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Air-Vac DRS25 manual 1.00

1. Probe 100 m ELM Cool Air Video Jog Be ae Bel Device Nozzle Separation Site Cleaning System Actual Sensor Auto Adj Z Pos Vacuum Clear Sensor Range 000 Adj Pulse 000 000 Clogged 000 Vacuum 000 1 1 Force Placement System Actual Dest Range ono l Zero Force DE Bel Vacuum Sensor Stop Force Placement Auto Adjust M Display Only Lower Heating System L Temp M Temp C R Temp Fon Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 Flow Off C Low Flow High Flow Action C Disable Standard Replace C Add C Subtract Data If ERROR Stop Process DRS25 User Manual 0025 00 901 5 9 Section 5 Software Overview 5 2 2 Open The Open option is used to load an existing profile from a library Selecting the Open option will display the Open Profile screen Three group categories are available to organize profiles into common or related processes e Customer e Board e Device New groups can be easily added to expand the profile library organization The profile list can be adjusted by changing the group selection combination Clicking on the down arrow of a group list box will display a window with all the available options for that group Use the scroll bar to view any additional entries beyond thos
2. DRS25 User Manual 0025 00 901 Section 5 Software Overview Force System The force system when combined with Z axis motion can be used to develop a close loop component placement removal event Teach LED Adjustment Build Photo Links Vision and Nozzle System Pos lnc Pos Rate 96 Temp C C Sec Dest 00 000 Dest 00 000 0 000 Be V 4 Replay Thermal Sequence 5 Z Move ABS C Air C mm 0 g ZMove REL N C Do Not Move Nitrogen inch A Time E Motion BE 2 Power Event Velocity Accel Velocity Vision Lights M Noz Vac Bi Probe 000 C Foot 6 Time 100 100 100 I Cool Air Video Bl BI Eu ES Device Nozzle Separation Miscellaneous Control Site Cleaning System B Alert Actual Sensor L7 Ato Adj Z Pos Pulses Solder Reflow 183 C Ginsor ange ED MM BRE c JR C Thermocouple System Force Placement System Actual Dest Range jam 0000 00 0000 00 0010 00 Rate 4 000 Zero Force Tia LU E Vacuum Sensor Stop Tis D Force Placement M Auto Adjust Display Removal System E Vacuum Retry M Actual Sensor Sensor Threshold 000 t Oe DE Counter 000 Time 000 Temp Incr 000 Action C Disable Standard Replace o Add C Subtract Data C If ERROR Stop Pr
3. Ss N 5 5 lt Yes NS un met A SEIEN 5 EC OW p Event 11 component drop off There is no operator involvement during this event The nozzle vacuum will be on the hold the component The component unload load platform will automatically extend The nozzle will move down to just above the component unload load tray The nozzle vacuum will be automatically be turned off Note Ifthe component hits to component unload load platform to hard advise programmer to correct Damage may occur to machine and or component Note A Universal unload load tray or custom component load unload may be inserted on the component unload load platform DRS25 User Manual 0025 00 901 7 16 Section 7 Operator Training Event 1112 There is operator involvement during this event The nozzle vacuum will be turned off and low pressure air will be applied to insure the component drops Event 13 Remove BGA This is a timed event 5 seconds The operator is to remove the BGA Note The event may be changed to allow more time for the
4. Nozzle Load Function Power B DRS25 User Manual 0025 00 901 4 13 Section 4 Machine Function Verifications 4 5 1 Install Vision Test Board Purpose To prompt the operator to install the vision test board with the QFP160 site 4 5 2 Place QFP into Loading Tray with Vacuum Probe Purpose To prompt the operator to place the QFP160 into loading tray e The load tray will project forward and the probe vacuum will be activated Use the probe with finger on hole to pick up the QFP160 e Place component into the QFP160 insertion tool on the loading tray e Release finger to release component the QFP160 is loaded into the pick up tray depress the footswitch until the yellow footswitch indicator on the run screen goes off 4 5 3 Automatic Component Pick up Purpose To allow the system to pick up the QFP160 No operator involvement is required The vision system will partially retract and the nozzle will descend to the component pick up position The nozzle vacuum will activate and the component will be picked up automatically 4 5 4 Verify Proper Pick Up Purpose To allow the operator to verify that the component has been picked up properly If the device is skewed in the nozzle after automatic pick up manually deactivate the nozzle vacuum reseat the device and reactivate the vacuum DRS25 User Manual 0025 00 901 4 14 4 5 5 Section 4 Machine Function Verif
5. 7 5 LEA al a H E 1 stort A ME UR mm BGA Removal 25profilenotesremoval b qaam 2 27PM When entering the Run screen the software will perform two automatic initialization routines The system will display the following messages e Opening Motion And Temperature Comm Link e Opening Thermocouple Comm Link The Cycle Start Stop button is used to activate or terminate the process cycle This button will display a green background when the cycle is active or a gray background when the cycle is not active Clicking on this button when the background is green will terminate the cycle Note During the cycle the operator may be prompted to press the foot switch before any processing can continue Some events are designed to allow the operator to perform a manual task final component alignment DRS25 User Manual 0025 00 901 5 50 Section 5 Software Overview Alarm Screen Control The DRS24 constantly monitors the controlling sub systems If any sub system fails due to a process or hardware issue the system will respond with the following Alarm screen This screen displays the last process hardware failure that occurred Alarm Control i Maximum Time Process Cycle History 1 Motion Communication Link Hun Graph History Force Communication Link Hun Export History Temp Communication Link Temperature Limits Cycle Counter 1 Flow Sensor Low Memory g Low Pressure Proc
6. C Cooling Ring Rate 000 Stop Be Force Placement Auto Adjust Display Only Lower Heating System L Temp C M Temp C R Temp Fon Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 Flow Off C Low Flow High Flow Action C Disable Standard Replace o Add C Subtract Data C If ERROR Stop Process DRS25 User Manual 0025 00 901 5 41 Section 5 Software Overview Thermocouple System The Thermocouple system allows the operator to program process control thermocouples K type maximum of 8 This system provides the operator with several control options Monitor Skip Stop and Maintain These control options can be used in a variety of ways to monitor control or thermal profile applications Thermocouple control options can be changed from event to event Process Control Options Monitor B This control option monitors a thermocouple channel during the process cycle Skip C This control option monitors a thermocouple channel during the process cycle In addition this control option requires a target temperature A to be programmed This target temperature is used to trigger an event change Target temperatures can be defined as increasing heating cycle or decreasing cool down cycle Stop D This control option monitors a thermocouple channel
7. DRS25 User Manual 0025 00 901 5 25 Section 5 Software Overview 5 3 1 Teach Process Events Selecting the Teach Process Events option from the Controls menu will present the operator with the Teach screen The Teach screen allows profile control parameters to be quickly and easily adjusted A control profile is developed by combining together simple events to create a complex motion and control sequence Events can have any combination of 1 motion 2 device control or 3 time Events can be added or deleted based on the application s processing requirements Teach LED Adjustment Build Photo Links Vision and Nozzle System Pos Pos Rate Temp C C I Sec Dest 00 000 Dest 00 000 080 en 000 Thermal Sequence Z Move ABS Air C mm C Z Move REL C Do Not Move Nitrogen inch SEIEN Key DT Vision Lights Noz T Probe 100 100 Cool Air Video Bi Jog me Device Nozzle Separation Site Cleaning System Actial Sensor Auto Adj 2 Vacuum Clear Sensor Range 000 Adj Pulse 000 000 Clogged 000 000 E Force Placement System Actual Dest Range 5 0000 00 0000 00 0010 007 mi EX EX EX EN Vacuum Sensor Stop Force Placement Auto Adjust M Display Only zo u t N Time sec F Motion 7 Z Power Events
8. Low memory e Process Thermocouple e Force removal e Temperature limits e Flow sensor e Low Pressure e No activity Time out e Force placement Computer must be rebooted to clear The various alarms are explained in further detail in the Software section DRS25 User Manual 0025 00 901 Section 8 Safety DRS25 User Manual 0025 00 901 8 8 Table Of Contents 9 Schematics List of schematic sheets DRS24NC 60 pin Ribbon Cable DRS24NC 30 pin Ribbon Cable DRS24NC 20 pin T C Ribbon Cable 16 DRS24NC 20 T C Ribbon Cable 20 DRS24NC 20 T C Ribbon Cable 52 DRS25 DRS25 DRS25 DRS25 DRS25 DRS25 DRS25 DRS25 DRS25 ochematic Package Controls Power Distribution Heater Controls Vision Upper Casting Force Motor LED FireBlox 1 FireBlox 2 Pneumatics Heater Control T C Cable DRS24NC Vision LED Assembly detail DRS25 User Manual 0025 00 901 Number 0024 90 136 0024 90 137 0024 90 138 0024 90 139 0024 90 140 0025 00 910 0025 00 911 0025 00 912 0025 00 913 0025 00 914 0025 00 915 0025 00 916 0025 00 917 0025 00 918 0024 90 933 gt gt gt gt gt gt gt gt gt gt gt gt gt gt lt Section 9 Schematics Section 9 Schematics DRS25 User Manual 0025 00 901 9 2 Section 10 Maintenance Table Of Contents 10 Maintenance 3 10 0 Preventative Maintenance Checklist amp Schedule 3 10 1 Nozzle Clamp Repair 12 10 2 Y Axis Bearing Adjustme
9. Use the X Y table to align the pads of the board to the leads of the QFP Each lead should be centered on each pad e Align the top row A of leads and then the left row B of leads e Once the top and left side has been aligned examine the opposite sides bottom C and right D If sides C and D are mis aligned theta adjustment is required A B Fig 1 D EUI In figure 1 sides A and B are aligned but sides C and D are not This is an indication of theta error e Use the Theta Adjustment knob to make a 50 correction then finalize the alignment with the X Y table Note Do not make a 100 correction of sides C and D with theta as this will simply transfer the theta error to All four sides are now aligned e Once all four sides are aligned as shown in figure 2 increase the zoom lens magnification to check your work Viewing a few leads under high magnification may reveal minor errors not seen while aligning the entire device sides A and B EUI e Lock the X Y table once the alignment is complete Depress the footswitch until the yellow footswitch indicator goes off DRS25 User Manual 0025 00 901 4 16 4 5 8 Section 4 Machine Function Verifications Check Alignment at Board Level The vision system will retract and the component will be lowered until it is approximately 025 above the pads During an actual process the heaters would be activated so
10. o0 C Foot Time D o El Alert DE Miscellaneous Control RSS Pulses Solder Reflow 183 Thermocouple System Action C Disable Standard Replace o Add Subtract Data C If ERROR Stop Process Lower Heating System L Temp C R Temp c ooo Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 Flow Off C Low Flow C High Flow Teach Screen Button Summary Teach Event The Teach event button is used to temporarily save any current event adjustments Insert Event 4 Insert event button allows the operator to temporarily add a new event in between two existing events The inserted event will be an exact copy of the current event The inserted event will be added ahead of the current event Delete Event Ls The Delete event button is used to temporarily remove the current event DRS25 User Manual 0025 00 901 5 26 Section 5 Software Overview Table Editor The Table Editor button allows the operator to adjust all control parameters using a tabular form This button will present the operator with a popup menu This menu will allow the operator to quickly position the table editor to the correct control column The Cycle button is used to stop any motion that may occur during the teaching process Moti
11. 000 Vacuum 000 21 Force Placement System Actual Dest Range v 9000 00 0000 00 0010 00 Zero Force Be Be Vacuum Sensor Stop Force Placement T Auto Adjust Display Only Lower Heating System L Temp C M Temp C R Temp From Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 Del Fe oe Flow Off Low Flow High Flow Action C Disable tandard Replace o Add C Subtract Data C If ERROR St p Process DRS25 User Manual 0025 00 901 5 42 Section 5 Software Overview Thermocouple Action Radio Buttons The Teach screen provides the operator with the ability to quickly adjust or repeat an edit operation the information contained in the thermocouple control table e This be accomplished by first entering the desired information into the Data edit box Note Note Next the operator must select the required Action A radio button Replace Add Subtract The Add button uses the Data edit box value to increase the selected table field The Subtract button uses the Data edit box value to decrease the selected table field The Replace button uses the Data edit box value to overwrite the selected table field The operator has the option of typing directly into a table field This is accomplished by clicking on the desired table field with the left button
12. C Disable Standard Replace o Add Subtract Data C If ERROR Stop Process DRS25 User Manual 0025 00 901 5 39 Vision Lights and Video Check Box Section 5 Software Overview The Vision Lights check box A allows the operator to activate the vision system s fiber optic lighting These lights are required for the component alignment procedure Programming this check box checked will activate the fiber optic lighting for the current event Run screen A clear check box will deactivate the fiber optic lighting for the current event Run screen The Video check box B allows the operator to activate the live video camera system This video system can be used to display images on the computer monitor Programming this check box checked will activate the video system for the current event Run screen A clear check box will deactivate the video system for the current event Run screen Teach LED Adjustment Build Photo Links Vision and Nozzle System Pos DELE Dest 00 000 Dest 00 000 z29 0 lt Velocity 9 Accel Velocity 26 19 fm Time sec Motion 7 Z Power Events EUN orm 7 DE ne ge Fe DE N Rate C Sec a Foo Replay Thermal Sequence Z Move ABS Air C mm C Z Move REL C Do Not Move Nitrogen inch vi CoofAir Device Nozzle epa
13. Installation Steps 1 Install Camera Camera Bracket A to Mount B on side of microscope camera trolley with screw C provided 2 Install Camera Cable E into camera DRS25 User Manual 0025 00 901 3 10 Section 3 Machine Overview Set Up amp Installation 3 3 8 IR Sensor Installation Sensor option is installed by Air Vac prior to shipment No installation is required Install the Thermocouple Plug on the IR Sensor into thermocouple channel 1 DRS25 User Manual 0025 00 901 3 11 Section 3 Machine Overview Set Up amp Installation 3 3 9 Fume Extraction Manifold Installation Installation Steps 1 Remove tape from Hook amp Loop Velcro on underside of Fume Extractor Box A 2 Set Fume Extractor Box A on top of the DRS25 at location B Press firmly in place 3 Connect a hose C to the rear of the Fume Manifold 4 Connect other end of the hose to central exhaust or other collection system pn cu MM A DRS25 User Manual 0025 00 901 Section 3 Machine Overview Set Up amp Installation 3 3 10 Site Solder Removal System Installation e Vacuum Jar assembly A mounts to side of module Installation Steps 1 Attach silicone tubing B from Vacuum Jar to Site Clean Fitting C on rear of module 2 Connect other piece silicone tubing from Site Cleaning Nozzle D to other end of Vacuum Jar E 3 The Site Cleaning Nozzle installs in
14. Numer cal Process Information Nozzle System 40 70 Set Point 200 D C Preheater System The Preheater System graphically displays as shown below Preheat System set Point Set Point Set Point Actual Actual Actual DRS25 User Manual 0025 00 901 Section 5 Software Overview Thermocouple System The Thermocouple System has maximum of eight thermocouple Section 5 Software Overview channels Only pre programmed active channels will be displayed Each channel will display an actual and a set point temperature Each thermocouple channel has an identification number positioned between the set point and actual displays When a thermocouple channel is controlling the process the T C Control A LED will change to yellow mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Nozze System 50 60 10 Preheat System Thermocouple System Set Point Set Point Set Point Actual Nozzle Set Point Actual Date 09 26 2005 14 27 Temperature vs Time 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 Temperature 0 00 00 00 48 01 36 Hamel Profile Time 02 24 0312 04 00 04 48 05 36 06 24 2 02 12 Event Time Bas stc c B mm BGA Removal S 25profilenotesremoval b Note Started Failure to do so will result in an a
15. ii Data Auto Scale Graph Load Process Link File View Photo Links Export History Nozze System Preheat System Thermocouple System 50 60 40 70 30 80 20 90 Set Point Set Point Set Point u ofofo 0 Actual Actual Actual Nozzle 6 A Idle Set Point Actual Ramp Load Function Jog Functions Machine Cooling Force System System Status 375 500 625 pa Em A EN Eu N2 FootSw OS 0 0 1000 Cycle Busy Alarm e0 Cooling Ring Grams n Click On The Cycle Start Button To Begin Process Date 09 26 2005 14 27 500 0 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 Temperature 04 00 0448 05 36 06 24 Time 0 00 00 00 48 01 36 0224 03 12 Temperature vs Time 07 12 T C Control 08 00 08 48 09 36 10 24 11 12 12 00 Z Power Event Time Profile Time t UR mm BGA Removal M 25profilenotesremoval b a Nozzle System A The Nozzle System upper heater graphically displays the following control parameters e Nozzle flow rate percentage set point A yellow needle e Nozzle flow rate actual percentage B blue needle B e Nozzle target temperature set point C white number e Nozzle actual temperature D red number e Nozzle temperature ramp set point ramp E red number DRS25 User Manual 0025 00 901 HS mi i Board T T 2 27 Pm
16. 00 000 Dest zo Ou Event Control Time Moti Per Events Velocity Accel 6 Velocity 26 BT are 100 A DE gi a IET Solder Refl older Reflow 18300 Action C Disable Standard Replace C Add Subtract Data IF ERROR Stop Process el Be Oo DE Zero Force Vacuum Sensor Stop Force Placement Auto Adjust Display Only Lower Heating System t XxX x N Site Cleaning System Actual Sensor Sensor Range 000 Adj Pulse 000 000 Clogged 000 Vacuum 000 21 Force Placement System Actual s 0000 00 9000 007 10100 ae L Temp C M Temp C R Temp Fon Flow Off C Low Flow High Flow Rate Temp C 000 000 000 Replay Thermal Sequence Z Move ABS Air C mm C Z Move REL C Do Not Move Nitrogen inch Vision Lights Noz Probe Cool Air Video RI Jog Device Nozzle Separation Auto Adj Z Pos Vacuum Clear Dest Range Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 Jog Check Box B The Jog check box B controls the maximum axis Z and Vision velocity that is used when the jog buttons C are pressed The following three velocity set points can be selected
17. 2 lt Ca 2 4 a ae AT 4 J LJ 4 QW n 1 P D Rotate the nozzle ring counter clockwise to open nozzle fingers The nozzle part number is engraved on the side of the nozzle For BGA s the nozzle part number will have EZ on it Install the nozzle relatively square in the nozzle fingers Rotate the nozzle ring clockwise to close the nozzle fingers Note The nozzle fingers may be hot during operation Do not touch nozzle fingers Note The nozzle may be hot during operation Use the nozzle pliers supplied to install and remove the nozzle DRS25 User Manual 0025 00 901 Section 7 Operator Training 7 1 6 Install Board zm is Board Rails A adjust to board width Note Optional board carrier extensions are available in 24 amp 30 widths for wider boards The standard width is 18 e Center board rails to allow the board to be centered over the diffuser e Hint lt may be beneficial to have the smaller side of the board positioned left and right to provide maximum holding stiffness e Hint It may be beneficial to allow left side area for the Temperature Sensor IR probe to be positioned without interference from the vision system extended e Loosen the Carrier Lock Knobs left and right to allow the carrier arms to adjust to the board width Tighten the carrier lock knobs to secure the board e Hint Tighten on carrier board rail lock knob to secure one side whil
