properly connected Turn the power switch to the 1 On position Fig 20 Observe startup messages on LCD screen Wait for READY Fig 3 and Section 7 0 The system is in INSTALL RUN or REMOVE RUN mode with the last used recipe loaded in memory Section 7 0 Operation for Component Removal Desoldering 1 2 OA e A 10 11 12 Load the desired Recipe using the MENU buttons Fig 3 and Section 7 0 Select REMOVE RUN or REMOVE TCH mode using the MENU buttons If REMOVE TCH is selected place the tip of the TCH T C in contact with the component solder joint Fig 3 6 and Section 7 0 Insert the proper nozzle into the heater head Fig 16 Insert the standard nest plate into the nest Fig 19 Ali
23. gn the nozzle to the board using the video alignment optics Fig 17 18 Lower the head to the rough DOWN position and then adjust the nozzle height to approximately 1 8 inch above the component to be removed The nozzle should NOT be touching the component Fig 13 15 Press lt Start gt to initiate the heating cycle The system will progress through Preheat PH Soak SK and Reflow RF steps at the programmed top and bottom heater settings When in REMOVE RUN mode the system will run at the programmed step heater settings for the step times programmed in the recipe This is a time driven cycle When in REMOVE TCH mode the system will heat at the programmed step heater settings until the TGT temperature is reached by the TCH T C This is a temperature driven cycle and is dependent on T C feedback Make sure the T C is securely in contact with the solder joint to ensure accurate temperature readings An L E D bar graph progressively illuminates from bottom to top indicating progress through the cycle Fig 3 and Section 7 0 At the completion of the RF heating time the vacuum will turn on and the system will begin to beep Adjust the Z height Fig 15 to bring the vacuum tip in contact with the top of the component and allow the vacuum to engage the component Adjust the Z height back away from the board at least 1 2 inch and then raise the head to the rough UP position Fig 15 Slide the component nest under the ho
24. h the machine A detailed procedure is explained below Z Axis Lead Screw Shaft for systems with Motorized Z Axis This should be lubricated once 1 every six months Manually drive the top heater head down to the bottom home position then turn the Power OFF The shaft should be lubricated with a heavy grease which will not melt or run at moderate temperatures preferably a Lithium Grease compound 12 Hydroxy Lithium Complex At the factory we use StaPlex Premium E P Restore power and Home Z AXIS Other The machine should be kept clean to prevent build up of flux or other substances or objects that may degrade performance or damage the machine 21 Troubleshooting Below is a general guide for troubleshooting certain operational problems Consult a qualified service technician if you do not understand basic troubleshooting techniques or if the problem can not be identified and corrected using the information provided in this manual Troubleshooting table Symptom Weak vacuum at tip References Fig 29 Possible Cause Corrective Action vacuum cup system Insufficient supply Increase supply pressure above 60 PSI Check Fig 20 pressure or volume supply capacity meets CFM requirements and Section 2 0 check supply tubing Component is not Improper Z height Review Section 4 0 for proper placement Section 4 0 placed accurately when vacuum is technique compared to video turned off Section 4 0 Fig 29 i
25. he images stay aligned 28 7 0 HMI Software Guide FR 1418 FRONT PANEL OPERATION POWER ON amp RUNNING A RECIPE First application of power Unit says American Hakko Rework System Note The current software revision X is displayed on the right side of the screen Unit shows recipe is loaded and ready to run by pushing lt START gt or push lt MENU gt to get main menu Note indicates recipe which is ready to run MAIN MENU From the RUN READY screen push the lt MENU gt keys to get additional menu choices Note Mode indicates either install or remove Use the MENU UP MENU DN keys to navigate from MENU to MENU Push lt MENU gt to select the choice shown Select CHANGE TO INSTALL OR REMOVE screen to toggle between install and remove modes Note Mode indicates either install or remove Select LOAD NEW RECIPE to go to a screen where a new Recipe can be chosen 29 Select EDIT TEACH SETTINGS to Edit or Teach a Recipe Select SETUP DIAGNOSTICS to enter Setup Mode pgm password or run Diagnostics Select MANUAL MODE to run the bottom heaters manually Select RAMP amp HOLD MODE to control the bottom heaters based on a desired set point temperature and an actual thermocouple reading LOADING A NEW RECIPE TO RUN From MAIN MENU select LOAD NEW RECIPE Use the SET UP SET DN keys