18. e Supply clean compressed air or nitrogen Do not allow the lines to be changed by unauthorized personnel WARNING Unfiltered air can result in the following problems premature heater failure contaminated flow meter vacuum pump and moisture exhaust in electrical compartment Unregulated air will shut off solenoid too high pressure or will not allow heater to activate too low Air requirement 85 120 psi 20 scfm clean dry compressed air or inert gas e Change the nozzle with the GNT1 or GNT4 tools only DO NOT GRAB at the bottom of the nozzle as it will damage the gas nozzle opening e Store nozzles in tray Do not drop nozzles e Donotforce the SMD into nozzle Damage will occur to the nozzle nest PCB or component e Donotapply excessive flux Consider fume extraction system e Remove the arrows from repair components They stick to the inside of the nozzle e Donotclean nozzle in cleaning solution or degreaser with vacuum cup still installed Do not run the process without a vacuum cup Change cups after long exposure to heat and flux e Transport the unit holding the base Do not lift unit by the board carrier or microscope DRS25 User Manual 0025 00 901 10 11 10 1 Section 10 Maintenance Nozzle Clamp Repair Disconnect power Remove nozzle assembly heat shield and heater head cap Check for keyway in heating element and heater cap gasket Two spanner wrenches with 2 5mm pins are necessary to unscrew heater
19. range adjustment throughout process 600 800 Mhz Pentium 32MB Windows 2000 v2 Yes Yes 17 Monitor keyboard and optical trackball English German Spanish and French 2 8 Thermal Profiling Thermocouple Channels Profile Tutor Software IR Temperature Probe 2 9 Heating Systems Top Heater Preheater IR based Section 2 Facility Requirements Technical Specifications 8 high speed K type thermocouple channels for profiling and process analysis Self calibrating Resolution of 0 15 degrees C res bit Automatic thermal profiling software with profile build function Optional feature for monitoring top side board temperature Non contact articulating arm 3 degrees C 1000 watt triple pass preheats incoming air heating element with imbedded thermocouple for process temperature control DRS25 25T 16 x16 2 zone 5000 watts DRS25XL 25XLT 16 x24 zone 7000 watts 2 10 Automatic Flow Adjustment Mass Flow Controller 2 11 Alignment System LTP Beamsplitter Vision 2 12 Illumination Green White LED s 2 13 Microscope Optics Stereo Microscope DRS25 User Manual 0025 00 901 Programmable software control for nozzle heat output From 0 4 to 3 0 scfm seamless adjustment Accuracy and linearity 1 F S repeatability typ 0 196 of full scale Patented alignment system for simultaneously viewing the component leads while super imposing the PCB p
20. L will exit the Graph Data screen and return the operator to the Run screen DRS25 User Manual 0025 00 901 5 69 Section 5 Software Overview Notepad The Notepad Options will load the File dat which is the index file from the export directory This file contains a listing of the long file name and the corresponding numeric dos file name of the exported data from the run screen Print Options This Print Options menu allows the operator to setup or print several reports based on the currently loaded graph data set Graph Page Printer Setup This option allows the operator to define several print related options In general the operator should match the options listed below Print Parameters Graph Window Background Upper Left Corner Plotting Area Background Border Iv Maintain Aspect Ratio Printing style Print graphs to max size Proportionate C Exact Size Cancel Print Graph Page This option allows the operator to print the Temperature vs Time plot for the currently loaded graph data set This report will be identical to the current screen display DRS25 User Manual 0025 00 901 5 70 Section 5 Software Overview Run Data Point Detail Report This option allows the operator to print the graph data set detail This report will be organized by seconds and will list all the data points that were used to produce the current Import screen display Note Selecting Print from the Fil
21. Section 5 Software Overview 5 4 History Menu The History menu has two options Cycle and Alarm Both options will activate the Windows WordPad tool and load the appropriate file To print a file select the File menu and click on the Print option To return to the Run screen select the File menu and click on the Close option 5 4 1 Cycle History A History file entry is recorded each time the operator cycles a process profile Note To activate this data logging feature the operator must activate this option from the General Setup option This file captures the following fields Field 1 The time of day the cycle was run Field2 The date the cycle was run Field 3 The board serial number Field 4 The operator who ran the cycle Field 5 The board description from the Profile Notes page Field 6 The profile s Long File name Field 7 The profile s Short Name B Lgs his W ordPad Ox 3 opel 22 14 09 30 97 pRS32 UNTITL D DRS A 22 15 09 3n 957 pRS f4 UNTITLED DRZ z231 09 40 97 DR at C UNTIT D DRS 22 33 09 30 97 f pR324 fJ UNTITHED DRS 22 35 09 3n 97 l nR za P UNTITLED DRZ 22 38 09 30 97 DRS24 f qfp160 aining removal profile 00000002 DRS 22 40 09 30 97 DRS24 qfp160 training removal profile 00000002 DRS Depan Ga l y l DRS dqfipi5n training removal profile 00000002 puis E o M tr
22. The variables on this page are used to control and adjust the speed that a DRS24B will process information and manage the windows resources The temperature and thermocouple offset technology requires tuning on each individual machine See calibration procedure for complete detail 5 9 3 Limits and Defaults New groups cannot be added to the list of available groups from this screen The Default Groups can be changed in this option only To change the default groups the operator must click on the down arrow A to the right of the groups edit box This will expand the edit box B to display all of the available groups After making a selection the list box collapses back down to one line The new group will be displayed in the edit box Click on the Thumbs Up C to save the changes and exit or click on the Thumbs Down D to discard the changes and exit the Limits and Defaults screen Video Screen E Users can now define the location of the live video window Screen position co ordinates can be entered Be sure to position the window so that the full video image can be displayed These co ordinates represent the upper left corner of the window Setting both values to zero will force the default centered window position DRS25 User Manual 0025 00 901 5 87 Section 5 Software Overview 5 9 4 Nozzle Flow Adjustment The Nozzle Air Flow is calibrated by adjusting the offset parameters These offsets are set at each air flow and c
23. en Rate 26 Temp C C Dest 00 000 Dest 00 000 ae un 000 Replay Thermal Sequence Z Move ABS Air C mm C Z Move REL C Do Not Move Nitrogen inch z9 0 lt s a x gt N Event Control Time Si Motion Events Velocity Accel Velocity Vision Li ghts Noz Vac Probe 1 0 nicis 000 C Foot Time 180 n zen F Cool Air Video Jog Alert E3 Ea Device Nozzle Separation Miscellaneous Control SR Pulses Solder Reflow 18300 Force Placement System Actual Dest Range Jed fe ooo o0v0 00 Zero Force Be Be Vacuum Sensor Stop Force Placement Auto Adjust Display Only Site Cleaning System Actual Sensor Auto Adj Z Pos Vacuum Clear Sensor Range 000 Adj Pulse 000 Clogged 000 Vacuum 9 000 Cooling Ring Rate BT Lower Heating System Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 L Temp R Temp 000 000 000 de C Disable Standard Replace o Add C Subtract Data If ERROR Stop Proces Flow Off C Low Flow C High Flow 1 C B DRS25 User Manual 0025 00 901 5 38 Section 5 Software Overview Probe Vacuum Check Box The Prob
24. highlight table field The operator can then press the enter key to enable the table field edit mode At this point the operator can use the standard keyboard to adjust the table field information Teach LED Adjustment Build Photo Links Vision and Nozzle System Pos pm Pos Rate 26 C Dest 00 000 Dest 00 000 ds en 000 Replay Thermal Sequence Z Move ABS Air C mm C Z Move REL C Do Not Move Nitrogen inch lt gt Event Control Time Motion Z Power Events Velocity 26 Accel Velocity 26 I Vision Li ghts Noz Vac Probe 1 0 SUUM 000 C Foot Time aog ius F Cool Air Video n Jog Bel Alert Bie Bei ae Device Nozzle Separation Miscellaneous Control Pulses Solder Reflow 183 Thermocouple System Site Cleaning System Actual Sensor Auto Adj Z Pos Vacuum Clear Sensor Range 000 Adj Pulse 000 ooo Clogged 000 Vacuum 000 21 Force Placement System Actual Dest Range 5 9000 00 0000 00 0010 07 Zero Force Vacuum Sensor Stop Force Placement Auto Adjust Display Only Lower Heating System 1 M Temp C R Temp Fon Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr
25. lemory 500 625 Set Point Set Point Set Point Actual Idle EN Date 09 26 2005 14 27 Temperature vs Time Control Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Time Z Power 9 Em i Site Clean Vac Common Icon Controls Cycle Start Stop Starts the program Repressing the Start Stop icon will stop the program The program will default back to the start of the program Thumbs Up Exits the Run screen to the Main screen Application Notes Allows the operator to review profile notes prior to running the program It may be useful to open when a linked profile is opened Z Power Z Power Check Box Allows the operator to depower or power z axis LED Adjustment LED Adjustment Allows operator to change the lighting of the component leads and or board pads When selected the LED Intensity Adjustment screen is opened Adjust Top LED to control component lead contrast Close Top Adjust Bottom LED to control board contrast p Bottom pen BH B DRS25 User Manual 0025 00 901 7 33 Section 7 Operator Training Secondary Icon Controls Zero Force System Re Sets force reading of carrier to zero Independent of weight on board Display will indicate zero force Force system i 315 zul 625 Probe Vacuum On off vacuum for vacuum probe port Nozzle Vacuum On
26. parts handling probe vacuum will activate Use the probe to return the device to its shipping container Use care to avoid damaging the leads e This completes the initial operator training overview Additional operator training by a trained individual is required prior to running actual process profiles A mm BGA Remove t 60980001 DRS LED Adjustment ae Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Mafhine Cooling Nozze System Preheat System Thermocouple System Force Syste System Status Memory 50 60 315 500 625 750 EN ES Set Point Set Point Set Point 2 FootSw Air EN EN Actual Actual Actual 1000 U BEE 9 Cooling Ring Set Point Actual Idle Idle Idle ER ER EI nnn T Cycle Busy Alarm Date 09 26 2005 14 27 Temperature vs Time 450 0 400 0 350 0 300 0 Control 250 0 200 0 150 0 100 0 50 0 Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Time Event Time Profile Time Z Power Board it A RM Mstart amp B mm BGA Removal Wr 2Sprofilenotesremoval b d anc 2 27 PM DRS25 User Manual 0025 00 901 4 18 Section 5 Software Overview Table Of Contents 9 SOWIE OVERVIEW 3 5 1 Windows Tools OYerVieW a nee nennen nie 3 3 2 Options
27. source 74 NPT Operating Notes IMPORTANT Electrical e This system is designed to operate on 220 VAC e Under full load conditions power must not drop below 208 VAC Full load is defined as DRS25 fully operating plus all other equipment down the line fully operating If 208 VAC is not met a buck up transformer or another line must be connected Under general conditions expect incoming line voltage to drop approximately 3 10 volts e Under no load conditions power must not exceed 240 VAC No load is defined as DRS25 off and all other equipment down the line turned off Air Nitrogen e With top heater and accessories operating at 100 flow system consumes up to 18 scfm 80 psi With all systems activated 70 psi must be maintained Requires both gas lines be direct plumbed no quick disconnect e These requirements must be addressed prior to the Air Vac installation and training visit This will assure that you receive a productive training program within the scheduled visit time Physical e Machine Operating Dimensions W x D x H 60 x 40 x 36 e Machine Weight 275 lbs e Monitor Dimension W x D x H 16 x17 x17 e Monitor Weight 53 Ibs e Operator Viewing Height from module base 21 24 adjustable height chair recommended DRS25 User Manual 0025 00 901 2 3 Section 2 Facility Requirements Technical Specifications 2 1 Component Requirements Beamsplitter Vision System Direct View perimeter Top a
28. 000 Action C Disable Standard Replace o Add C Subtract Data C If ERROR Stop Process Flow Off C Low Flow High Flow 4 A B DRS25 User Manual 0025 00 901 These Action adjustments can be quickly applied by positioning the cursor over the desired table field and clicking on the right mouse button Section 5 Software Overview Global Thermocouple Control The global thermocouple control radio buttons C are used to define the state of the thermocouple control system for a specific profile all events e Standard This button allows the operator to enable the thermocouple control system Specific thermocouple control actions will be processed Disable This button allows the operator to disable the thermocouple control system Specific thermocouple control actions will not be processed Note Profiles are typically developed using several control thermocouples In many cases these control thermocouples are not required during the production Run cycle This button allows the thermocouple system to be quickly disabled without making any adjustments to the individual event control parameters e If ERROR Stop Process This button will terminate the Run cycle if a thermocouple control condition Skip or Stop fails A typical example might be the failure of the board to reach a target temperature Note If the process is terminated an alarm history entry
29. 2 12 2 13 Electrical Pneumatic Physical Component Requirements Component Positioning Adjustments Internal Vacuum System Accuracy and Repeatability Force Measurement System Computer System Voice Commands Thermal Profiling Heating Systems Automatic Flow Adjustment Alignment System Illumination Microscope Optics DRS25 User Manual 0025 00 901 Section 2 Facility Requirements Technical Specifications Uu a a A A WH C Section 2 Facility Requirements Technical Specifications DRS25 User Manual 0025 00 901 2 2 Section 2 Facility Requirements Technical Specifications 2 Facility Requirements Technical Specifications 2 0 Electrical Pneumatic Physical Electrical also see Operating Notes e Machine Power 220 VAC 5 50 60 Hz single phase 6 3K VA 21A DRS25 25T 28A DRS25XL 25XLT Nema L6 30P 30 amps 2 pole 3 wire supplied For 25T amp XLT IP20 50A 250V HBL 8265C or equivalent supplied e Power 220VAC 50 60Hz 2 amp power from DRS e Monitor Power 220VAC 50 60Hz 1 amp power from DRS e Camera Power FireWire Camera powered from FireWire PC card e Speaker Power 120VAC power cube 60 Hz 125 ma Air Nitrogen also see Operating Notes Compressed Air 90 130 psi 3 scfm and up to 18 scfm intermitent clean dry air non condensing source 1 4 NPT with 3 8 hose diameter supplied Direct plumb e Nitrogen optional 0 80 psi clean dry non condensing
30. 375 625 250 125 0 1000 Cycle Busy Alarm Cooling Ring n Grams Temperature vs Time T C Control 04 48 05 36 06 24 Time Z Power 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Indicates the amount of free memory available to the software Indicates that the pneumatic connection to upper heater is being used for the upper heater Indicates event is in a footswitch mode and footswitch response is required to continue Indicates that the pneumatic connection to the diffuser is being used for the upper heater Indicates the process has been activated Indicates that the computer is actively controlling functions Indicates the status of the controlling sub systems A red LED means an alarm condition Event Timelndicates the time of the current event Profile Time Indicates the total time of the program at that point Board Indicates the board serial number as input by bar code option or manually Event of Indicates the current event number and total number of events Open Box Displays status of thermal smart track profile Option The Run screen can be simplified if desired The Nozzle Diffuser and Thermocouple system displays can be removed from the Run screen Option The camera view live video window can be repositioned on the Run screen Contact supervisor DRS25 User Manual 0025 00 901 Section 7 Operator Training 7 1 9 Alarm Screen When the system senses an un
31. Air Vac Engineering Services under warranty shall not affect an extension of the warranty period nor will a new warranty period be granted for the parts which were replaced repaired The title of the replaced parts will automatically pass to Air Vac Air Vac reserves the right to reject replacement under this warranty where in the sole opinion of Air Vac the defect is due to obvious misuse and or improper maintenance of the module or any part thereof The express and or implied warranty of Air Vac is limited to the replacement and or repair of any item defective in material and or workmanship Other damages if any direct or consequential are expressly excluded from this warranty Air Vac shall be liable under this warranty only if 1 Air Vac receives notice during the appropriate warranty period 90 days or 1 year as applicable 2 The products are operated in accordance with the supplied documentation and 3 Such products are to Air Vac s satisfaction determined to be defective When contacting Air Vac for warranty inquiries please provide the following information Order number which the parts were shipped Model and serial number of the product Reason for warranty Products cannot be returned to Air Vac without authorization please call for an RMA Heater Limited Life Warranty Air Vac Engineering Company warrants the heaters for a period of ninety 90 days from date of shipment Air Vac agrees to repair or replace any or
32. Air Vac has tested and approved the Omega Simulator Model CL23A for use in the calibration procedure The simulator must be set for a mean temperature of each range when adjusting the set point Calibration of the ranges below 25 and above 480 C is not practical and is not recommended See calibration procedure for complete detail DR524 TC Range Adjustments Hillivolt Set Points 0 10degc 35 11 20 deg c 116 2 25 deg c 230 26 30 deg c 320 31 40 deg c 360 41 50 deg c 460 51 60 deg 5 0 61 80 deg c 81 100 deg c 470 101 120 deg c 1155 121 140 deg c 1355 141 150 deg c 1550 161 180 deg c 1760 181 200 deg c 1930 201 220 deg c 2140 REPE DRS25 User Manual 0025 00 901 221 240 deg c 241 260 deg c 261 260 deg c 281 300 deg c 301 320 deg c 321 340 deg c 341 360 deg c 361 360 deg c 381 400 deg c AU1 420 deg c 421 440 deg c 441 460 deg c 461 460 deg c 461 500 deg c DI La DI DI Zu L2 L2 na j c en uu c Zn 1 a L2 En ra Zu En En En Section 5 Software Overview 5 9 7 Temperature Controllers Screen The Temperature Controllers Screen was intended as a means to manually control the upper and lower heater and airflow This screen should not be used as manual controls for process work because there is no maximum time limit for
33. System Status 50 60 Memory m a grams ER 90 Set Point N2 Foot Sw Air 110 Nozzle o Set Point Actual Ramp ER EX EX Em Click On The Cycle Start Button To Begin Process Graph Process Information Date 04 01 98 08 15 Temperature vs Time 500 0 450 0 400 0 350 0 200 0 T C Control 250 0 200 0 150 0 100 0 50 0 Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Time Event Time Profile Time 1 Iv Power DRS25 User Manual 0025 00 901 5 12 Section 5 Software Overview 5 2 3 Save The Save option is used to save a new profile or re save an existing profile A Name and Link Control B Short Name 7008002 DRS Link Name 2008001 DRS Soldering Desoldering C Link Name Site Cleaning D Long Name SBGA 352 063 N35EZ35EB Desoldering Group Control Customer Group Air Vac 1 99 E Board Group Profile Library 1 99 Device Group Area Arrays 1 99 Thermal Sequence Attachment Control F Long Name smart trak sbga 352 Short Name 7008001 THL e Short Name The Short Name A is used to uniquely identify the profile The Short Name is automatically generated and is composed of two separate elements The first four characters of the Short Name are taken from the DRS25 machine serial number The remaining numbers represent a sequence number This sequence nu