26. he outer cardboard or wooden crating material Remove the two 5 16 lag bolts 2 and the hold down brace 1 from the cushioned skid 4 Remove the outer plastic sheeting shrink wrap or optional vapor barrier bag 3 Remove the nozzle kit 5 accessory pack 6 and any LCD monitor 7 and or optional equipment The machine can now be lifted off the skid using at least two people The uncrated machine weighs approximately 140 pounds Place the machine on a stable bench with a solid top The bench should not wobble or bend under the weight of the machine If necessary adjust the four leveling feet so that the machine sits flat on the bench without rocking Remove any final shrink wrap plastic or foam except the foam block 8 under the head Raise the head to remove the final foam block Remove the cardboard 9 covering the bottom heater _ Figures 22 amp 23 Axes Blocked Stop Collars 1 are used to secure the axes for shipment Loosen the 10 32 set screws and slide the collars out of the way 12 Power and Air N2 Connections Connect air or nitrogen to the rear panel fitting using 1 4 inch plastic tubing See Fig 20 on page 11 The supply gas must be clean dry and regulated to 60PSI The supply should be capable of delivering 5 CFM minimum continuous supply at 80 PSI Poor filtration or wet air lines will degrade heater and pneumatic component performance Plug the power cord into an appropriate dedicated 120VAC ou
27. ht based on TCH actual temp reaching Teach Temp see Running A Recipe When you are done using Teach Mode push the lt STOP gt key If you have made any changes the unit asks if you want to Exit amp Save lt MENU gt key or Exit without Saving lt STOP gt key SETUP DIAGNOSTICS From MAIN MENU select SETUP DIAGNOSTICS and enter the password When the password is entered amp accepted see ENTERING THE PASSWORD the Unit asks if you want System Setup Pushing lt MENU gt from this screen allows you to program a new password Push MENU DN and it asks 1f you want diagnostics Pushing lt MENU gt from this screen puts you into the Diagnostic Mode 35 SYSTEM SETUP PROGRAMMING A NEW PASSWORD Use the SET UP SET DN keys to select the Ist digit of the new password and push lt SET gt to enter it Repeat until all 6 password digits are entered After all 6 digits are entered this screen is shown Push lt MENU gt key to Exit amp Save the new password or push lt STOP gt to Exit without saving DIAGNOSTICS The state of the four input lines can be viewed on the LCD readout by pushing lt MENU gt at this screen Or push MENU DN to select next diagnostic menu choice The four output lines can be tested using the LCD readout by pushing lt MENU gt at this screen Or push MENU DN to select next diagnostic menu choice The four thermocouple inputs can be
28. icating progress through the cycle Fig 3 and Section 7 0 Cooling CL is the last timed step When this is complete adjust the head away from the component and then raise the head to the rough UP position The board may be removed when it has sufficiently cooled Note When in INSTALL TCH mode the step times in the recipe are updated automatically upon the completion of the TCH cycle See Section 7 0 for detailed information on the recipe 18 5 0 Options A variety of nozzles vacuum tips accessories and factory installed options are available to meet the needs of different rework applications Consult your sales representative for the most up to date information on accessories and options Some major system options are briefly described below Additional operation and maintenance supplements to this manual may be supplied with some options Major System Options l Two Zone Bottom Heater This option provides a second 10 x 12 inch bottom infrared heating zone which can be turned on or off in any heating step of each recipe The total bottom heat area with this option installed is 12 inches in the Y direction and 20 inches in the X direction The left hand zone is Zone 1 in the recipe while the right hand zone is Zone 2 a Ti FT Figure 28 Two Zone Bottom Heater Option Thermal Analysis and Control Software An advanced software control and temperature profiling software package is available that allows the
29. into the board fixture To move the head left or right squeeze the X Axis adjust handle and push or pull the head to the desired position To move the head front to back squeeze the Y Axis adjust handle and push or pull the head to the desired position Fine adjustments such as when aligning a component or nozzle to a PCB can be made by rotating the fine adjust knob for the each axis Figure 12 Theta Adjust The lower heater head can be rotated by turning the Theta Adjust knob This rotates the nozzle and the vacuum pick up so the component and or nozzle can be aligned to the PCB in the Theta or rotational direction The Theta adjust is a precision assembly with limited travel in either direction Take care not to continue to turn the knob once the Theta has been adjusted to the end of travel to avoid damaging the assembly Also see Nozzle Installation Figure 13 Z Axis Adjust Handle Figure 14 Z Axis Fine Adjust Knob Figure 15 Z Axis Rack Gear Assembly Adjusting the heater head height figures 13 and 14 The Z Axis adjust handle 1 is attached to the heater head It is used to select the rough position of the heater head 7 This position is either UP or DOWN Squeezing the adjust handle disengages a pin from the Z Axis fine adjust rack gear assembly 3 allowing the head to be lifted or lowered to the top 4 or bottom 5 travel stop There is a slot in the rack assembly at either end of travel in which th
30. mage Component sticks to Clean vacuum tip use a different size vacuum vacuum cup and then tip or modify Z height used when placing and drops back to board releasing the component on the board inaccurately mo a inaccurate procedure below not turn on as out lamps a blown fuse then replace the fuse Component or board A halogen bulb is Inspect the bulb filaments Replace burnt out ae 31 32 lighting does not burnt out bulbs work centered in video requires adjustment described in the optical calibration procedure window Check and or adjust the flat mirror as described Fig 36 adjustment in the optical calibration procedure Figure 29 Vacuum Pick Up System Interchangeable vacuum tips 1 which may or may not have a silicone vacuum cup 2 are screwed into the vacuum stem 3 with 10 32 threads The vacuum transfer tube 4 pipes the vacuum from the tubing 5 to through the lower heater housing 6 to the stem A vacuum generator Item 2 Fig 30 generates the vacuum pressure A leak anywhere in this system may cause weak vacuum at the tip 22 ee ee ee i Figure 30 Rear Head Enclosure Details Item Description Item Description 2 Vacuum generator 8 Head distribution dimmer board 3 Medium air fow solenoid vave 9 Heater power connections 6 Air pressure switch Routine Service Procedures 1 To change the component or board lighting halogen bulbs found on the standard op
31. n be accessed while the Recipe Setup screen remains open to help set up the Z Move Table Focus Nest The height at which the underside of the component is in focus when performing an alignment The height the Z axis will move to prior to extending the nest in preparation for picking up or dropping off a component The height should be set to accommodate the thickness of the component to avoid collision with the nest 45 Nest Place Preheat Soak Reflow Board Board Place When placing a component into the nest or picking up when Nest Board Place is selected in the Part Detect section the Z Axis will slowly seek to this height with the vacuum turned on This height is typically set at the point where the vacuum tip just touches the top of the component to avoid placing too much load on the component Each of these heights controls the position of the Z axis during each of the three heating stages The Z axis will move to this height prior to picking up or placing a component on the board When placing a component onto the board or picking up when Nest Place Board is selected in the Part Detect section the Z Axis will seek to this height with the vacuum turned on The height should be set at the point where the vacuum tip just touches the top of the component to avoid placing too much load on the component Camera View Screen Figure 3 This window is accessed by clicking on the Camera View b
32. n the Time field When running in Run Mode this field will be ignored When running in Run Mode the software will use this time to determine when to advance to the next stage The following settings apply to each of the three heat stages Preheat Soak and Reflow Part TC Target Heater Temp Time Board Heater Power Air Flow Rate Cooling Stage Settings Time Air Flow Rate When running in Teach Mode the software will compare the Part Thermocouple reading to this temperature to determine when to advance to the next stage The time required to reach this temperature is recorded in the Time field In Run Mode this field will be ignored This is the temperature setting for the top heater In Run Mode this field is used by the software to determine when to advance to the next stage The power setting for the board heaters can be set for each stage The setting can range from 0 off to 100 full power These three buttons control the air flow setting through the top heater for each stage The amount of time spent in the cooling stage Sets the air flow setting for the cooling stage Z Move Table Auto Z equipped machines only Each recipe has an independent set of Z positions The Set button next to each field applies the current Z location to that field The GoTo button moves the Z axis to the current setting for that field The Jog buttons opened from the Manual Control button on the Main Screen ca