34. The profile s Short Name Alarm his WordPad I x osa silo PN O4 22 09 20 97 No Activity Time Out cdqfp 16 soldering 7 T C DO0O000028 DRS 05 31 09 20 97 Activity Time Out qfp 160 amp ldering 7 T C 0006000028 DR5 23 07 09 32 97 Missing Th rmocouple 7 Temp fil amp Last changes made using the TEACH screen TEMF DRS ae3 08 0895 32 97 Missing Thetmocouple 7 Temp file Last changes made using the TEACH screen TEMP DES 23 09 Missing Thermacouple 7 Wee wale else WENDE Eug Ess EINE ze cep ermocoupie Temp file Last changes made using the TEACH screen TEMP DRS 235 47 09 22 97 Low Pressure Temp file Last changes made using the TEACH screen TEMP DRS 00 53 09 24 97 Force Placement 09 26 97 Low Pressure 5 01 44 09 27 97 Motion Communication Link OFP160 Removal Training Profile 00000001 DRS 02 04 09 27 97 Motion Communication Link OFP160 Removal Training Frofile 00000001 DRS 02 35 09 27 97 Temperature Limits QFP160 Removal Training Frofile 00000001 DR5 02 55 09 27 97 Motion Communication Link OFP160 Removal Training Frofile 00000001 DR5S 22 30 Low Pressurms 23 27 09 30 97 Motion Communication Link g fp160 training removal profile OO000002 DR5 23 26 09 30 97 Motion Communication Link qfpi60 training removal profile 00
35. a EREREN Je OSS No rre System FE eit y SEI 0 J 110 Actual Actual Actual D 0 1000 Cycle Busy Alarm Nozzle 6 Force 60 Ps gt Cooling Ring 96 Set Point Actual Rami Idle Idle Idle ER ER on n n og 00 00 0048 0136 02 24 To review the Application Notes for the Site Cleaning Program select the Application Notes icon IGA Site Cleaning 60980003 DRS The O pen Profi le Note screen Control History Video Screen Utiities Reset Cycle Counter Setup Reset Operator will appear It provides information prior to running the program open io Description BGA SITE CLEANING Component Location Flux Type PASTE FLUX Nozzle SITE CLEANING NOZZLE It is important that the site cleaning Notes INSTALL BOARD nozzle be clean See Maintenance Section POSITION BOARD SUPPORTS Application Notes REFERENCE SITE CLEANING NOZZLE MUST BE CLEAN PLUG TEMPERATURE SENSOR OR THERMOCOUPLE INTO CHANNEL 1 Continue to Run Screen WWVW alr Vac erig cor Select the Cycle Start Stop icon to begin the site cleaning program Process Hints Running the site cleaning program immediately after the removal program will take advantage of the board being preheated Less time will be required to heat the assembly DRS25 User Manual 0025 00 901 7 18 Section 7 Operator Training Typical Site Cleaning Program Eve
36. applications The computer monitor will display the Operator Registration screen as shown below Log on as DRS25 and select the Thumbs Up icon system is shipped with DRS25 as the default operator e Select Thumbs Up again when prompted for the password the system is shipped with no password DRS Software System ER Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator AIR VAC 58 Operator me Lead Free Rework Repair amp Assembly DRS25 User Manual 0025 00 901 3 7 Section 3 Machine Overview Set Up amp Installation 3 3 5 Microscope Installation e Remove protective cap from Microscope Zoom Lens A e Position Microscope Eyepiece Housing B parallel to Microscope Trolley C and install e Tighten Lock Screw D B DRS25 User Manual 0025 00 901 3 8 Section 3 Machine Overview Set Up amp Installation 3 3 6 Vacuum Probe Installation e Attach silicone tubing to Fitting A provided in rear of module e Attach remaining items as shown Attach Tool Holder B to convenient operator position ie right side of right base DRS25 User Manual 0025 00 901 Section 3 Machine Overview Set Up amp Installation 3 4 Installation of Options Note Some or all of the listed options may not be purchased with the DRS25 system 3 3 Multimedia Package Installation CAUTION The machine should be powered off prior to installing this option
37. applying power to the heater If hose is not in place or secure the heater will burn out Calibration Hose NOTE Whenever heaters are changed the machine will need to be recalibrated DRS25 User Manual 0025 00 901 10 22 Section 10 Maintenance 10 1 4 Relay Replacement for DRS Models 1 Solid State Relays are located in the right side of unit power module 2 Open right box Power Module Right Box 3 Located inside are the relays Remove the protective plexi glass cover and the bad nozzle relay DRS25 User Manual 0025 00 901 10 23 Section 10 Maintenance DRS25 User Manual 0025 00 901 10 24 Section 11 Troubleshooting Table Of Contents 11 Troubleshooting 11 1 No Heat 11 2 Noor Low Flow Condition 11 3 Nozzle Does Not Pick Up Component 11 4 No Motion 11 5 Machine Alarm Conditions amp Alarm Screen BW UU U UQ 11 6 Force Measurement Problems DRS25 User Manual 0025 00 901 11 1 Section 11 Troubleshooting DRS25 User Manual 0025 00 901 11 2 Section 11 Troubleshooting 11 Troubleshooting 11 1 No Heat 11 1 1 Nozzle Heater If the upper heater is not putting out any heat run through some of the items on this list e Verify that the process profile has not been inadvertently saved with no heat in that event e Verify that the incoming air line is still connected Look for problems with the lines e Verify that the incoming pressure is set for 80 PSI on both the Nitro
38. cycle This button will display a green background when the cycle is active or a gray background when the cycle is not active Clicking on the button when the background is green will terminate the cycle Thumbs Up OK Exit This button will exit the Run screen and return the operator to the Main screen Multi Media a The Multi Media button activates the Live Video option The live video window will be positioned in the upper left hand corner of the screen Note The About DRS25 menu option will display the software version number for the Live Video program Live Video Window DRS24 Live Video Close About DRS24 Live Video About Page DRS24 Live Y deo Close About DRS24 AirVac Engineering Company Inc 30 Progress Avenue Seymour CT 06483 USA Version 1 60 Phone 203 888 3900 Fax 203 888 1145 DRS25 User Manual 0025 00 901 5 62 Section 5 Software Overview Bar Code Board Serial Number Tracking 1 This section of the Run screen allows a board serial number to be tracked and recorded in the cycle history file The operator has the option to enter this information using the standard keyboard or to use the optional bar code scanner mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File Nozze System 50 60 70 Preheat System Set Point Set Point Set Point Nozzle Set Point Actual Ra
39. degree of automation including automated device pickup and removal motorized beam splitter vision automatic placement using a precision force measurement system with real time display and software based process control of virtually all rework parameters allowing the operator to follow a clear simple procedure If complex functions are performed they will be largely transparent to the operator For the process engineer the controls and features of the system provide the flexibility and capability required to meet today s packaging and assembly challenges Profiles and procedures can be easily modified to meet specific requirements A concise logical teach function allows profiles to be quickly and easily created or modified DRS25 User Manual 0025 00 901 1 3 Section 1 Introduction Getting Started 11 Warranty General Air Vac Engineering Company warrants its equipment for a period of one 1 year from date of shipment on all parts materials and labor costs required to repair the system except for component parts that are considered wear and tear items which are warranted for ninety 90 days These include but are not limited to heaters belts lights vacuum cups and tubing Air Vac agrees to repair or replace any or all such equipment that may prove to be defective within the warranty period without expense excluding shipping to the owner This warranty shall not apply to any products that have been repaired or altered except by
40. display the control parameters for the first event if any events exist Motion control Motion control involves activities that relate to movement in the Z or Vision axis Force placement removal is also considered motion control Device control Device control involves activities that relate to the following items temperature flow rate vacuum lights video and thermocouple control Time or footswitch control Time control involves activities that require a fixed or unknown duration Fixed time is represented by standard seconds An unknown time is represented by the use of a foot switch event During a foot switch event the process will not continue change events until the operator presses the foot switch Note The Teach button must be selected to temporarily save any control parameter event adjustments DRS25 User Manual 0025 00 901 5 29 Section 5 Software Overview Motion Check Box The Motion check box helps to control which parameters are saved during the Teach function Also the operator can use this check box to suspend any future motor activity allowing event selection to be quickly and easily completed up down event buttons Additionally this check box can be used to re synchronize the actual and destination motor coordinates Z and Vision axis A Display A These motor coordinates represent the actual position for the Z and Vision axis Pos 0 036 Pos 03 380 Display B These moto
41. during the process cycle In addition this control option requires a target temperature A to be programmed This target temperature is used to stop the process cycle Target temperatures can be defined as increasing heating cycle or decreasing cool down cycle Maintain E This control option monitors a thermocouple channel during the process cycle and is connected to the control logic for the diffuser heating system If the actual board temperature measured by a thermocouple is above the target temperature AJ then the diffuser system heat air is turned OFF If the actual board temperature measured by a thermocouple is below the target temperature A then the diffuser system heat air is turned ON Teach E LED Adjustment Build Photo Links Options Vision and Nozzle System Pos BE Pos mmm Rate Temp C C Sec 000 000 000 E Dest 00 000 Dest 00 000 oe oo Replay Thermal Sequence D X ZMove ABS C Air C mm 0 L C ZMove REL tan N C Do Not Move Nitrogen inch C Tim sec Ei Motion IE 2 Powet Events Velocity Accel Velocity 26 Bi Vision Lights M Bi Probe C Foot amp Time Fa 100 10 100 Cool Air Video Alert DE Be Bea Eat E3l Device Nozzle Separation B Site Cleaning System mmi Auto Adj 2 Vacuum Clear Actual Sensor Sensor Range 000 Adj Pulse 000 ooo Clogged
42. is written Duration Time or Foot Switch After programming any motion and device control for a specific event the operator has the ability to add a time delay duration This delay can be Time fixed seconds or Foot switch based A Time based event can be programmed from 0 600 seconds A Foot switch based event is only limited by the maximum profile time 45 minutes Delays typically allow activities such as heating cycles or operator interaction component alignment to be time tracked and graphically plotted DRS25 User Manual 0025 00 901 5 44 Section 5 Software Overview Build Photo Links The operator has the ability to link multiple photo captured video images to a control profile The same photo image can be linked to multiple profiles The maximum number of photo links per profile is 49 Selecting the Build Photo Links menu Teach screen allows the operator to adjust the existing photo link list _ Add Entry The operator must enter the exact photo bitmap name without the extension into the Bitmap File edit box The operator must click on the Add Entry button to temporarily insert the file name into the existing photo list Delete Entry The operator must highlight click the entry to be deleted The operator must click on En the Delete Entry button to temporarily remove the file name from the existing photo list Build Photo Links Photo Link Information BGA 225 Clean Site BGA 22
43. necessary e he Cycle Stop C button allows the operator to terminate the load procedure if necessary he Up Thumb button D will return the operator to the Run screen Nozzle Load Function D C A B DRS25 User Manual 0025 00 901 5 66 Section 5 Software Overview Jog Function Menu Option This menu option allows the operator to access a motion jog screen This screen provides the following motion tools Z and Vision axis jog controls A B C Power check box power de power Z axis D Home Z and Vision axis return each axis to an initialization position E Vision Alignment Position this button will open the vision cube activate the fiber optic lights and position the nozzle at the default alignment position G e Cycle Start Stop This button F will display a green background when the motion cycle is active or a gray background when the motion cycle is not active Clicking on the button when the background is green will terminate the motion cycle C D Jog Functions Vision Axis C mm Z AXIS inch H F G DRS25 User Manual 0025 00 901 5 67 Section 5 Software Overview 5 3 3 Import Graph Data The Import menu allows the operator to reload and analyze historical graph data Graph data is organized and stored using an 8 digit file sequence number These sequenced files are stored in the CAWINDOWS DRS25 EXPORT directory The largest seq
44. operator to remove the part Or this event may be changed to footswitch based allowing the operator as much time as required Process Complete Heater Cooldown There is no operator involvement during this event Event 14 This is a timed event The purpose of this event is to provide process repeatability for the next cycle At the end of the process the operator has three options Select the Load Process Link File for the Site Cleaning or Soldering Program HH mm BGA Removal amp 0980001 DR S LED Adjustment Graph Data Auto Scale Graph Load Process Link File view Photo Links Numerical Process Information Soldering Desoldering j Site Cleaning Nozze System reheat System 50 60 70 30 Press the Thumbs Up icon to exit the screen DRS25 User Manual 0025 00 901 7 17 Section 7 Operator Training Running a Typical Site Cleaning Program After the Load Process Link File is selected the profile name at the top of the Run Screen will change to the Site Cleaning Program tx mm BGA Removal 60980001 DRS TE u LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File ae Preheat System Thermocouple System Force System 50 Memory 375 500 u Numerical Process Information eine Desoldering 1 FUE 2s i
45. performed outside of the Air Vac software Consult the factory technical support group DRS25 User Manual 0025 00 901 11 8
46. process is not cycling View Photo Links LTD Photo Links EDDIE 25 balls bga 25 component bgaee5 site Selecting double click a photo image will use Windows Paint tool to display the video snapshot To exit Paint and return to the DRS25 software click on the File menu and select the Exit option Fr 225 SITE Paint File Edit View Image Options Help mna iin PBG 225 a et fet tet i 1 Toca DRS25 User Manual 0025 00 901 5 65 Section 5 Software Overview Export History Menu Option Graph data can be manually save by selecting the Export History menu e Selecting this option will copy the current data set to the Export directory e This information can be retrieved at a later time using the Import option A help message will inform the operator that the graph data was successfully saved e Clicking on the OK button will return the operator to the Run screen Help Message The Graph Data Has Been Saved To An Export File Load Nozzle Function Menu Option The Nozzle Load menu allows the operator to activate a general motion utility to semi automatically load remove a nozzle e This utility can be activated by selecting the Nozzle Load button Z axis be de powered by clearing the Power check box A This allows the operator to manually reposition the nozzle during the load procedure if
47. that already exists The system will allow identical long names to exist in the profile library e Customer Board and Device Group These groups E allow profiles to be organized using a combination of customer board and device name New groups can be easily created see Setup Group Categorizing profiles by group can significantly improve the operator s ability to find the correct application profile e Thermal Sequence File The Thermal Sequence Attachment Control F where the thermal sequence is attached to the profile When the operator clicks on the insert buttons a list box comes up with the choices of available thermal sequences Selecting one of the thermals sequence files will insert the long and short file names into the profile Warning Message x When the operator clicks on the thumbs up button to save a profile the system may File Ex a le Exists Overwrite notify the operator that they are about to replace an existing file this will only occur if the profile currently exists in the library Short Name To complete the save the operator must click on the Ok button Help Message When the operator completes the save function the following confirmation message will be displayed Profile Save Completed Warning Message If the operator Cancels the save function the following confirmation message will be displayed Profile Save Was Not Completed DRS25 User Manual 00
48. that the pads would reflow prior to placing the device This hot air solder leveling step helps prevent placement error caused by skewing of the component when the leads contact a curved ie unreflowed solder on pads surface No heaters are activated during this training profile During this step check the accuracy of your alignment efforts Lower and refocus the microscope so that you can see the front row of leads in relation to the pads Rotate the entire microscope assembly to view the opposite sides Note Rear side not viewable at board level Depress the footswitch until the yellow footswitch indicator goes off DA524 Live Video ajx File Scale To Window About DAS 24 Proper lead to pad registration at board level Leads are approximately 025 above pads DRS25 User Manual 0025 00 901 4 17 Section 4 Machine Function Verifications 4 5 9 Automatic Placement Hands Off The device will be automatically placed with the aid of the Force Measurement System No operator involvement is required during this event however it is important that the operator keeps his her hands off the machine during this event as any contact with the system will impact the force reading e During this event the force set point should read 75 grams with a range of 20 grams and the actual force value will also be displayed A e After the automatic placement is complete the nozzle vacuum will shut off and the nozzle will raise up The
49. the screen Select the Shut Down the Computer option Shut Down Windows 0 Click on the Yes Button to start the Windows Shut Down Windows ae ony nate V shut down EDS MES EPIS ete f Shut down the computer C Restart the computer Restart the computer in 5 005 mode Close all programs and log on as a different user Tes Ma Help DRS25 User Manual 0025 00 901 5 23 Section 5 Software Overview Safe Shutdown Screen Message This is the message that will be displayed on the screen when Windows has been shut down properly At this point it is now safe to press the E Stop button and de power the DRS25 machine It s now safe to turn off your computer E Stop Button The E Stop button will de power the DRS25 machine It should only be used in the case of an emergency or after Windows has been properly shut down Warning File Damage may occur when pressing the e stop button if Windows has not been shut down properly DRS25 User Manual 0025 00 901 5 24 Section 5 Software Overview 5 3 Control Menu Functions View of the Control Menu DRS Software System Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Teach Process Events Thermal SMART Track gt Automatic Profile Build A y Run Process Import Graph Data DHS525 Lead Free Rework Repair amp Assembly WWw air vac eng com