33. nd SET DN Push lt SET gt to enter the value Edit HEAT 1 Teach Target using SET UP and SET DN Push lt SET gt to enter the value Edit HEAT 1 Time using SET UP and SET DN Push lt SET gt to enter the value Edit HEAT 1 Zones using SET UP and SET DN Push lt SET gt to enter the value Repeat for both zones Edit HEAT Bottom Heat using SET UP and SET DN Push lt SET gt to enter the value EDIT HEAT 2 SETTINGS Note Manual displays default values Note SK Soak Edit HEAT Top Temp using SET UP and SET DN Push lt SET gt to enter the value Edit HEAT 1 Air Flow using SET UP and SET DN Push lt SET gt to enter the value Edit HEAT 1 Teach Target using SET UP and SET DN Push lt SET gt to enter the value 32 Edit HEAT 1 Time using SET UP and SET DN Push lt SET gt to enter the value Edit HEAT 1 Zones using SET UP and SET DN Push lt SET gt to enter the value Repeat for both zones Edit HEAT 1 Bottom Heat using SET UP and SET DN Push lt SET gt to enter the value EDIT HEAT 3 SETTINGS Note Manual displays default values Note RF Reflow Edit HEAT Top Temp using SET UP and SET DN Push lt SET gt to enter the value Edit HEAT 1 Air Flow using SET UP and SET DN Push lt SET gt to enter the value Edit HEAT 1 Teach Target using SET UP and SET DN Push lt SET gt to enter the value Edit HEAT Time using SET UP and SET DN Pu
34. ng process An easy to use graphical HMI for running the rework system using the PC Programmable automatic Z Axis control for systems equipped with Motorized Z Axis Teach mode interactive programming for simplified development of accurate and repeatable soldering profiles Single screen viewing and editing of all computer controlled recipe parameters Advanced manual controls and optimization tools for experienced users Process recipe and thermal profile documentation and printing Human Machine Interface Not available on all configurations Main Screen Figure 1A Figure 1B 39 This is the first screen shown upon starting the software The bottom area of the screen shows the temperature profile graphing area while the upper part of the screen shows the operation buttons status data timers recipe name and description Tot Time Bupsed Eda hane Gumeni Sage Time Derresan Part Target Tap H ier sepdim Timp Abad REYN a3 Thersdcopeies S ipui a e owa ie Tee Harfa O Ename Graph re O 250 Process Tharmocowses THI TA Figure 1A FR 1418 Thermal Analysis and Control Software Main Run Screen with standard Manual Z Axis 40 Main Screen Continued Tete Time Eapen fie hide Eon Renpe Curent Stage Time Dpp men Part Target Teng Haie Beth cin ia F Tine Abort Reto lea Procogs Merecoup sis and Control Software Main Run Scre
35. nputs The LH input is the TEACH or TCH input and the RH input is the SPARE or TC2 input These are Type K T C inputs 36 gauge fine wire Teflon insulated T Cs are recommended The TCH input is used to measure the solder joint temperature The TC2 input can be used to measure temperature at any point on the board or component being soldered Note There must be a T C or jumper Pue into each port in order for the machine to operate in TEACH or RUN Modes The system will generate a fault message if either channel is open Board Fixture and Axis Definition Figure 7 Board Fixture The standard board fixture consists of front 1 and rear 2 dovetail rails with adjustable spring clips 3 attached to them The rear dovetail rail may be adjusted front to back to allow holding boards also called PCB or PWB of varying depths To adjust the rear rail loosen the black knobs at both ends and slide the rail forward or backward using one hand on each end Keep the rear rail parallel to the front rail for easiest adjustment without binding For convention left to right on the machine is called the X Axis The front to back direction is called the Y Axis The heater head 4 travels up and down in the Z AXIS Axis Adjustment Controls Figure 10 Y Axis Fine Adjust Knob Figure 11 Y Axis Adjust Handle Figures 8 through 11 show the X and Y Axis adjustment controls for positioning the heater head relative to the board loaded
36. roce PH 3 16 Se Le a le a ple ea ee ale ee el le ee ee eda ee lige epee te ele a ela oe ali i eel 0 00 0 20 0 40 1 00 1 20 1 40 200 220 2 40 3 00 20 340 4 00 4 20 440 5 00 5 20 5 40 6 00 Elapsed Time Figure 7 Screen capture from system operating in Teach Mode The graph shows that the part thermocouple has passed the Preheat Target PH 140 and is approaching the Soak Target SK 175 Note that the Soak indicator is highlighted bright yellow This is the active step The paler colored steps have already been completed The Current Stage Time counts up in Teach Mode and down in Run Mode 51 ey HAKO American Hakko Products Inc 28920 Avenue Williams Valencia CA 91355 4182 U nited States of America Tel 661 294 0090 Fax 661 294 0096 Toll Free 1 800 88 HAKKO 42556 www H akkoU SA com
37. sh lt SET gt to enter the value Edit HEAT 1 zone using SET UP and SET DN Push lt SET gt to enter the value Repeat for all zones Edit HEAT 1 Bottom Heat using SET UP and SET DN Push lt SET gt to enter the value EDIT COOL 1 SETTINGS Edit COOL 1 Air Flow using SET UP and SET DN Push lt SET gt to enter the value Edit COOL 1 Time using SET UP and SET DN Push lt SET gt to enter the value 33 When you are done editing push the lt STOP gt key If you have made any changes the unit asks if you want to Exit amp Save lt MENU gt key or Exit without Saving lt STOP gt key RUNNING THE RECIPE Push lt START gt to run the recipe Note The following screens are displayed as the unit progresses through a cycle HEAT 1 HEAT 1 alternate screen HEAT 2 HEAT 2 alternate screen HEAT 3 HEAT 3 alternate screen COOL 1 COOL 1 alternate screen Push any key to exit this screen or wait 5 seconds 34 TEACHING A RECIPE From MAIN MENU select EDIT TEACH SETTINGS and enter the password When the password is entered amp accepted see ENTERING THE PASSWORD the Unit asks if you want to Edit Settings Push the MENU DN key to get the teach screen Push lt MENU gt at the teach screen to run the Teach Mode The unit will run normally except TCH will show on the LCD instead of RUN and the times will be taug
38. t component and lower the head near it Fig 19 Press the VAC button to release the component from the tip and initiate the Cooling CL timed step then retract the head away from the nest The cycle is complete when the CL timer reaches the programmed value Note Once the vacuum turns on at the completion of the RF recipe step the operator has 20 seconds to remove the component from the board and place it in the nest Steps 8 through 11 above If the VAC button is not pushed within 20 seconds the system will go into an alarm fault mode and terminate the run to prevent accidental board overheating 17 Note When in REMOVE TCH mode the step times in the recipe are updated automatically upon the completion of the TCH cycle Operation for Component Installation Soldering l 2 Load the desired Recipe using the MENU buttons Fig 3 and Section 7 0 Select INSTALL RUN or INSTALL TCH mode using the MENU buttons If INSTALL TCH is selected place the tip of the TCH T C in contact with the component solder joint Fig 3 6 and Section 7 0 3 Insert the proper nozzle into the heater head Fig 16 Insert the component into the nest with the standard nest plate or optional CPF Solder paste or flux paste may be pre applied to some components when using a CPF Orient the component to meet any polarity requirements for the PCB assembly Fig 19 Section 3 0 5 With the head in the rough UP position slide the nest under th
39. t system put the head in the UP position and slide the optics train 10 to its right most position underneath the nozzle Top lighting 1 illuminates the component and or the end of the nozzle and vacuum tip Bottom lighting 2 illuminates the board Light reflected from the component and board travels through the beam splitting prism 3 reflects off the flat mirror 4 into the zoom lens 9 and finally onto the CCD imaging device 8 The CCD imaging device transmits a video signal to an LCD flat screen an analog monitor or a PC for high magnification viewing of the superimposed component board image The intensity of the component or board image can be adjusted by varying the light intensity The image is adjusted using the focus 5 zoom 6 and f stop 7 controls on the zoom lens 9 Always focus the camera on the BOARD and adjust the Z height of the component or nozzle to focus the top image When focusing a component adjust the Z height of the component so that the pitch of the leads on the component matches the pitch of the in focus pads on the board This is easiest when the X Y Theta adjusts are used to set the leads on the component parallel to and one half pitch offset in the Y direction from the pads on the board Figure 18 Camera amp Zoom Lens Figure 17 Optics Components 10 Component Nest Note The component nest and optics train are shown in their retracted positions The component nest 1 and op