50. tube from nozzle cone 9 Hold one wrench in heater cap to keep from twisting place second wrench in top of tube and unscrew when reassembling do not overtighten snug is best Pull tube completely out and set aside Run a 2mm allen wrench down the vacuum tube 5 and carefully straighten Nozzle clamp assembly should slide down do not use too much force vacuum tube can be stripped out easily rotate tube to help removal Lift heat shield off 2 if hand ring 4 has slipped down not seated at base press together to seat Remove spring clip 8 and fingers 7 and inspect for twisting or wear replace if necessary To lubricate use Never Seez or other high temperature grease Lubrication points are Top of brass ring 1 Inside brass ring on compression screws Top of fingers spring clip groove on fingers sides of fingers above bottom plate Inside threads of heater tube Reassemble in reverse order carefully bending vacuum tube to clear heater tube Clamp should now open fully and hold and snap closed when released Nozzle Clamp Assembly 5 3 2 3 1 Ne 1 10 N E LS 14 an TH 16 TE 7 NE 5 4 A 13 TE 15 492 2 IE Y Ec 6 8 un 9 17 7 DRS25 User Manual 0025 00 901 10 12 10 2 Section 10 Maintenance Y Axis Bearing Adjustment Bring the carrier to the forward most position center carrier and lock in place Remove
51. uses the thermocouple or temperature sensor to record board temperature as the bottom heater heats it It also controls when the bottom heater in events prior to and following the board preheat event It must be plugged in for this program Note Failure to have a thermocouple or temperature sensor plugged into channel 1 will result in an alarm and will stop in running the program in the Run next screen Note The thermocouple or temperature sensor may not be used for certain programs For those programs an alarm will not occur Note The programmer has the ability to insert or change any notes on the Open Profile Note screen to make procedure easier and with more detail mm Removal 60980001 DRS BENE E Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Open Profile Notes Description lt lt COMPONENT REMOVAL Component pO e Click on the Thumbs Up icon Location oo to proceed FluxType PASTEFLU OK Nozzle D 4444447 Notes INSTALL NOZZLE INSTALL BOARD POSITION BOARD SUPPORTS UNDER BGA gt POSITION TEMPERATURE SENSOR OR TAPE THERMOCOUPLE TO BOARD Application Notes RERERENCE PLUG TEMPERATURE SENSOR OR THERMOCOUPLE INTO CHANNEL 1 Led Continue to Run Screen DRS25 User Manual 0025 00 901 7 11 Section 7 Operator Training 7 4 Running A Typical Removal Program The Run screen will automatically appear a
52. with each operator priority level Edit Password Ea Low Priority Password Medium Priority Password fs High Priority Password DRS25 User Manual 0025 00 901 5 82 Section 5 Software Overview 5 7 7 Message Text This screen displays all system messages These messages can be adjusted to better meet the communication needs of all the operators If a language other than English is selected this file can be converted Message Notepad OR x File Edit Search Help Changes Have Not Been Saved Continue 7 Security Access Failed Invalid Long File Name Information Invalid Group Information Profile Save Completed File Exists Overwrite Profile Save Was Hot Completed Hemory Resources Are Very Low Please Exit The DRS Software And Reboot The Computer Continue With Delete File Delete File FAILED Delete File Was Cancelled Ho File pen Continue With Delete HISTORY Delete HISTORY Failed Delete HISTORY Was Cancelled WARNING The Run Graph History File FAILED Load Device Please Wait Hotor positions may be adjusted Click On The Cycle Start Button To Begin Process Open Nozzle Clamps Close Nozzle Clamps Low Pressure Detected Load Nozzle Nozzle Preheat Has Been Activated WAITING Power Haintain DRS25 User Manual 0025 00 901 5 83 Section 5 Software Overview 9 7 8 Message Title This screen displays all system titles These titles can be adjusted to better mee
53. 0 0 150 0 100 0 50 0 Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Time Event Time Profile Tme Z Power Board jmd Em Zi gt w I mm BGA Removal 25profilenotesremoval b 3l anc 2 27 PM LED Adjustment Menu Option Allows adjustment of the intensity of the top and bottom LED s Can be accessed through the Run Video and Vision System Setup Adjustment screens Auto Scale Graph Menu Option The Auto Scale Graph menu allows the operator to display the entire cycle data set on a single graph window During the cycle a 12 minute graph window is maintained and displayed Many process cycle times including final alignment time may extend beyond this 12 minute window This menu option is only available when the process is not cycling Load Process Link File Menu Option The Load Process Link File menu allows the operator to toggle between the soldering desoldering and site cleaning profiles This allows a related profiles to be cycled without leaving the Run screen This menu option is only available when the process is not cycling DRS25 User Manual 0025 00 901 5 64 Section 5 Software Overview View Photo Links Menu Option The View Photo Links menu allows the operator to access any photo images that may have been linked to the profile These captured video images are only available when the
54. 0 000 Dest 00 000 008 o0 Be ae oe Replay Thermal Sequence 1 Motion 2 Device Events 3 Time are processed Z Move ABS C Air C mm C Z Move REL C Do Not Move Nitrogen inch yeladi Vision Lights Noz Probe 100 0 uM Cool Air Video Jog zo u lt Qe X2TN Event Control Time sec F Motion 7 Z Power Events C Foot Time Eu o ish ee Bei using the following control sequence Miscellaneous Control Site Cleaning System Lad Alert Actual Sensor Adj 2 Vacuum 1 1 min auser RELO 183 C Sensor Range o00 Adj Pulse ooo do Highest priority Motion EA er Force place remove Thermocouple System Action C Disable Standard Replace Add C Subtract Data If ERROR Stop Process Force Placement System Actual Dest Range FA e oos v0 00 Zero Force DE Ea Eat Vacuum Sensor Stop Force Placement Auto Adjust V Display Only Middle priority Device control Lower Heating System L Temp M Temp C R Temp Foo Fon Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 Lowest priority Time or foot switch Be ae Flow Off C Low Flow High Flow Note Entering the Teach screen will
55. 00 G Nitrogen 2 In gt G B Making Flow Controller 100 Verifications and Adjustments e Click on the 100 radio button A The air flow will activate after 1 4 seconds e Wait 45 seconds before making any adjustments e Check the 100 scribe line on the flow meter If the flow meter reads too high or too low adjustments can be made immediately by entering a new value into the 100 Nozzle Flow Controller box B The air flow should not be interrupted The adjustments will be automatically applied within 3 5 seconds Note No adjustment is necessary if the flow is off by less than the thickness of the float Flow Meter Flow Meter Value Chart 1 Software Screen Flow Meter Target Value Meter should settle at 100 Read bottom 100 scribe 2 75 scfm of float head largest diameter 60 scribe 1 65 scfm DRS25 User Manual 0025 00 901 4 7 Section 4 Machine Function Verifications Note It is recommended that you use the tab key to enter into the adjustment box to change the setting 4 3 2 If the flow meter reads too high decrease the value by increments of 5 in the 100 Nozzle Flow Controller box B If the flow meter reads too low increase the value by increments of 5 in the 100 Nozzle Flow Controller box B Nozzle Flow Controller Verification and Adjustment 20 90 only Making Flow Controller 20 90 Verifications and Adjustments 4 3 3 At this point the 100 Flow Cont
56. 00000z2 DRS 23 26 09 30 97 Motion Communication Link qfpl60 training removal profile 00000002 DRS 23 26 09 30 97 Motion Communication Link qfpi60 training removal profile 00000002 DRS 23 29 09 30 97 Motion Communication Link dqgfpli50 training removal profile 0000000z2 DRS For Help press F1 DRS25 User Manual 0025 00 901 5 74 Section 5 Software Overview 5 5 Video Screen Utilities Menu The Video Screen Utilities option will allow the operator to capture or modify video images 5 5 1 Save Video Image The Save Video option will allow the operator to review capture a live video image The operator must first setup the live video image After completing this task the operator can freeze or capture the video snapshot Step 1 Setup Live Video Image DRS24 Video Maintenance DRS24 Live Video File Get Video Snapshot About DRS24 Live Video 111111117 uses DRS25 User Manual 0025 00 901 5 75 Section 5 Software Overview Step 2 Get Video Snapshot Select the Get Video Snapshot menu to capture the video image DRS25 User Manual 0025 00 901 5 76 Section 5 Software Overview Save As Photo images can be permanently saved and linked to specific profiles The same video snapshot can be used by several profiles The Save As option will allow the operator to copy the video snapshot to the DRS25 photo directory The operator must be sure the correct directory has been se
57. 10 1 DRS25 User Manual 0025 00 901 1 6 Section 1 Introduction Getting Started Options The following machine options may be included depending on whether they were ordered by the customer Description Qty Work Station 1 11003050001 Site Solder Removal System 1 1101500014 Multi Media Package 1 002427010 Non Contact Temperature Probe 11 101202011 Adjustable Area Array Insertion Tool 7 1 1 AUSLGAS6SQ Fume Extraction Manifold amp Hose Assy 1 102001040 Air Purification System 11 102001101 Board Cooling System 1 1 00250148 Paste On Device Stencil Adaptor 1 002424111 Expanded Recommended Spare Parts For users with three or more systems Description Solid State Relay 9002 06 003 77 Heater Head Harness 24 25 1 22 02 187 Heater Head Harness 24CXX 25T 25XLT 1 0024 90 046 Solenoid Valve 3 way 2 9001 11 007 Pressure Switch 0 15 PSI Low Pressure Sensor 3 010001 120 Proximity Switch Assembly 1 00440404 J Z Belt need on belt 1 1068800 Z Motor Belt 1 1054600 Please note the configuration of machine when ordering these parts DRS25 User Manual 0025 00 901 1 7 Section 1 Introduction Getting Started DRS25 User Manual 0025 00 901 1 8 Table Of Contents 2 Facility Requirements Technical Specifications 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11
58. 25 00 901 5 14 Section 5 Software Overview 5 2 4 Save As The Save As option functions very similar to the Save option however the Save As option also allows the operator to make a copy of an existing profile The Short name is always automatically updated incremented to the next available sequence number see the Save option The operator can change the long name to reflect the new functionality of the profile The operator has the option to move the new profile to a different group New link names can be added at any time The Long Name will automatically be appended using the This helps to insure that the Long Name remains unique The operator should edit the long name to reflect the new functionality of the profile The Short Name will automatically be updated with a new unique name Name and Link Control The Link Names for Short Name 6113001 DRS ooldering Desoldering and Site Cleaning will automatically be Link Name Soldering Desoldering cleared Link Name Site Cleaning Long Name SBGA 352 063 N35EZ35EB Desoldering Group Control Customer Group Air Vac 1799 Board Group Profile Library 1 99 Device Group Area Arrays 1 99 Thermal Sequence Attachment Control Long Name smart trak sbga 352 Short Name 7008001 THL Note The original profile remains unchanged and completely intact Warning The operator should be careful
59. 5 Damaged Site Note Photo images are available to the operator from the Run screen DRS25 User Manual 0025 00 901 5 45 Section 5 Software Overview Application Notes Miscellaneous Control This screen allows application specific notes to be entered These notes are made available to the operator during the Run cycle In addition there are a few miscellaneous profile control parameters apply to all events Edit Application Notes Miscellaneous Control Miscellaneous Control Hemoval Hetry Counter po Temp Increment poo m Continue Diffuser Idle Nozzle Load Position 0 Miscellaneous Control Time e Continue Diffuser Idle Diffuser idle is typically used to maintain a low temperature in the diffuser heating panels Diffuser idle can minimize and stabilize the warm up time required at the start of each cycle This control defines whether or not the diffuser idle will be continued when the Run screen is selected e Nozzle Load Position This parameter allows the default nozzle load position to be adjusted for a specific profile In general the standard default position is acceptable for most nozzle load requirements If a unique nozzle component insertion tool combination is designed a custom nozzle load position can be programmed A zero in this edit box will use the default position This position is measured in motor pulses Any change to this value should be base
60. Cleaning with SG100DRS 100 thick board 5 0885 PHGA 119 Soldering 100 inch thick board N570 885 PRGA 225 256 Removal Customer Group Air Vac Engineering Company Board Group Le Profile Library Device Group El Area Arrays arming Message CJ Continue With Delete File GA 256 Soldering 100 inch thick board 945045 7 drs 7 Cancel DRS25 User Manual 0025 00 901 5 17 Section 5 Software Overview 5 2 7 Backup Restore Profiles The Backup Restore Profile screen allows the operator to delete files based on the Long Name This allows a user to copy profiles without the need to know the short file name Backup Profile Screen Backup Prafile Files 000 SITE CLEANING MASTER PROFILE FOR 24c 2f Site Cleaning auto adjust CEGA 256 303 Removal 100 inch thick board CBGA 256 303 Soldering 100 inch thick board CBGA CCGA 625 Removal 100 inch thick board N1305 1305D 7 CBGA CCGA 625 Soldering 100 inch thick board NT305X1305D CCGA 44 mm Removal 100 inch thick board N1 7301 300 CCGA 44 mm Soldering 100 inch thick board N1730 1730D CSP Flux application directly on spheres N500DYG 4 CSP 46 Removal 062 inch thick board NS00DYG 4A CSP 46 Soldering 062 inch thick board N38D vG 3 CSP 46 Soldering 062 inch thick board NSO00DYG 4 machine warm up PEGA 119 Removal 062 inch thick board M570 885 PBGA 119 Solde
61. DRS29 Users Manual 0025 00 901 Temperature vs Time Reflow Cool pr d o Thermocouples 042 T C 1 Board 025 2 Package UTE lt lt 027 TiC 3 Joint 000 Tic 4 emperature 000 M TIC 5 Average 000 TiC 6 Reflow Temperature 000 000 2 000 48 Options LeadFree Lead Free SMT Rework amp Assembly AR VAC www air vac eng com AIR VAC ENGINEERING COMPANY INC Aff Lc INSTALLATION AND TRAINING DOCUMENT Customer 1 1 1 1 atte Machine Type Address SerialNumber Contacts 2 Phones JQEmalFrac 0 2 Phones JjEmalFrac 0 Phones X jjEmalFac This is to certify that the Air Vac Representative has installed and calibrated the above machine and that all items have been received or are noted below The machine is in excellent working order and adequate training was provided The customer is now capable of operating the system Customer Signature Date Air Vac Representative Signature Date Issues Items Missing Please fax this completed document to Air Vac Engineering 203 888 1145 Attn John Browning Controller DRS25 USERS MANUAL Part No Rev Date 0025 00 901 01 00 9 26 05 1 INTRODUCTION EMNG STARTED 2 Faciur REQUIREMENTS TECHNICAL SPECS 3 OVERVIEW Set Up amp INSTALLATION MACHINE FUNCTI
62. FF Nozzle Rate ggg Hozzle Temp HHH Hozzle Ramp ggg LDiff Flou OFF LDiff Temp agg Left Right Average RDiff Flow OFF RDiff Temp 2 Axis Motion Absolute Z Axis Power Hozzle Axis Pos 88 0689 Hnzzle Wel 050 Nozzle Accel 050 Vision fixis Pos 86 682 Uision Uel 05 B Uision Accel a5 8 Uision Lights OFF Live Wideo OFF Hitrogen OH Nozzle Wac OFF Probe Uac OFF Site Clean OFF Hoz Deu Separate OFF Hoz Cold Air OFF Zero Force Force Place Force Adjust Force Target ggg Force Range B Cooling Ring T C 1 Honitor Temp dad Control UP Speech Alert T C 2 Hot In Use Temp 888 Control UP Date 84761798 PROFILE FARAHETER REPORT Page 002 PBGA 225 256 Removal B68 thick board H1BB1X1881 1811838 drs Speech Alert T C 43 Not In Use Temp Bd Control UP speech Alert 06525 User Manual 0025 00 901 5 20 Section 5 Software Overview 5 2 9 Print Process Notes Photo Links This option functions identically to the Process Control Parameters report Fracess Control Parameters Process Notes Photo Links Edit Search Help PEGA 225 256 Removal 868 thick board H1881518081 1811838 drs Customer Group Air Vac Engineering Company Board Group Profile Library Deuice Group Area Arrays Solder Desolder Link 1811883 DRS Site Cleaning Link 1811817 DRS COMPONENT REHDURL PEGA 225725672727324 27 HOHE PLEA
63. Menu FUlcHOlS5 719 3220200415229 uni 8 5 3 Runctions u a a 25 5 4 History Menu 73 5 5 buses AMI m 75 5 6 Reset Cycle Counter 79 5 7 S 79 5 8 Reset OCU ALOR e M 85 5 9 Protected System Security ACCESS 86 DRS25 User Manual 0025 00 901 5 1 Section 5 Software Overview DRS25 User Manual 0025 00 901 5 2 Section 5 Software Overview 5 Software Overview 5 1 Windows Tools Overview DRS25 Software Main Screen DRS Software System Options 5 1 1 Buttons History Video Screen Utilities Reset Cycle Counter Setup Reset Operator DHS525 Lead Free Rework Repair amp Assembly WWW air vac eng com Icon buttons are generally used to activate a procedure or function Moving the cursor over the top of the icon and clicking on the left mouse button will initiate the button s functionality Button icons have a popup message that tell the operator what the purpose of the button is Ok Exit Screen this automatically occurs when the cursor is placed over the top of the icon Note If a button is completely gray the functions associated with that button a
64. ON VERIFICATIONS 5 SOFTWARE verview RELEASE NOTES 6 PROGRAMMING G UIDE PROFILE TUTOR 7 OPERATOR GUIDE 8 SAFETY SCHEMATICS 10 MAINTENANCE 11 TROUBLESHOOTING Section 1 Introduction Getting Started Table Of Contents 1 Introduction Getting Started 1 0 DRS25 Overview 1 1 Warranty General 1 2 Unpacking 1 3 Material Check List aA Un UC DRS25 User Manual 0025 00 901 1 1 Section 1 Introduction Getting Started DRS25 User Manual 0025 00 901 1 2 Section 1 Introduction Getting Started 1 Introduction Getting Started 1 0 DRS25 Overview The DRS25 represents Air Vac s latest technology for SMT rework and low volume assembly Considerable time has been spent in an attempt to provide in depth instructions in regards to the unpacking installation verification operation and maintenance of this system If you have any questions please do not hesitate to call Air Vac Engineering Company Inc 30 Progress Avenue e Seymour CT 06483 e Tel 203 888 9900 e Fax 203 888 1145 WWW air vac eng com e mail General Sales amp Tooling Information rework sales air vac eng com Technical Support rework tech air vac eng com The DRS25 is designed to provide semi automated rework and low volume assembly of virtually any surface mount component including BGA s CSP s QFP s Flip Chip connectors sockets PLCC s and specialty components on a wide range of assemblies The system provides a high
65. OVAL Component Location PO FuxType PASTE LURKS Nozzle it Notes INSTALLNOZAE _ 7 a S POSITION BOARD SUPPORTS UNDERBR mm POSITION TEMPERATURE SENSOR OR TAPE THERMOCOUPLE TO BOARD Application Notes RERERENCE PLUG TEMPERATURE SENSOR OR THERMOCOUPLE INTO CHANNEL 1 Continue to Run Screen e Follow all instructions on the Open Profile Description Provides generic program title For example BGA225 Component Removal Component Describes the device to be reworked For example BGA225 Location Describes position on the board For example U43 Flux Type Describes the flux to be used For example manufacturers name and flux type Nozzle The nozzle used For example N27EZ2T Notes Saves helpful information about the assembly Provides operator tasks and checks prior to running the program Prior to going to the Run Screen e INSTALL NOZZLE e INSTALL BOARD e POSITION BOARD SUPPORTS IN A 3 4 INCH SQUARE PATTERN UNDER BGA e POSITION TEMPERATURE SENSOR OR TAPE THERMCOUPLE TO BOARD REFERENCE e PLUG TEMPERATURE SENSOR OR THERMOCOUPLE INTO CHANNEL 1 DRS25 User Manual 0025 00 901 7 7 Section 7 Operator Training 7 1 5 Install Nozzle eee 11 1 amp E d a T 4 j gt T 4 4 4 T 4 7 d 4 1 4 d 2 2
66. S25 User Manual 0025 00 901 7 28 Section 7 Operator Training Align top left lead to pad using the x and y adjustment wheels to align BGA to pads le Sle i Each lead must be centered to each pad Check top right side lead to pad alignment If the top right side is aligned theta adjustment is required This is not uncommon Multiple x y and theta adjustments are normal Use the theta adjustment to make correction until leads are in a horizontal row Balls must be parallel to pads r r rn r r 1 r Ja Theta Finalize the alignment by readjusting with the x and y Adjustment fine adjustment wheels Check alignment of top row and bottom row to insure correct theta x and y position Option Use zoom lens at maximum setting to increase operator alignment accuracy Viewing under high magnification may reveal minor errors not seen while aligning the entire device Tilt the microscope up and down to view overall site for theta error Check for slightest theta adjustment Magnify image and tilt microscope up and down Theta Adjustment DRS25 User Manual 0025 00 901 7 29 Section 7 Operator Training Event 5 Flux site unless solder paste has been applied Press Footswitch to Continue The vision system will automatic