40. tics train 4 must be fully retracted for the head to be lowered to the DOWN position Rear Panel Figure 19 Component Nest The component nest 1 is provided for aligning a component to the heater nozzle and for receiving a hot component after it has been removed from the board The system is furnished with a generic plate not shown which fits into the component nest to aid in aligning new components with the heater nozzle 5 Component Print Frames or CPF 2 also fit into the component nest and are available for stencil printing solder paste onto BGA 3 and some other SMT components With the head UP extend the component nest to its right most position to align the center of the nest insert 2 with the nozzle 5 for receiving hot components or transferring a new component to the nozzle Figure 20 Rear Pane Item 6 Item Description 2 On Off Switch Power Switch Air N2 Supply Inlet 1 4 Tubing Services to Head Assembly 11 Serial Number Decal Host PC and or Options Connector s Description 2 0 Unpacking and Installation The rework system packaging may vary due to the specific model purchased options installed and shipping transportation requirements The following figures provide a general guide for unpacking the system Figure 21 Outer cardboard or crating removed Figure 22 Bracing and Plastic Removed To unpack the machine Remove t
41. tics train follow the steps outlined in Figures 31 and 32 below 2 To change the bottom heater quartz lamps remove the base cover plate Fig 7 Item 5 and collimator grille Fig 7 Item 6 and then follow the steps outlined in Figures 33 and 34 below 3 To replace fuses first find and correct the cause of the blown fuse then remove the base cover plate Fig 7 Item 5 locate the appropriate fuse on the power board Fig 35 Item 3 and replace the fuse with one of the same type and rating Reinstall the cover 23 Figure 31 Removing the lighting cover Remove the four corner screws 1 securing the top or bottom lighting cover 2 as required Carefully pull the cover straight out of the housing 3 with the bulb mount 4 still attached See Fig 32 replacement bulbs must be of the exact type as the original equipment 75 W Max Figure 32 Changing halogen bulbs Pull the bulb 5 straight out of the socket 6 and insert the new bulb in the reverse fashion It may be necessary to slightly bend the contact pins on the new bulb to fit the socket Do not touch the bulbs with bare hands Be sure to observe the handling warning stated at the beginning of this section Take care not to pinch the supply wires 7 when replacing the cover Figure 33 Replacing the bottom heater quartz lamps Grasp the lamp 1 near one end Push slightly towards the opposite contact block 2 then tilt the lamp up and out of the heater ass
42. tlet Itis now safe to turn on the power to the machine The machine will run through a brief self check on power up and then be ready for operation See section 4 0 Operation and Programming Section 7 0 HMI Software guide or Section 8 0 Thermal Analysis and Control Software for more information Repackaging the system Reverse the unpacking procedure taking special care to secure all moving parts as indicated Note The minimum packaging for local delivery or relocating of systems requires that the machine be securely fastened to a cushioned skid with the head blocked axes locked bottom heater covered and system shrink wrapped as described in this section 13 3 0 Process Overview This section is intended to provide a brief and general overview of the SMT rework process using the FR 1418 Your process and corresponding requirements may vary considerably The typical rework process using this equipment would include the following three phases each of which has several steps Rework Phases I Component Removal I Board and Component Preparation for Installation IMI Component Installation Rework Phase I Component Removal Typical steps 1 Load the board with the component to be removed in the board fixture Fig 7 2 Align the nozzle with the component using the video image and X Y Theta adjust knobs Fig 8 12 17 18 3 Retract Optics and lower head near board Fig 13 15 4 Press lt Start gt to initiate the RUN
43. to move to a height below this setting then the software will automatically retract the nest to avoid collision However when jogging the software does not check this value Sets the value to the current Z Axis position This setting s purpose and functionality is identical to the Nest Clearance but for the Optics assembly 49 Working with Recipes Creating a new Recipe 1 Click on the Edit Recipe button from the Main Screen 2 Select File gt gt New and then select a recipe template A default recipe template default rct comes with the software You may create your own templates from any recipe using the Save As file options 3 Edit the recipe parameters as desired 4 Save the recipe Teaching and Running a Recipe 1 Open a recipe and check that the parameters represent the rework profile you want to achieve 2 Plug a thermocouple into the left hand port on the front of the machine and attach the exposed junction to a solder joint on the component to be taught It plots on the graph as the Part Thermocouple 3 Plug a thermocouple into the right hand port on the front of the machine and attach the exposed junction to an area of the circuit board away from the target component This is the thermocouple which will be used to control the Start Preheat at temperature as specified in the Board Heater section of the recipe It plots on the graph as the Board Thermocouple 4 Insert the proper noz
44. ust the lens zoom control through its entire travel to ensure the image remains centered on the screen Re tighten the center screw Figure 41 Aligning the calibration tip with the plate Adjust the head down and align the calibration tip 2 with the blind hole in the calibration plate 3 using the X and Y fine adjustments Adjust the X and Y axes so that the tip can be moved easily in and out of the hole in the Z direction Figure 42 Prism Left Right Image Adjustment 21 Figure 43 Prism Front Rear Image Adjustment To Adjust The Prism The prism 11 1s bonded to an adjustable mount 12 which allows it to be oriented squarely to the Z Axis This can correct any optical image misalignment observed during the calibration procedure above Do not adjust the prism mount for any reason unless the above calibration procedure indicates you should do so Slightly loosen the three socket head cap screws 8 on the prism bracket To correct a left to right image misalignment adjust the set screws 9 to produce the desired effect To correct a front to back top to bottom on video monitor image misalignment adjust the set screws 10 to produce the desired effect Note When adjusting the set screws loosen one and tighten the opposite one After accomplishing the alignment of the two images gently tighten the three socket head cap screws on the prism bracket Watch the video image as the screws are tightened to ensure that t
45. utton in the Main Screen It is also automatically opened by the software during the alignment stage The camera image is seen in the panel on the right only if the system is equipped with a PC based frame grabber as an option to the standard LCD monitor Camera View Current 7 Position Save Image Click Continue when finshed or Cancel to abort cycle Continue Cancel Figure 3 Camera View Screen The Camera View Screen has the following elements Current Z Position Jog Z Axis Simply displays the current position of the Z Axis The Up and Down buttons can be used to jog the Z Axis while viewing the camera image 46 Save Image Clicking this button will capture the camera view to a JPG file The file is named capture jpg and is stored in the application directory Frame grabber equipped systems only Continue amp Cancel Both of these buttons will close the Camera View window When running a recipe clicking the Continue button will inform the software that you are finished with alignment and that it can proceed with the rest of the cycle The Cancel button is used for telling the software to end the cycle prematurely Z Axis Jog Panel Figure 4 Clicking the Manual Control button on the Main Screen will show this panel On systems equipped with an automatic motorized Z axis this panel allows manual motion of the heater head Z height for setting the values in the
46. zle into the machine and align with the target component 5 Select Teach and either Install or Remove from the main control screen Fig 1 Itis recommended to teach recipes in Install mode since you can see the effect of the cooling and the teach thermocouple remain in place at the end of the run making it easier to make adjustments to the recipe heating profile 6 Run the recipe using the Start button The system will keep track of the time required to reach the target temperatures programmed into the recipe The picture below illustrates the machine operating in Teach Mode 7 If satisfied with the results save the recipe after teaching If you want to make adjustments to slow down or speed up heating etc Edit the recipe parameters cool the board down and re teach the recipe 8 When a recipe has been successfully taught and saved it can be run in Run Mode without thermocouples Run Mode will use the Preheat Soak and Reflow times learned in Teach Mode 50 Gi Rework HMI DER Total Time Elapsed File Name sample Current Stage Time Description Sample A Fart Target Temp E Heater Setpoint x soak Time Above Reflow Manual Contro HAKO aay Thermocouples C M inputs M Z Axis Ppa 2 RY Pos tor 17558 Board i05 iw Top Heater 303 kel NEST OUT Home spare is2_ E BUSY ha Thermocouples PE tn P
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