67. SE NOTE NOZZLE HUST BE LOADED BEFORE RUNNING PROCESS THE FIRST TIHE AFTER NEXT SCHEEH RUH APPEARS DO HOT FOLLOW THE IHITIRLTEST UEHBRL PROMPT TO CLICK ON THE START CYCLE ICON H1 68741681 INSERTION TOOL h188151881 OPEN TOOL BAR TO JOG FUNCTIONS MENU OPEN AND SELECT NOZZLE LOAD ICON WHEN FINISHED CLICK ON THUMBS UP ICON CLICK ON CYCLE START ICON TU BEGIN PROCESS Date 84 81 98 PROFILE NOTES REPORT Page 002 PBGA 225 256 Removal 868 thick board HiBB1x1881 1811838 dr5 PLUG THERHOCOUPLE OR SENSOR INTO CHANNEL 1 DIFFUSER SHOULD BE HEATED IN IDLE MODE PRIOR TO RUNNING THIS PROCESS Process Limits 1 k DRS25 User Manual 0025 00 901 5 21 Section 5 Software Overview 5 2 10 Notepad The Notepad selection from the Options menu will automatically call the Windows Notepad Program This will allow the operator to have access to notepad without leaving the DRS25 software 5 2 11 About DRS The About screen contains general information about Air Vac Engineering and the current software version DRS25 User Manual 0025 00 901 5 22 Section 5 Software Overview 5 2 12 Exit Itis very important to shutdown the DRS25 system correctly Click on the Options menu and select the Exit option This will close the DRS25 software and shut down any active devices vacuum air flow etc The Windows Desktop screen will be displayed Click on the Start menu located in the lower left corner of
68. Temperature vs Time 500 0 450 0 400 0 350 0 300 0 Control 250 0 200 0 150 0 G 100 0 50 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Temperature 00 00 00 48 01 36 02 24 03 12 04 00 04 48 Event Time Profile Time Z Power Zero Force The Zero Force A button will clear any currently applied force that may have been generated during the X YIZ axis positioning Probe Vacuum r The Probe Vacuum button will activate or deactivate the special vacuum probe port used with mS component handling tool Nozzle Vacuum The Nozzle Vacuum button will activate or deactivate the nozzle vacuum When this function is active the button background will be display in green Nozzle Device Separation The Device Nozzle Separation button will activate a small volume of air back through the nozzle vacuum tube helps to separate the component from the nozzle When this function is active the button background will be display in green DRS25 User Manual 0025 00 901 Section 5 Software Overview Site Cleaning Vacuum 4 The Site Cleaning button will activate a special vacuum port used for site cleaning The site cleaning tool requires a vacuum source to remove the molten solder from the site When this function is active the button background will be display in green Cycle Start Sto The Cycle Start Stop button is used to activate or terminate the process
69. ads on top of each other LED sensor for height reference Top green and Bottom white LED s with independent programmable intensity adjustment provides enhanced optical contrast during alignment Leica M3 binocular with adjustable 10X eyepieces MZ6 1 6 zoom magnifier seamless adjustment custom focusing ring Section 2 Facility Requirements Technical Specifications DRS25 User Manual 0025 00 901 2 6 Table Of Contents 3 Machine Overview Set Up amp Installation 3 0 3 1 3 2 3 3 3 4 Electrical System Board Carrier System top and bottom Viewing Alignment System Installation of Standard Machine Hardware Installation of Options DRS25 User Manual 0025 00 901 Section 3 Machine Overview Set Up amp Installation 99 UU Q 10 Section 3 Machine Overview Set Up amp Installation DRS25 User Manual 0025 00 901 3 2 3 3 0 C A 3 1 Section 3 Machine Overview Set Up amp Installation Machine Overview Set Up amp Installation Electrical System Power Switch A provides electrical power to the module Emergency Stop B stops electrical power to all systems Light Switch C turns external lights on and off B Board Carrier System top and bottom Board Segments A hold and support PC boards level adjustable PCB Lock B secures PC board in carrier system Carrier Lock C adjusts arms board edge supports to width of PC board X Adjustment D rotates t
70. aining removal profile 00000002 DRs 23 33 09 30 9 7 DRS24 qfp160 training removal profile 00000002 DR 05 21 10701 97 DRS24 UNTITLED DRZ D5 25 10 01 97 DRSZ4 UNTITLED DRZ 20 48 10 07 97 DRS24 Flow Ramp 20 110 00000005 DR 20 52 10 07 97 DRSZ24 Flow Ramp 20 110 00000005 DR 20 53 10 07 97 DRSZ4 Flow Ramp 20 110 00000005 DR 20 54 10 07 97 DRS24 Flow Ramp 20 110 00000005 DR 20 55 10 07 97 DRSZ24 Flow Ramp 20 110 00000005 DR 20 58 10 07 97 DRSZ4 Flow Ramp 20 110 00000005 DR 20 598 10 07 97 DRS24 Flow Ramp 20 110 00000005 DR 21 01 10 07 97 DRS24 Flow Ramp 20 110 00000005 DR 4 an an d mm mnm 1 bod M TORTE Tm am ume 1 1 omn nmn em nj Tai 1 4 k For Help press F1 DRS25 User Manual 0025 00 901 5 73 Section 5 Software Overview 5 4 2 Alarm History The software continuously monitors the controlling sub systems If an alarm condition occurs for any process or hardware issue an Alarm file entry will be recorded Note This data logging feature is not optional The system records all alarm condition This file captures the following fields Field 1 The time of day the cycle was run Field2 The date the cycle was run Field 3 The Alarm condition that stopped the cycle Field 4 The profiles Long Name Field 5
71. alibrated to a certified flow meter The Flow Sensor and Flow Controller have individual dial indicators and are adjusted individually starting at 100 Nozzle Flow Adjustments Nozze Flow System v 0 C 2096 C 3096 50 60 40 70 30 50 40 C 50 60 2ll 00 10 100 70 C 80 90 Er er 0 Hozzle 6 110 100 Nozzle Flow Sensor Nozzle Flow Controller 20 Offset 30 Offset 2096 Offset 30 Offset 60 Offset 225 050 125 40 Offset 175 50 Offset 100 40 Offset 100 50 0 755 90 70 Offset 100 100 1235 25 00 60 Offset 75 70 Offset 20 80 Offset 90 Offset 80 Offset zl 90 Offset 20 100 4600 100 4650 Nitrogen As an example for the 100 setting If the flow meter reads too high decrease the 100 Nozzle Flow Controller value If the flow meter reads too low increase the 100 Nozzle Flow Controller value See calibration procedure for complete detail DRS25 User Manual 0025 00 901 5 88 5 9 5 Run Screen Displays Section 5 Software Overview The Run Screen Display setup page is used to configure the software to match the type of DRS25 system hardware These parameters refer to the positioning of the Nozzle Diffuser and Thermocouple Couple groups on the run screen 5 9 6 TC Range Adjustments Screen The TC Range Adjustment Table is used in the to linearize and adjust the thermocouple channels
72. all other flow controller and flow sensor adjustments DRS25 User Manual 0025 00 901 4 8 Section 4 Machine Function Verifications 4 3 4 Nozzle Flow Sensor Verification and Adjustment 20 90 only Making Flow Sensor 20 90 Verifications and Adjustments At this point the 100 Flow Sensor value has been set For each of the remaining radio buttons 20 90 location C the operator should run through a similar verification and adjustment procedure that was just completed for the 100 Nozzle Flow Sensor value If the blue needle is too high decrease the value by increments of 5 in the appropriate 20 9076 Nozzle Flow Sensor box location H If the blue needle is too low increase the value by increments of 5 in the appropriate 20 90 Nozzle Flow Sensor box location H Note After completing this calibration procedure the operator should quickly run through all of the Flow Sensor ranges 20 9096 The purpose of this step is to assess the overall performance of the flow system oelect the Thumbs Up icon to save changes and exit the Flow Adjustment screen IMPORTANT DISCONNECT THE BLUE FLOW METER HOSE FROM THE FLOW CALIBRATION FITTING AND RECONNECT THE BLUE UPPER HEATER HOSE FAILURE TO RECONNECT THE UPPER HEATER HOSE PRIOR TO RUNNING THE TOP HEATER WILL CAUSE THE TOP HEATER ELEMENT TO FAIL DRS25 User Manual 0025 00 901 4 9 Section 4 Machine Function Verifications 4 4 Temperature Verification After the machine pressur
73. all such equipment that may prove to be defective within the warranty period without expense excluding shipping to the owner This warranty shall not apply to any products that have been repaired or altered except by Air Vac Engineering Services under warranty shall not affect an extension of the warranty period nor will a new warranty period be granted for the parts which were replaced repaired The title of the replaced parts will automatically pass to Air Vac Air Vac reserves the right to reject replacement under this warranty where in the sole opinion of Air Vac the defect is due to obvious misuse and or improper maintenance of the module or any part thereof Heating element life is affected by several factors temperature airflow condition of incoming air water and oil contamination and overall process cycle These products are considered a consumable item The length of useful service will vary based on the conditions under which they are run Higher temperatures and or lower flows will cause shortened life The express and or implied warranty of Air Vac is limited to the replacement and or repair of any item defective in material and or workmanship Other damages if any direct or consequential are expressly excluded from this warranty Air Vac shall be liable under this warranty only if 1 Air Vac receives notice during the warranty period 2 The products are operated in accordance with the supplied documentation and 3 S
74. ally close Apply flux paste generously over the entire site Do not use a low solids flux If solder paste has been applied for your application the board must stay cool until the component is placed and the heating cycle has been started Event 6 Position Temperature Sensor 3 Inches From Site near place position Press Footswitch to Continue The nozzle will move down to approximately 1 8 inch from board It is important that the component does not hit the board Advise programmer if the height is too low or excessively high Position the thermocouple or temperature sensor option over the board If a thermocouple is used use Kapton tape to attach it to the board material This could be done prior the program being activated Note The sensor is meant to read the board temperature It is important to position the sensor thermocouple away from the nozzle and on or over another device or at the edge of the board Event 7 No operator involvement is required Using Profile Tutor Software requires the board to be under a programmed temperature to start the heating sequence This insures consistency and repeatability for the soldering heating process The program will have up to 600 seconds wait until the board is cooler than the set temperature 65c is normal The programmer controls sets the temperature Event 8 will automatically be lowered to board until the programmed force is reached Note Operator mu
75. ample Moz Vat The nozzle vacuum is off and the live video camera system is programmed to be active Video 5 1 5 Radio Buttons oimilarly radio buttons allow a functions or activities to be programmed Typically radio buttons are grouped together by related functionality Within a group only one option can be selected at a time C ABS Selected C Z Move REL Do Not Move For Example The Vision and Nozzle System group located on the Teach screen provides 3 motion types Absolute ABS Relative REL and Do Not Move This can be used in the following way After a component has been placed selecting the Do Not Move button will keep the nozzle from moving in subsequent events DRS25 User Manual 0025 00 901 5 5 Section 5 Software Overview 5 1 6 List Boxes A list box is a multiple line display of information The operator can scroll through the list using the scroll bar to the right of the list box The operator can select any line within the list by moving the mouse to that line and clicking left button on that line Full List Box Files CBGA 256 Site Cleaning 100 thick board N545 845 CBGA 256 Removal 100 thick board N8455x845 CBGA 256 Soldering 100 thick board N845x845 CSP paste application directly on spheres N26DY G 3 CSP Removal MH28D YG 3 CSP 46 site cleaning 56100085 280 3 CSP Soldering AFTER fluxfsolder paste on sphere applicat
76. ange the Max Process Cycle under set up process counters e Call Air Vac Technical Support 11 5 6 Low Memory This alarm occurs when Windows can no longer manage your DRS25 s 32MB of RAM e Shut down Windows and re boot the DRS25 e Call Air Vac Technical Support to re configure Run Screen Displays By doing this you will change the look of your run screen but this will save on memory DRS25 User Manual 0025 00 901 11 5 Section 11 Troubleshooting 11 5 7 Process Thermocouple The process you are running requires one or more thermocouples to continue e Install thermocouples in the appropriate channels e Verify that the thermocouple is good Plug into a handheld meter to test Make sure the thin wires on the end of the thermocouples are twisted or shorted together e Call Air Vac Technical Support 11 5 8 Component Removal The machine has tried a pre determined number of component removal attempts and failed Modify removal profile e Call Air Vac Technical Support 11 5 9 Site Cleaning Vacuum Your site cleaning tool requires cleaning or is clogged e See instructions for cleaning the tool e Check vacuum filters if clogged then replace e Check profile Teach Screen for Clogged e Call Air Vac Technical Support 11 5 10 Run Graph History This alarm occurs when there is an error when the software attempts to read or write to the graph history file e Check that the directory you are trying t
77. ator access to computer screens and restricts parameters from being changed This allows all profiles to be run as programmed and minimizes operator responsibility DAS Software System Options Hun Process Reset Operator Open About DAS Exit Open The programs are opened selected by clicking Open A file directory will be shown listing all created programs See next page for screen About DRS Provides the current version of the software on the machine Please note software upgrades are available free using the order form on our website at www air vac eng com Exit Closes the software prior to shutting the machine down Note Do not turn off machine prior to closing the software first Run Process Activates screen to run the program This screen is automatically displayed after a program is opened and the Open Profile screen is presented Reset Operator Allows a new operator to log on Note It is good procedure to press Reset Operator when leaving the machine This prevents unqualified personnel from using the machine under this operator s name Programs are recorded in a History file DRS25 User Manual 0025 00 901 7 5 Section 7 Operator Training 7 3 Opening A Removal Program 7 1 4 Open Profile All Listings Screen Selecting Options then Open will present the Open Profile All Listings Screen bc test Soldering 80140006085 7 Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Ope
78. ce and system integrity The pc is not intended for personal use The operator should not be in any screen other than the Air Vac DRS25 program The intent of this section is to assist the operator in becoming familiar with the DRS25 Hardware and Software In addition to this information operator training may be supplemented by formal training from a qualified individual The DRS25 software is Windows based When the module is powered it automatically boots to the customized software Extensive software knowledge is not required The graphics interface is based on symbols icon or word buttons for operator functions Operators use the software to run pre tested pre approved profiles Automatic steps and helpful prompt messages provide clear operation Password protection restricts access to high security areas DRS25 User Manual 0025 00 901 7 3 Section 7 Operator Training 7 1 Power Up Note It is important to provide the operator with a comfortable working condition Please note the operator viewing height is 18 22 from the base of the module Sufficient chair height is needed 1 Turn PC on and let it boot up to the Air Vac password screen The Operator Registration Screen will appear Operator Registration Operator With cursor in the Operator Box left click mouse A pop up keyboard keypad will be displayed Type in operator or oe operator name given to you The keypad screen or the e a Clear BackSpace computer ke
79. ce o Add Subtract Data C If ERROR Stop Process DRS25 User Manual 0025 00 901 5 37 Section 5 Software Overview Diffuser Heater Temperature and Flow Rate The diffuser heating system bottom can independently A B control flow rate and temperature the left and right side heating panels For example the left side panel can be used for soldering desoldering a component and the right side can be used for board cooling or solder pasting The diffuser heater temperature Temp C can be programmed from 1 C to 420 C Each diffuser panel has two programmable flow rates The Low flow rate is fixed at 4 0 scfm The High flow rate is fixed at 7 0 scfm During a normal run cycle the left and right diffuser temperatures are averaged together before being graphically plotted If separate heating cooling functions left right are programmed the operator can disable the temperature average by clearing the Average L R Temperature C check box If this check box is clear the system will attempt to plot only the actual right diffuser temperature If the right diffuser temperature set point is programmed to zero current event the system will attempt to plot only the actual left diffuser temperature Note During the process cycle Run screen the diffuser event controls will override any global diffuser idle that may have been activated Teach LED Adjustment Build Photo Links Vision and Nozzle System Pos EXE Pos
80. ck nozzle clamp must open completely and hold and snap closed Rebuild if necessary Run wire brush through vacuum tube Check for air tube cracks at heater head cap and insulation on wires inside Check for tie wraps tube input to hold vacuum hose around hose and tube through vertical supports Check vision alignment verification Perform daily weekly and monthly preventative maintenance schedule Maintenance is based on normal usage Depending on environment and usage the maintenance schedule may need to be adjusted If machine is moved the installation and verification should be repeated Proper electrical input 208 240 VAC 50 60 Hz and air supply 90 130psi MUST be provided DRS25 User Manual 0025 00 901 10 3 Section 10 Maintenance 10 1 1 Preventative Maintenance Schedule Procedure Daily Self explanatory Weekly mirror and vision system prism A with J Clean Microscope and Vision System Optics Wipe eyepieces alcohol Clean bottom of vision prism Wipe flux from table arms and rails Apply a film of light oil to the X and Y rails Remove any flux build up on supports etc 2 5 O 9 Q 10 4 DRS25 User Manual 0025 00 901 Section 10 Maintenance Replace the two vacuum filter elements A of Site Solder Removal System Flux vapors in the vacuum pump will result in insufficient vacuum operation Unscrew glass jar Unscrew stem to remove and insta
81. clicking left mouse on that line The edit box will return to its original state with the new selection being displayed Board Group Profile Library BGA Conversion Files Demo Board LEADED DEVICES Profile Libra DRS25 User Manual 0025 00 901 Section 5 Software Overview 5 2 Options Menu Functions View of the Options Menu DRS Software System Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Mew Open Save Hove AlPR VAC Backup Restore File Maintenance Princ Mate Pad About DRS Exil Lead Free Rework Repair amp Assembly WWW air vac eng com DRS25 User Manual 0025 00 901 Section 5 Software Overview 5 2 1 New The New option located on the Options menu will automatically clear the current profile from memory and display the teach screen The system is ready to teach a new profile Teach LED Adjustment Build Photo Links Vision and Nozzle System Pos Pos Rate Temp C C Sec Dest 00 000 Dest 00 000 080 an 000 Bo Replay Thermal Sequence Z Move ABS Air C mm C Z Move REL C Do Not Move Nitrogen inch 20 0 lt N Time sec 7 Motion 7 2 Events 000 C Foot Time o ee Miscellaneous Control Alert Pulses Solder Reflow 183 Thermocouple System Vision Lights Noz
82. component expansion and will only be applied if the actual force is outside the force range tolerance DRS25 User Manual 0025 00 901 5 35 Section 5 Software Overview Force Removal otep 1 Program a Z axis nozzle position to be in contact with the component to be removed Be sure the nozzle is accurately aligned Step 2 The next event must be designed to have a negative Destination B force value This negative force will be used to detect board lifting Board lifting will occur during the component removal motion if all the joints are not at the required solder reflow temperature Note This negative force value is used to determine the success of a removal process Run screen If the removal process fails Run screen the software will discontinue any motion de power the Z axis and terminate the nozzle vacuum The operator now has the control option to continue the removal process manually Note The Teach button must be selected to temporarily save any control parameter event adjustments Device Control Device control includes the following programming tools flow rate temperature vacuum video lights and thermocouples These event elements are activated after all the required motion has been completed Z Vision and Force placement Note It is important to remember the priority of event processing Some device control elements should be activated before the current event is processed For example it is important to activat
83. cting Do Not Move the Do Not Move option prohibits any motion from occurring during the current event DRS25 User Manual 0025 00 901 5 31 Section 5 Software Overview Zand Vision Axis Velocity Acceleration Buttons Velocity and acceleration parameters provide the ability to fine adjust the overall motion Velocity controls the maximum speed that the axis will reach To achieve a maximum velocity set the axis parameter to 10096 Acceleration controls the length of time the axis will need to reach the maximum speed The Z and Vision axis share a single event acceleration parameter To achieve a maximum acceleration shortest time set the event parameter to 100 Note The default values for velocity and acceleration are 50 DRS25 User Manual 0025 00 901 5 32 Power Check Box Section 5 Software Overview The Power check box A helps to provide maximum Z axis flexibility to the operator during the Teach and Run procedures This check box can be used to program the state powered de powered of the Z axis motor after completing any required event motion Run screen In addition this check box can be used to immediately adjust the state of the Z axis motor power during the development process Teach screen When the Z axis motor is de powered adjustments can be made by manually rotating the Z axis knob C Teach LED Adjustment Build Photo Links Vision and Nozzle Sysfem Pos Pos Dest
84. cy and safety by well trained personnel Do not attempt to operate or maintain this system without proper training from qualified personnel 8 1 1 Machine Operation Both the top and bottom heating elements be programmed to reach temperatures as high as 420 C Use caution near heated surfaces including the nozzle and the diffuser plates e Always use the gas nozzle handling tool when installing or removing nozzles e Always cover the diffuser plates with the safety shields when the diffuser is not in use but is being heated in the idle mode e he nozzle and vision systems are powered by stepper motors and are programmed to move during operation Use caution near these two moving areas e Observe the legal and specific national regulations concerning accident prevention and protection of the environment e Observe the general safety regulations concerning working with solder and flux Fume extraction should be seriously considered 8 1 2 Maintenance e Asa basic rule disconnect the main 220 Vac power before servicing the machine or when the machine is taken off line e Only use the tools for their defined purpose Never remove or disable any DRS25 safety features or software Make sure that all electrical devices are leakage current protected and are stored and used in dry dust free surroundings e The machine contains static sensitive devices Use caution to avoid static discharge when handling DRS25 machine part
85. d Reheat Press Footswitch to Continue The nozzle automatically moves up After raising the nozzle moves the operator can clean the residual flux with alcohol and a lint free wipe The site can be inspected Flux can be reapplied and the nozzle manually lowered to touch up areas of not completely removed solder The pads should be flat The pads and via s must not have the solder mask removed before the soldering process Note There are various tip sizes and fittings to allow site cleaning on very small area s and on boards with tall devices Consult supervisor if you believe a different tip would work better Remove Nozzle Keep Nozzle Clamping Fingers Open Press Footswitch to Continue Caution the Nozzle is Hot Use the Nozzle Pliers to remove nozzle Event 9 Note It is important to place the Site Cleaning Nozzle in the Site Cleaning Holder If the site cleaning nozzle is left on its side after a site cleaning process solder may clog the tool Reference Maintenance Section Event 10 Put Nozzle In Loading Tool Tray to Load Nozzle In Load Station Press Footswitch to Continue Event 11 Close Locking Clamps Press Footswitch to Continue Event 12 heater cooldown process complete DRS25 User Manual 0025 00 901 7 23 Section 7 Operator Training This is a timed event The purpose of this event is to provide process repeatability for the next cycle At the end of the process the operator has three options Se
86. d on an offset plus the default position i e new Nozzle Load Position default 1000 motor pulses DRS25 User Manual 0025 00 901 5 46 Section 5 Software Overview Removal Retry An option is available to monitor the vacuum levels during the component removal process A specific event can be programmed to detect vacuum reduction nozzle component separation during Z axis upward motion Run screen If detected the event will retry the removal process up to a maximum number of attempts Time and temperature adjustments can be applied to each retry attempt e Counter This parameter determines the maximum number of component removal attempts retry If component removal fails the process cycle will be terminated e Temp Increment This parameter determines the temperature increment that will be applied to each component removal attempt retry e Time This parameter determines the maximum time between retry attempts Note Theretry Z axis position will be automatically recorded before the initial removal motion occurs DRS25 User Manual 0025 00 901 5 47 Section 5 Software Overview Table Event Editor The Table Event Editor allows the operator to adjust all profile control parameters using a tabular form Selecting this button will present the operator with a pop up menu This menu will provide a list of parameter categories Selecting a category will quickly position the table editor to the exact column and row of the curr
87. desirable condition an alarm screen will appear The alarm screen will indicate the nature of the problem Call a supervisor or Air Vac Technical Support for assistance if you continue to have problems Maximum Time The maximum time of the profile has expired 45 minutes Modify profile Or work faster Temperature Verifies that the temperature controllers have power Call supervisor Communication Link Cycle Counter You have reached the maximum number of process cycles Call supervisor to that has been pre set reset Low Memory Windows program can no longer manger software Shutdown the software and reboot Note The Run screen displays can be re configured By doing this you will change the look of the run screen but this will save on memory Call Air Vac Technical Support Preheat Occurs when the preheat cycle continues for more than 8 Call supervisor to modify minutes without reaching the board target temperature The allow preheat temperature process is terminated to be reached Or change global default setting Process The process running requires one or more thermocouple to Install t c in appropriate Thermocouple continue channel Verify that the T C is good Process Cycle History Occurs when there is an error when the software tries to Ask supervisor to call Run Graph History read or write to the cycle history file Air Vac technical support Run Export History Temperature Limits Occurs when a pre determined tempera
88. e Loosen Nut Loosen rear bearing and remove Lubricate bearings Loosen set screws small A of front face of carrier bar Loosen screws of front bearing and remove Lubricate bearing Re install rear bearing and tighten Install front bearing Tighten set screws Tighten screws of front bearing Slide rail Movement should be firm but not stiff Check tension by twisting rail Reattach the x bearing rail Reattach the diffuser and board carrier Check perpendicularity of carrier Check diffuser to carrier parallelism A Remove heater cover Remove all grease from bearings and shafts top and bottom with alcohol Brush on and wipe Apply silicon vacuum grease on shafts and bearings Remove heater shield Loosen nut under plate of center front bearing C Adjust nut under center bearing Do not over tighten bearings will separate Retighten nut under plate C Adjust Nut DRS25 User Manual 0025 00 901 10 9 Section 10 Maintenance To correct nozzle clamping mechanism Disconnect power Remove heat shield opread carrier arms far apart Remove the 3 screws A of the heater head cap Note all washer and spacers of the heating element must go back in the right order Heating element is keyed Remove heating element D Tighten theta mechanism e Cleaning of nozzle vacuum tube C Check heating element for cold joints or burnt areas Use spanner wrench turn counterclockw
89. e and flow have been verified the next step is to verify heater temperature accuracy IMPORTANT DISCONNECT THE BLUE FLOW METER HOSE FROM THE FLOW CALIBRATION FITTING AND RECONNECT THE BLUE UPPER HEATER HOSE FAILURE TO RECONNECT THE UPPER HEATER HOSE PRIOR TO RUNNING THE TOP HEATER WILL CAUSE THE TOP HEATER ELEMENT TO FAIL 4 4 1 Upper Heater Verification Note These 4 steps are to be performed only when the nozzle heater is replaced At the Main Screen right click on the Air Vac logo Go to Set Up Communications Screen Zero out all of the Temperature Offset Numbers Exit Screen Perform a Heater Burn In Test to break in the heater then proceed to the steps below Perform Temperature Scale Test select Options from the menu bar Select Open File Group System System System Select the Temperature Scale Testing profile and click on the Thumbs Up icon Click Thumbs Up again The Run screen for the Temperature Scale Testing profile will appear RS Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jag Functions Machine Cooling Process Information Nozze System Preheat System Thermocouple System Force System System Status 500 Memory 625 E EN hoo N2 FootSw 1000 Gele Cooling Ring Grams nm 315 Inforn on Date 09 26 2005 14 27 Temperature vs Time 0 Control A Cycle Start e Install the NCAL 1 Temperature Calibration N
90. e check box B allows the operator to program a special vacuum port used for the probe handling tool The probe handling tool helps to minimize any potential damage to the component during the load removal procedure Programming this check box checked will activate the vacuum for the current event Run screen A clear check box will deactivate the vacuum for the current event Run screen Device Nozzle Separation Check Box The Device Nozzle Separation check box D allows the operator to program a small volume of air back through the nozzle vacuum tube This puff of air helps to separate the component from the nozzle Programming this check box checked will activate the air flow for the current event Run screen A clear check box will deactivate the air flow for the current event Run screen Nozzle Vacuum Check Box The Nozzle Vacuum check box A allows the operator to program nozzle vacuum The operator can use this device control to pick up or release the component at the appropriate process time Programming this check box checked will activate the vacuum for the current event Run screen A clear check box will deactivate the vacuum for the current event Run screen Cool Air Injection Check Box The Cool Air Injection C check box allows the operator to program an air flow bypass of the upper heating element nozzle If this option is installed air can be routed around the heating element producing cool air throu
91. e following metal placards are affixed to the DRS25 system This label describes the electrical and air requirements for the system The overall system requirements can be found in the facilities section of this manual AIR VAC ENGINEERING COMPANY INC AIR VAC SEYMOUR CONNECTICUT 06483 e U S A DRS25 Serial Number Voltage 220 VAC 5 50 60Hz 30A Air Nitrogen Pressure 90 130 PSI 8 3 1 Warning Label Description and Placement The warning and hot surface labels found on the DRS25 system are intended to prevent injury to the operators and users of the DRS25 system Warning HOT the upper heater and diffuser plates of the system are required to reach temperatures well above 100 C Labels are found on the covers of each heated surface CAUTION HOT SURFACE AVOID CONTACT WITH DIFFUSER PLATE High power and static sensitive warning labels advise personnel of potential issues when the machine covers are opened CAUTION CAUTION HIGH VOLTAGE CONTENTS SUBJECT TO DAMAGE BY STATIC ELECTRICITY DISCONNECT POWER DO NOT OPEN BEFORE OPENING EXCEPT AT APPROVED STATIC FREE WORK STATION DRS25 User Manual 0025 00 901 8 6 8 4 DRS25 System Alarms Section 8 Safety The following alarms to the DRS25 system will halt the process until the problem has been corrected and the alarm is cleared e Maximum Time Motion Communication link Force Communication link e Temperature Communication link e Cycle counter
92. e menu will send the report to the default printer 2 Report Hotepad iols Fie Edt Seach Date 84 16 98 DATA POIHT DETAIL REPORT Page 881 PEGA 225 Soldering Air Vac demo board H18815x1881 18111354 DRS GC 4WINDOWSYDRSZAYEXPORTYBBBBB P 05 dat 15 254 03 05 98 Sec E Hoz Dif 1 2 3 4 5 7 8 1 2 81 A 31 A A B 0 2 2 81 76 A A A B B 3 2 81 145 68 B B B B 4 2 81 145 61 B B B B E Edit Search 5 2 81 155 61 8 8 8 8 8 8 g T 6 2 81 1 61 B B B B 7 3 81 148 31 B B B a Open 8 3 80 148 38 B B B A 0 3 BB 1580 38 B B B a Save 18 6 79 151 34 a a B 0 B 8 11 6 79 158 38 B B B a save As 42 79 158 31 B B B 13 6 78 1580 31 B B B B Page Setup 14 78 151 3B B B Pr 15 78 151 31 B B B a rnnt 16 78 151 21 B B B B B B 17 78 151 38 B B B a E wit 18 78 151 38 B B B en 19 78 1580 31 B B B a 28 78 1580 38 B B B 21 6 78 158 31 B B B 22 6 78 159 38 B B B 23 6 78 159 31 B B B a 6 78 159 31 B B B B 25 6 78 159 38 B B B B 26 6 78 159 31 B B B B 27 6 78 150 38 B B B B 28 6 78 150 38 B B B a B DRS25 User Manual 0025 00 901 5 71 Section 5 Software Overview Run Data Point Summary Report This option allows the operator to print the graph data s
93. e nozzle vacuum in the event prior to the component removal motion event Teach en LED Adjustment Build Photo Links ARE SAREE gt Vision and Nozzle System Pos Pos Rate Temp C Sec Dest 00 000 Dest 00 000 zn o0 o0 Be x Replay Thermal Sequence 5 ovg ABS Air C mm 0 S C 2 REL N Nitrogen inch SELTENE Vision Lights 2 Probe 100 s 108 Cool Air Video Jog Ed ESI Site Cleaning System Arial Sensor Auto Adj Z Pos Vacuum Sensor Range ooo Adj Pulse 000 Clogged 000 Vacuum 000 Cooling Ring Time Motion 7 Z Power Events 000 C Foot Time DE uen Miscellaneous Control dd Pulses Solder Reflow 18300 BA Ms 7 Thermocouple System a aa a Action C Disable Standard Replace o Add C Subtract Data C If ERROR Stop Process l Device Nozzle Separation mm sme Ez Em il mmm EX Force Placement System Actual Dest Range Jed fe ooo ooo Zero Force Be Vacuum Sensor Stop Force Placement Auto Adjust Display Only Rate BT Lower Heating System Removal System a si m Vacuum Retry Wm Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Tem
94. e placing board in Board Edge Supports C e Hint Locking the carrier with the table lock may hold the carrier in place for easier adjustment e Adjust the Board Edge Supports D to enhance the overall board stiffness e Hint Optional fixturing may be required for thin or boards which warp easily e Slightly tighten the Board Edge Supports C to secure the board DRS25 User Manual 0025 00 901 7 9 Section 7 Operator Training 7 3 4 Position Board Supports under BGA Pull the carrier to the front Raise the nozzle using the z axis knob Lock the carrier using the table lock Raise the carrier board until the carrier catches on the side supports Note The bottom heater will be hot during operation DO NOT TOUCH THE BOTTOM HEATER DURING OPERATION e Move the board supports in a 3 4 inch square pattern under the BGA against the board material Note Do not place the board supports against any device The board will bend when placed against the diffuser Note During actual operation the board may flatten by the bottom heat The board will also expand carrier is spring loaded to allow for expansion DRS25 User Manual 0025 00 901 7 10 Section 7 Operator Training 7 1 7 Position Temperature Sensor or Tape Thermocouple to Board If a thermocouple is used attach it to the board using Kapton tape approximately 3 inches from the device Plug temperature sensor or thermocouple into channel 1 The program
95. e source or target profiles Next the destination group combination customer board device must be selected At this point the operator can click on the Move button to execute the operation This option performs a move not a copy Profiles are permanently moved to the destination group DRS25 User Manual 0025 00 901 5 16 Section 5 Software Overview 5 2 6 Delete Profiles The Delete Profile screen allows the operator to delete files based on the Long Name similar to the Open option The operator will be prompted before any files are removed Delete Profile Screen Delete Profile Files CBGA 256 Removal 100 inch thick board N845x8 45 CBGA 256 Site Cleaning with 5G100DRS 100 thick board N845X845 CBGA 256 Soldering 100 inch thick board M845x845 CCGA 1088 Removal 100 inch thick board M1730X1 730 CCGA 1088 Site Cleaning with 56100085 100 thick board 3071 730 CCGA 1088 Soldering 100 inch thick board N1730xX1 730 CCGA 625 Removal 100 inch thick board M1 3051305 CCGA 625 Site Cleaning with 50100085 100 thick board 1 3051305 CCGA 625 Soldering 100 inch thick board 1 3051305 CSP 46 Flux application directly on spheres N26D G 3 CSP 46 Removal 030 inch thick board N28D v 3 CSP 46 Site cleaning with SG100DRS N28DYG 3 CSP 46 Soldering after application of tacky flux on spheres 030 board M28D PBG 119 Removal 100 inch thick board N570x885 PRGA 119 Site
96. e that are currently displayed Files Profiles listed under a specific Customer Board Device group Customer Groups Air Vac Engineering Company Open Profile NotePad Files CBGA 256 Site Cleaning 100 thick board N845X845 256 Removal 100 thick board N845X845 256 Soldering 100 thick board N845X845 CSP 46 paste application directly on spheres N28DVG 3 Board Groups CSP 46 Removal N28DVG 3 Demo Board CSP 46 site cleaning SG100DRS N28DVG 3 CSP 46 Soldering AFTER flux solder paste on sphere application N28DVG 3 Profile Library PBGA 225 256 Removal 068 thick board N1081X1081 PBGA 225 256 Removal 100 thick board N1081X1081 PBGA 225 256 Site Cleaning 068 thick board N1081X1081 PBGA 225 256 Site Cleaning 100 thick board N1081X1081 225 256 Soldering 068 thick board N1081X1081 PBGA 225 256 Soldering 100 thick board N1081X1081 PBGA 352 Site Cleaning 068 thick board N1396X1396 Device Groups PBGA 352 Removal 068 thick board 1396 1396 Area Arrays PBGA 352 Soldering 068 thick board N1396X1396 Demo Board SBGA 432 Removal 100 thick board N1589X1589 Leaded Devices Cremer Air Vac Engineering Company Board Group Profile Library Device Group rea Arrays To make a profile selection click on the desired entry File list box then click on the Ok button to open this file DRS25 User Manua
97. ed reference flow meter supplied with the machine Initial conditions e Machine power must be turned on for a minimum of 30 minutes e Pressure to upper heater must be set precisely to 80 psi 5psi Set Up Disconnect the current Blue Hose from the Flow Cal Fitting A e Connect the Blue Hose from the Flow Meter into the Flow Cal Fitting A Meter exhausts to atmosphere WARNING Be certain all hoses are inserted into fittings completely A bad connection can result in a burned out heater or erroneous calibration readings du gi a Lo uu FE Moe n ans ds Ww a y goce DRS25 User Manual 0025 00 901 4 6 Section 4 Machine Function Verifications To access the Flow Adjustment Screen Log on as DRS25 or any high level security operator and select the Thumbs Up icon Using right side mouse button click on the Air Vac logo You are now in the Hidden Setup window Select Setup from the menu bar oelect Nozzle Flow Meter The Nozzle Flow Adjustment screen will appear as shown below 6 096 C 20 30 e C 40 50 60 C Nozzle Flow Sensor Nozzle Flow Controller 20 Ofset O aexotsec 25 20 Offset 3096 Offset 40 Offset 1 sosottset 40 Offset 25 soxotsec 75 H 60 25 rexotsec 25 60 Offset 70 Offset D 80 Offset 25 90 Offset 80 Offset 25 so omsec 0 Contolleridie 0 C Air 100 1
98. em senses an undesirable condition an alarm screen will appear The alarm screen will indicate the nature of the problem The light tower if your machine is equipped with will illuminate a red light next to the alarm that is occurring The following pages list all alarms and what causes them Alarm Control Maximum Time Process Cycle History ri Motion Communication Link Hun Graph History Force Communication Link Hun Export History Temp Communication Link Temperature Limits Flow Sensor Cycle Counter Low Memory Low Pressure Process Thermocouple 1 No Activity Time Qut Force Removal ri Force Placement Press ENTER key ta stop audible alarm 11 5 1 Maximum Time Alarm The maximum time of the profile has expired e Modify profile e Work faster e Call Air Vac Process Support DRS25 User Manual 0025 00 901 11 4 Section 11 Troubleshooting 11 5 2 Motion Com Link The communications link between your computer and your motor drivers for your vision cube and your Z axis is not functioning Make sure the cables are plugged into your two motor drivers e sure the green LED lights are lit on the two drivers e Check that your DB25 cable is plugged into the COM4 port expander and that the ribbon cable that connects that port to the expander card is plugged in e Shut down Windows re boot and try motion again in set up vision system screen e Call Air Vac Technical Support 11 5 3 Force C
99. en Profle Notes e Select Thumbs Up to advance to the Run screen DRS25 User Manual 0025 00 901 4 12 Section 4 Machine Function Verifications e The Run screen should now appear as shown below e Select Load Functions A Click on the Nozzle Load icon B and follow the prompts to properly load the nozzle N1103B1103 provided with the system The insertion tool A1103B1103 must be placed in the loading station prior to this process e Once the nozzle is loaded select the Thumbs Up icon to close the load function window and then click on Cycle Start C to start the training profile A mm BGA Removal 60980001 DR5 LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling Nozze System Preheat System Thermocouple System Force System System Status 50 60 500 mory 375 625 s EN EN m Set Point Set Point Set Point 2 FootSw Air 875 1000 Cycle Busy Alarm Nozzle n Ring 6 Point EI Grams Date 09 26 2005 14 27 Temperature vs Time 0 450 0 400 0 350 0 300 0 T C Control 250 0 e 200 0 150 0 100 0 50 0 0 00 00 00 48 01 36 0224 03 12 0400 0448 05 36 06 24 0712 08 00 08 48 09 36 10 24 11 12 12 00 Temperature Time Event Time Profile Tme Z Power Board it Zu di start m mm BGA Removal 25profilenotesremoval b qp ag I 2 27 PM
100. ent event Nozzle System 111 Diffuser System Vision System Force System Board Cooling Event Control Event Message Alert Message 1 0 EEEEEEBEEEE EEEEEEBEEEE mi mi na mi m mi mim oy Go RO EEEEE SIT 3 mm Action B DRS25 User Manual 0025 00 901 5 48 Section 5 Software Overview The Table Event Editor provides the operator with the ability to quickly adjust any information contained in the parameter control table e his can be accomplished by first entering the desired information into the Data edit box B Next the operator must select the required Action A radio button Replace Add Subtract The Add button uses the Data edit box value to increase the selected table field The Subtract button uses the Data edit box value to decrease the selected table field The Replace button uses the Data edit box value to overwrite the selected table field Note These Action adjustments can be quickly applied by positioning the cursor over the desired table field and clicking on the right mouse button Note The operator has the option of typing directly into a table field This is accomplished by clicking on the desired table field with the left button highlight table field The operator can then press the enter key to enable the table field edit mode At this point the operator can use the standard keyboard to adjust the table field information DRS25 Us
101. er Manual 0025 00 901 5 49 Section 5 Software Overview 5 3 2 Run Process The Run screen allows the operator to cycle a process profile A profile must first be opened using the Open option or created using the Teach option During each event of the cycle the system continuously monitors and reports the following control information e Heater and thermocouple temperatures Nozzle and diffuser flow rates Force placement removal procedures Foot switch control Alarm conditions Event messages and temperature plotting graphically show the progress of a cycle xx mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling Nozze System Preheat System Thermocouple System Force System System Status 50 60 500 40 70 375 625 7 i 250 750 a ES 20 00 Set Point Set Point Set Point FootSw Air 125 875 Actual Actual 0 1000 Cycle Busy Alarm Nozzle Cooling Ring Grams n Set Point Actual Ramp EX EN Gra ph Process Date 09 26 2005 14 27 Temperature vs Time 500 0 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 Control Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Time Event Time IJ Profile Time 0 Z Power Board i
102. erator to clear zero the cycle counter The cycle counter controls the number of consecutive cycles that can be processed without interruption When the maximum number of cycles is achieved the system will generate an alarm The alarm condition will continue until the operator selects this men option 5 7 Setup The standard Setup menu allows the operator to adjust machine related setup or control parameters These opti are only available to high priority operators 5 7 1 Diffuser Idle Selecting the Diffuser Idle from the Setup menu will present the operator with the Diffuser Idle Control screen This screen allows the operator to adjust the temperature and flow DR524 Diffuser Idle Control u Ons rate for the diffuser system left right These settings are Left Diffuser Temp Right Diffuser Temp global and will control the diffuser during all screens except the Run screen Individual profiles may be programmed to deactivate the Diffuser Idle feature during the Run screen Low Low High High 5 7 2 DRS Maintenance Process Counters oelecting the Process Counter option from the Setup menu will present the DRS Maintenance Process Counter screen This screen displays the Current Process Cycles and Max Process Cycles parameters The operator change these counters by deleting the old value and retyping the new value The Machine Cycles counter is not an adjustable number This represents the total number o
103. erature setting display white Idle Temperature setting when machine is not used Thermocouple System Top Box Set point temperature This is the target temperature for that event Bottom Box Actual temperature Note The system has a maximum of 8 thermocouple channels Only pre programmed active channels will be displayed Each channel has an identification number When a thermocouple channel is controlling the process the T C Control LED will change to yellow Note All active thermocouple channels must be connected to a thermocouple sensor before the process cycle is started Failure to do so will result in an alarm condition DRS25 User Manual 0025 00 901 7 35 xx mm BGA Removal 60980001 DRS Auto Scale Graph Load Process Link File TOREM Soldering Desoldering Site Cleaning zie System reheat System 50 60 40 70 30 80 20 90 10 100 a 0 110 Nozzle Set Point Set Point Set Point Idle Set Actual Ramp Idie Idle Date 09 26 2005 14 27 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 Event Event lr of k Ed Site Clean System Status Footswitch Air Cycle Busy Alarm View Photo Links Time Profile Time EM 1 Section 7 Operator Training Export History Load Function Jog Functions Machine Cooling Thermocouple System Farce System 500 System Status
104. es Force Placement Removal Procedures Standard Force Placement Step 1 Program a Z axis component position that is slightly above the board Select the Zero Force check box Step 2 To the same event the operator must enter a Destination B and a Range C force value The Range value allows a tolerance to be applied to the force placement accuracy Step 3 All events beyond the actual force placement event steps 1 2 must be designed to eliminate any Z axis motion This is accomplished by checking the Do Not Move radio button Note Standard force placement does not consider any force changes that may occur during subsequent heating events Note The Teach button must be selected to temporarily save any control parameter event adjustments Force Placement Auto Adjustment otep 1 Program a Z axis component position that is slightly above the board Select the Zero Force check box Step 2 To the same event the operator must enter a Destination B and a Range C force value The Range value allows a tolerance to be applied to the force placement accuracy otep 3 All events beyond the actual force placement event steps 1 2 must be designed to eliminate any Z axis motion This is accomplished by checking the Do Not Move radio button otep 4 Any event that has the Auto Adjustment check box selected will allow the system to make force corrections These corrections may be necessary due to board nozzle or
105. ess Thermocouple 1 No Activity Time Out Force Hemoval 3 Force Placement Press ENTER key to stop audible alarm This screen is not real time correcting the problem will not reset the alarm LED red yellow Selecting the Up Thumb will close the Alarm and Run screens and return the operator to the Main screen Assuming the alarm condition has been corrected the operator can attempt to re run the cycle DRS25 User Manual 0025 00 901 5 51 Section 5 Software Overview Profile Notes Page The Profile Notes button allows the operator to refer to any application related notes that may have been setup by the process engineer The operator cannot access these notes while a cycle is active Open Profile Notes Description COMPONENT REMOVAL Component PBGA 225 255 272 324 27 MM Location Flux Type NONE Nozzle INSERTION TOOL ATUSTATUST Notes PLEASE NOTE NOZZLE MUST BE LOADED BEFORE RUNNING PROCESS THE FIRST TIME TO CLICK ON THE START CYCLE ICON Application OPEN TOOL BAR TO JOG FUNCTIONS MENU OPEM AND SELECT NOZZLE LOAD ICON Notes PLUG THERMOCOUPLE OR NON CONTACT SENSOR INTO CHANNEL 1 DIFFUSER SHOULD BE HEATED IN IDLE MODE PRIOR TO RUNNING THIS PROCESS DRS25 User Manual 0025 00 901 5 52 Section 5 Software Overview General Run Screen Layout The Run screen is organized into the following sections mm BGA Removal 60980001 DRS Numeric Process Info
106. estination drive recognized by the system ZIP drive network drive he user can choose between Profile and Thermal Sequence Thermal SMART Track files The user retains the flexibility to copy files directly using the Explorer tool The new backup and restore utilities will recognize any method of file transfer DRS25 tools or Explorer DRS25 User Manual 0025 00 901 Options Control New Open Save Save Delete Backup Profile Restore Thermal Sequence File Maintenance Print Mate Pad About DAS Exit Section 5 Software Overview 5 2 8 Print Process Control Parameters This option requires a control profile to be open Selecting this option will format the currently open profile parameters and display the report using the NotePad tool In addition the operator will be prompted to enter the number of lines per page Printers can be configured in many different ways Some trial and error may be required to correctly identify the printable lines per page selecting the Print option from the File menu will Printer Setup Send the report to the default printer Process Control Parameters Process Notes Photo Links Report Notepad File Edit Search Help Date 84761798 PROFILE FARAHETER REPORT Page 861 FEGA 225 256 Removal d 868 thick board H188151881 1811838 drs Event 1 Plastic Ball Grid Array 225 256 272 Removal Profile Event Control Time 863 Speech ON Alert O
107. et Point Nozzle Set Point Actual Ramp Date 09 26 2005 14 27 Temperature vs Time Temperature Load Function 250 Jog Functions Force System 500 Grams 09 36 Board 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 Time Event Time Profile Time Z Power Ed EM zi D 4 mm RAGA BemoxaL 5 orofilenotesremoyal b E F Event Time D Time remaining in the current event Event Counter E Current and maximum profile event counters Process Time F Total overall cycle time all events DRS25 User Manual 0025 00 901 Machine Cooling System Status Memory m FootSw Air 625 750 EN 875 Cycle Busy Alarm 1000 Cooling Ring n T C Control 10 24 11 12 12 00 Section 5 Software Overview Function Buttons G This section of the Run screen displays the function buttons that are available to the operator xx mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling Nozze System Preheat System Thermocouple System Force System System Status 500 Memory SU 60 315 625 EN EX El 40 250 750 N2 FodSw Air Set Point Set Point Set Point 875 Actual Actual Actual T CUBES n Ring Idle Idle Idle Grams i ooo Barr e Date 09 26 2005 14 27
108. et summary This report will be organized by thermocouple channels and will list the same summary information that can be displayed screen using the Graph Data menu Note Selecting Print from the File menu will send the report to the default printer B Report Hotepad Ic x File Edit Search Help Date 85 16 98 DATA POINT SUMMARY REPORT Page 661 225 Soldering fiir Uac demo board H188151881 18111354 DR5 EC SAWINDOWS DRS 2S EXPORTS 860080265 dat 15 24 03705798 T C Temperature 096 Light Green Hin Temperature 629 Temperature Slope 80 24 Time Over 183 C 666 Time Over 666 C AHA Edit Search Save Save Page Setup Frint Exit 5 3 4 Auto Scale Graph Menu Option The Auto Scale Graph menu allows the operator to display the entire cycle data set on a single graph window During the cycle a 12 minute graph window is maintained and displayed Many process cycle times including final alignment time may extend beyond this 12 minute window This menu option is only available when the process is not cycling 5 3 5 Load Process Link File Menu Option The Load Process Link File menu allows the operator to toggle between the soldering desoldering and site cleaning profiles This allows a related profile to be cycled without leaving the Run screen This menu option is only available when the process is not cycling DRS25 User Manual 0025 00 901 5 72
109. eyond the last event DRS25 User Manual 0025 00 901 5 30 Section 5 Software Overview Zand Vision Axis Jog Buttons Z Axis Display A This motor coordinate represents the actual position of the Z axis Display B This motor coordinate represents the destination event position of the Z axis This coordinate is taught during the profile motion development phase The Z axis Up button C will raise the nozzle The Z axis Down button D will lower nozzle Vision Axis Display A This motor coordinate represents the actual position of the Vision axis Eu B Display B This motor coordinate represents the destination event position of the Vision axis This coordinate is taught during the profile motion development phase The Vision Up button C will close the Vision axis toward back of machine The Vision Down button D will open the Vision axis toward front of machine Note The Jog check box controls the axis velocity Note Ifthe Motion check box is selected checked the Z and Vision axis coordinates will be saved each time the Teach function is performed current event C 7Z Move ABS Z axis motion can be defined as an Absolute Relative or Do Not Move event An Absolute ABS move positions the Z axis directly at the specified motor coordinate A Relative REL Z Mowe REL move positions the Z axis a fixed number of pulses from the current motor coordinate Sele
110. f l machine cycles that this machine has Current Process Cycles Max Process Cycles Machine Cycles processed Ur can DAS Maintenance Process Counters DRS25 User Manual 0025 00 901 Section 5 Software Overview 5 7 3 Customer and Network Setup Screen The Customer and Network setup screen allows operator to adjust several customer specific parameters e he Customer Name field will be displayed on the Main screen e Serial field is used as part of the profile name that is saved to the hard disk drive This number should exactly match the serial number of the machine This value is setup at the factory and should not be changed e The following edit boxes control the critical system directories Open Export History Photo DRS Setup Customer and Network Customer Network Information Name CUSTOMER NAME Serial 11234 System Dir cAWINDOWS DRS24 SYSTEM Open Dir C3wINDOWSYDRS2 PROFILES Thermal Dir C AWINDOWS DRS24 THERMALS Export Dir CAWINDOWS DRS24 EXPORT History Dir cAwINDOWS D HS 24 5 YSTEM Photo Dir CAWINDOWS D HS 24PHOTOS DRS25 User Manual 0025 00 901 5 80 Section 5 Software Overview 5 7 4 Customer Board and Device Group Setup Screens The group maintenance screens allow the operator to create or delete a group To create a new group name type the desired group name into the group edit box A Click on the New Add Entry button to insert the new gr
111. fingers the parts handling vacuum probe can be used Event 3 Position Temperature Sensor component pick up Position the thermocouple or temperature sensor option over the board If a thermocouple is used use Kapton tape to attach it to the board material This could be done prior the program being activated Note The sensor is meant to read the board temperature It is important to position the sensor thermocouple away from the nozzle and on or over another device or at the edge of the board The nozzle vacuum will automatically moved to the component pick up position and the nozzle vacuum will be turned on to hold the BGA DRS25 User Manual 0025 00 901 7 26 Event 4 Align Device Lock Table After Alignment Press Footswitch to Continue The vision system will automatically be presented This is the most important step for component replacement Please spend adequate time to align components properly 1 Check that the microscope is in the top highest position Press the microscope slide lock Push the ul along the track to the highest position Note Lowering the microscope for alignment will result in placement error due to incorrect viewing angle during alignment 2 Use the x y adjustment wheels of the table to move the board so that the leads and pads are in the field of view 3 Tilt the microscope as required to see the site and BGA in vision system DRS25 User Manual 0025 00 901 Sect
112. fter the Open Profile Notes screen xx mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling Numerical Process Information Ec Nozze System Preheat System Thermocouple System Force System System Status 500 625 Memory EN EN El Set Point Set Point Set Point 2 FootSw Air 90 4 Actual Act F 110 ual Actual 1000 Cycle Busy Alarm 375 Nozzle E E Cooling Ring Set Point Actual Ramp Idle Idle Idle EN ER mo fo ol idi B Date 09 26 2005 14 27 Temperature vs Time 500 0 450 0 400 0 350 0 300 0 T C Control 250 0 200 0 Temperature 150 0 100 0 50 0 0 00 00 00 48 01 36 02 24 03 12 04 00 0448 05 36 06 24 07 12 08 00 08 48 09 36 1024 11 12 12 00 Event Time Profile Time Z Power Board La He Lei EM Mstart LB mm BGA Removal 25profilenotesremoval b fi BS 2 27PM The operator s only task is to follow the instructions on the screen Click On The Cycle Start Button To Begin Process A program consists of a number of steps or events The Message Box will change for each event to provide instructions The information on the screen is only for recording to a history file The operator is not responsible for process development Temperatures times and air flow settings cannot be chan
113. ged on this screen Option The nozzle diffuser and thermocouple system displays may be removed from the Run screen Click on the Cycle Start Stop icon The Cycle Start Stop Button is located at the bottom right side of the screen Move the cursor to the icon and click Note The Cycle Stop icon is used to stop the process at any time DRS25 User Manual 0025 00 901 7 12 Section 7 Operator Training Typical Removal Program Event 1 It is a timed event This is shown at the bottom left side of the Run Screen After programmed timed has occurred Event 2 will automatically 00 00 00 48 01 36 02 24 be actived Event 2 nozzle to board position There is no operator task involvement during this event This is a timed event Time is set to zero seconds The nozzle automatically move to approximately one inch from the board Note The nozzle must not hit any device on the board or the board carrier Notify the programmer to correct Damage may occur to machine or board Event 3 Position Nozzle Over Device Vacuum Tube Should Lightly Contact the BGA Press Footswitch to Continue 1 Move carrier to center BGA under nozzle 2 Using the z axis knob lower the nozzle using it slightly touches the top of the BGA Press footswitch to continue Note The operator has as much time as needed as this is a footswitch not time controlled step DRS25 User Manual 0025 00 901 7 13 Section 7 Operato
114. gen and Air inputs to the machine Measure both legs of the incoming 220V ac line to insure the voltage is within tolerance of the heating element 210 232 VAC Check fuse F3 and replace if blown e Measure the resistance of the upper heater element It should be 52 ohms See section 10 Maintenance for details on how to checkout the heating element Replace the element if required 11 1 2 Communications Problems If the temp communications link alarm is persistent e Insure that the communication cables relating to the temperature control are connected properly see schematic or block diagram in the schematics section of this manual e Reboot computer to unlock COM port e Verify the setup parameters 11 2 No or Low Flow Condition e Verify that the incoming air line is still connected Look for problems with the lines e Verify that the incoming pressure is set for 80 PSI e Check fuse F6 should be O S A Slo Blo fuse 11 3 Nozzle Does Not Pick Up Component e Check nozzle vacuum filter Clean and replace element F1AE e Check nozzle vacuum cup Replace if worn or missing 11 4 No Motion e Reboot computer to unlock COM port DRS25 User Manual 0025 00 901 11 3 Section 11 Troubleshooting 11 5 Machine Alarm Conditions amp Alarm Screen Alarm indication explanation e Green condition OK e Yellow warning may effect the process results Red process aborted process problem issue When the syst
115. gh the nozzle Component cool down is an example of the potential usage Note This is an optional feature Teach LED Adjustment Build Photo Links Vision and Nozzle System Pos ERES Pos Rate 4 Temp C Sec Dest 00 000 Dest 00 000 0 000 000 Be ae Options V l Replay Thermal Sequence S Z Move ABS Air C mm A 0 S C Z Move REL Event Control N C Do Not Move Nitrogen jn Time sec Motion V Z Power Event T Vision Lights Noz Vac Probe B alas C Foot Time 180 un i9 F Cool Air Video Jog ope EE ECF vewice nozzle Separa Miscellaneous Control Site Cleaning System Alert Ak SERSUE Auto Adj Z Pos Vacuum Pul Solder Reflow 183 C Clear ulses bd Sensor Range 000 Adj Pulse 000 EA Msg Clogged 000 Vacuum 000 D Cooling Ring Rate _ Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 Force Placement System Actual Dest Range 0000 00 0000 00 0010 00 DE Vacuum Sensor Stop Force Placement Auto Adjust Display Only Thermocouple System Lower Heating System 1 R Temp From De amu a Flow Off C Low Flow High Flow Action
116. has occurred Auto Adjust During the heating process the nozzle the board or the component may experience expansion or growth The Auto Adjust F check box allows the operator to adjust control the applied force that occurs during an event Run screen The force Destination and Range values are used as a target control points for the adjustment procedure Zero Force Button Actual Force Display A H The Teach screen allows the operator to manually visually test approximate target force placement removal values For Force placement testing the component can be lowered to an above board position Clicking on the Zero Force A button will clear any currently applied force that may have been generated during the X Y Z axis positioning The operator can then manually powered or de powered lower the component while watching the Actual H force display For Force removal testing the nozzle can be lowered to the component engagement position At this point the nozzle vacuum should be activated Clicking on the Zero Force A button will clear any currently applied force that may have been generated during the X Y Z axis positioning The operator can then manually powered or de powered raise the component while watching the Actual H force display A negative force will be displayed just before the nozzle breaks loose from the component This negative force can be used to determine the success of a removal process Run screen Exampl
117. hed The next event will occur automatically when the preheat temperature is reached Note Board preheating does time will vary depending on the initial temperature of the bottom heater board and machine Note Board preheating temperature may be programmed differently for various assemblies Event 7 There is no operator involvement during this event The programmed heating of the BGA is automatic This is a timed event The total time is displayed 00 00 00 48 01 36 at the bottom left of the Run screen These segments may be broken up into separate events Event 8 There is no operator involvement during this event The nozzle will automatically move slowly to the BGA with the nozzle vacuum activated Note Nozzle vacuum is displayed The DRS25 has a vacuum sensor to sense the BGA and automatically go to the next event DRS25 User Manual 0025 00 901 7 15 Section 7 Operator Training Event 9 There is no operator involvement during this event The nozzle vacuum will be on the hold the component The nozzle automatically move up to approximately 3 16 of an inch from the board Event 10 M M There is no operator involvement during this event The nozzle vacuum will be on the hold the component The nozzle will automatically move up to highest home position
118. his button executes a general motion utility This general motion utility can t be directly programmed as a complete function however the results of this motion can be saved to an event Typically this general position is adjusted to exactly match the specific component pickup requirements Vision Alignment a The Vision Alignment button will position the component to a predefined set of Z and Vision coordinates This position will be graphically displayed using a green button background The vision eee fiber optic lights will be automatically turned ON after all the axis motion has been completed This general motion utility can t be programmed as a complete function however the results of this motion can be saved to an event Typically this general position is adjusted to exactly match the specific vision alignment requirements This button can also be used to close and home the Z and Vision axis Live Video The Live Video button will activate the camera system and generate a live video image on the computer monitor DRS25 User Manual 0025 00 901 5 27 Section 5 Software Overview Limit Control set of process control parameters These limits are continuously monitored during the entire profile If a limit error occurs after the first 30 seconds of an event the process is immediately stopped and an alarm history entry is written emauil E E E E E a E This screen allows the engineer to program ap
119. ically detect a low memory condition Alarm screen N2 LED D indicates green the secondary pressure input nitrogen when required available has been connected to the upper heater Air LED E indicates green the main air source has been connected to the upper heater FootSw LED F indicates yellow the DRS25 machine is waiting for a foot switch response from the operator Cycle LED G indicates the process has been activated Busy LED H indicates yellow the computer is actively controlling motion force temperature or flow rate Warning When this LED is ON the operator should not touch the machine or interrupt any event activity Alarm LED I indicates the status of the controlling sub systems A red LED indicates an alarm condition A B C ER EE ER Foot Sw Air D G H 1 DRS25 User Manual 0025 00 901 5 58 Section 5 Software Overview Profile Event Alert Foot Switch Messages B This section of the Run screen displays system foot switch messages or pre programmed event alert messages Messages are used to inform the operator when machine interaction is required or to communicate the general progress of the profile cycle Note mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling Numerical Process Inform Nozze System Preheat System Thermocouple System Fo
120. ications Press Microscope Slide Lock and Push Scope to top of Track Purpose To train the operator in the use of the microscope 4 5 6 The nozzle and component will move automatically to the vision position Press microscope S ide Lock A Push microscope along track to the top highest position This step ensures that the microscope is in the proper highest position for vision alignment Note Lowering the microscope for alignment will result in placement error due to incorrect viewing angle during alignment When this task is complete depress footswitch until yellow footswitch indicator goes off B D A C Event 4 Viewing the Component and Pads in the Beam Splitter Turn the Zoom Lens B to 63 its lowest setting Use the X Y table to move the test board so that both the leads and pads are in the field of view Note Tilt the microscope as required to see the images Turn the zoom lens to approximately 1 25 to optimize the magnification of this device Adjust the focus using the Black Focusing Ring C Additional focal adjustment can be done by turning the adjustable Eye Pieces D Adjust the LED lighting intensity by clicking on LED Adjustment in the top left corner Close window when complete After this task is complete depress the footswitch until the yellow footswitch indicator goes off DRS25 User Manual 0025 00 901 4 15 Section 4 Machine Function Verifications 4 5 7 Align Device
121. ield Z Axis ODOODODOOOGOQ 0060050050050 2050090050000 Disconnect machine main power Remove heat shield to expose the element Using the z axis adjustment knob lower the assembly to the bottom most position Remove the 3 allen head screws from the heater head cap Carefully separate cap from heater DRS25 User Manual 0025 00 901 10 20 Section 10 Maintenance 2 Note orientation of heater before seating into nozzle housing 3 Place heater into nozzle housing with keyway to the right side viewed from operator position wiggle side to side to be certain heater is seated Keyway Keyway right side left side No Thermocouple Thermocouple Correct Orientation Incorrect Orientation 4 Place gasket over heater Gasket Nozzle Housing DRS25 User Manual 0025 00 901 10 21 Section 10 Maintenance 5 Before attaching Heater Head Harness to heater turn heater cap over and inspect heater wires for breaks air lines for leaks and condition of the PCB that interfaces with heater If damage is present do not attempt to use Call Air Vac Technical Support Air In Wire Bundle PCB 6 Once harness passes inspection attach to heater Snug only screws in place alternating bolt pattern Over tightening the screws will damage cap NOTE For CXX modules the stack up will be gasket spacer gasket 7 Be certain the calibration hose is securely attached in the rear of the machine before
122. ing system Remove hose from Filter to Site Cleaning Nozzle to determine if hose must be replaced Remove Filter element and recheck to determine if Filter element must be replaced Remove Vacuum pump muffler and recheck to determine if muffler must be replaced Disassemble Vacuum pump clean and recheck to determine if vacuum pump must be cleaned or replaced e Vacuum gage must read at least 18 Hg with system closed e Close end of hose with your finger and turn on site cleaning vacuum If vacuum gage reads under 18 Hg system has vacuum leakage or vacuum pump is clogged e Tighten Filter jar Tighten all connections e Remove Vacuum pump muffler and recheck to determine if muffler must be replaced e Disassemble Vacuum pump clean and recheck to determine if vacuum pump must be cleaned or replaced e Replace Filter element Replace Hose from Site cleaning nozzle to Filter Replace Hose from vacuum pump to Filter e Recheck system with Site Cleaning Nozzle connected e Vacuum gage must read 8 Hg or less with system open e Vacuum gage must read at least 18 Hg with system closed DRS25 User Manual 0025 00 901 7 40 Table Of Contents 8 Safety 8 0 Safety System Overview 8 1 General Safety 8 2 Additional Safety Precautions 8 3 Label Description and Placement 8 4 DRS25 System Alarms DRS25 User Manual 0025 00 901 Section 8 Safety NI A na A 9 C Section 8 Safety DRS25 User Manual 0025 00 901 8 2 Section 8 Safet
123. ion N26D G 3 PBGA 225 256 Removal 066 thick board N1081X1081 PRGA 225 256 Removal 100 thick board N1061 1061 PRGA 225 256 Site Cleaning 066 thick board M1081X1081 PBGA 225 256 Site Cleaning 100 thick board M1081X1081 PRGA 225 256 Soldering 066 thick board M1081X1081 PBGA 225 256 Soldering 100 thick board N1081 1081 PRGA 352 Site Cleaning 066 thick board N139641 395 PBGA 352 Removal 066 thick board N1395X1395 PRGA 352 Soldering 066 thick board 1 3961396 432 Removal 100 thick board N1589x1589 To select an entry the operator can highlight the line click and then select the OK button Up Thumb The operator can also select an entry by double clicking on the line DRS25 User Manual 0025 00 901 5 6 Section 5 Software Overview A pull down list box is very similar to a full list box except that this control is displayed on a single line and provides a pull down arrow By clicking on that arrow the list box expands to display several lines of information on the screen After making a selection the list box collapses back down to one line Pull Down List Box Customer Group Air Yac Engineering Company Board Group Profile Library Device Group Area Arrays For Example By clicking left button on the down arrow the board group list box will expand to show more of the possible choices The operator can select any line within the list box by simply
124. ion 7 Operator Training Section 7 Operator Training 4 Adjust the oculars to operator Focus microscope on the pads of the board using the focus ring and adjustable eyepieces 5 Adjust the zoom lens to increase magnification to enhance viewing Refocus as required Option A camera may be provided for operator viewing on the computer screen Note The auto height programmed may not be correct With the microscope focused correctly for the pads the BGA may be out of focus The BGA leads balls must be at the same level plane as the pads The operator has the ability to adjust the BGA height position Uncheck the Z Power box The z axis is now unpowered and free to move Using the z axis knob slowly raise or lower the nozzle until the component leads are in focus The leads balls will appear to be at the same height as the pads of the board If the nozzle is too high or low they will appear to be above or below the board pads 2 Check the Z power box to lock power the z axis motor Note The LED Lighting may be adjusted to operator preference Select LED Adjustment The LED Intensity Adjustment Screen will appear Adjust lighting intensity of BGA top and or board bottom to provide best contrast Ey LED Intensity Adjustment 4 Idle Close ale Graph Load Process Link File f 000 Soldering Desoldering m mH Site Cleaning Bottom oo BH DR
125. ise to loosen heater tube B Lift tube to remove Clean tube Run a 2 5 mm allen wrench down the vacuum tube C and carefully straighten Remove housing carefully rotate tube Remove nozzle ring D Clean all areas of anti seize Apply pressure stand on it with your foot on nozzle ring and housing to seat Remove spring clip and fingers Clean all areas of anti sieze Inspect for wear File burrs at top of fingers if necessary Apply anti seize at the two contact points E as shown Reassemble Move assembly up and down Check if all pem nuts are in place If not plate must be replaced Clean brass ring G of anti seize Apply anti seize at curved surfaces of top Apply a light bead around the outside Reassemble in reverse order Slide back into machine nozzle clamp goes in front Carefully bending vacuum tube to hold assembly in place G E y H I ai UJ UU 171419 i aj NERONE peces alvi viviviwiv Bj VA A A ATATATATA p 4 CL y pom 9 2 ant Snel na EiL M ee HA E CJUI X Loosen set screw F of ring Press rod to left side Retighten set screw 55504 K EX 5656 rs S oz f A U L Use the stainless steel brush STB7 to clean DRS25 User Manual 0025 00 901 10 10 Section 10 Maintenance 10 1 2 Process Related Preventative Maintenance
126. itical facilities issue applications can be programmed to only use the nitrogen option during process steps where stabile flow rate is essential A B Teach LE LED Adjustment Build Photo Links RE Options Vision and Nozzle System f Pos Pos a Rate Temp C gt 000 000 000 Dest 00 000 Dest 00 000 V q Replay Thermal Sequence D X Z Move ABS Air mm 0 C Z Move REL N C Do Not Move inch Time E Motion M 2 Power Events Velocity Accel Velocity 26 000 C Foot Time EN 100 5m zus er zo die zo Be F Alert meal Miscellaneous Control Site Cleaning System Actual Sensor Auto Adj 2 Vacuum Clear Sensor Range 000 Adj Pulse 000 Clogged 9 000 Vacuum 000 Cooling Ring Pulses Solder Reflow 183 Thermocouple System Force Placement System Actual Dest Range Jd Fo Rate 000 r r Sassi Stop Force Placement Auto Adjust Display Only Lower Heating System Removal System Vacuum Retry Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 L Temp M Temp C R Temp ooo From De ua ae Flow Off C Low Flow High Flow Action C Disable Standard Repla
127. k on Exit under Options Click on the Windows Start icon at the bottom of the screen and select Shut Down Press the Emergency Stop knob when the computer screen indicates that it is now safe to turn off the machine DRS25 User Manual 0025 00 901 7 38 Section 7 Operator Training 7 8 Preventative Maintenance Schedule Procedure Daily e Report any problem to supervisor Weekly Clean carrier area of fallen parts e e Clean microscope and vision system optics with lens cleaner kit e Clean site cleaning tool Quarterl e Wipe flux from table carrier arms and overall machine e Clean nozzles with flux remover and soft brush e Advise maintenance to perform preventative maintenance procedures e Check and clean site cleaning tool system Clean as required Clean microscope and vision system optics with lens cleaner kit or alcohol e Wipe eyepieces mirror top and bottom of vision cube DRS25 User Manual 0025 00 901 7 39 Section 7 Operator Training Verify Vacuum of Hoses Filter and Vacuum Pump To Activate Site Cleaning Vacuum use icon from Run Screen A 9001 15 036 Tubing blue 18 D 9001 15 031 Tubing silcicone 3 G S147AV Muffler Air HAV147HDRS24 Vacuum Pump E 9001 12 027 Filter Vacuum Canister C 1015 70 025 Canister Kit F VG30 Vacuum Gauge e Vacuum gage must read 8 Hg or less with system open Turn on site cleaning vacuum If vacuum gage reads over 8 Hg material is clogg
128. l 0025 00 901 5 10 Section 5 Software Overview After selecting a file the system will automatically take the operator to the Open Profile Notes screen Open Profile Notes Description CBGA 256 SITE CLEANING Component CBGA 256 SITE Location Flux Type TACKY NO CLEAN PASTE FLUX DO NOT USE LOW SOLIDS FLUX Nozzle 845X845 Notes THIS PROCESS I5 DESIGNED TO BE RUN IMMEDIATELY FOLLOWING THE PBGA 225 REMOVAL PROFILE THIS 15 IMPORTANT TO INSURE THAT THE BOARD 15 IM THE PROPER POSITION AND IS STILL HOT FROM THE REMOVAL PROCESS Application Notes CHECK TO INSURE THAT THE SG100DH5 15 CLEAR CHANGE TIF IF REQUIRED SENSOR THERMOCOUPLE MUST BE PLUGGED INTO CHANNEL 1 This screen is used to display general setup or process related information Clicking on the Ok button will take the operator to the Run screen DRS25 User Manual 0025 00 901 5 11 Section 5 Software Overview This screen allows the operator to process an application In general this screen provides the operator with messages heating and flow rate information thermocouple readings and the overall progress of the cycle Please see the Run screen section for detailed information CBGA 256 Site Cleaning 100 thick board N845X845 1067016 drs Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Joq Functions Numerical Process Information Nozzle System Thermocouple System Force System
129. larm condition DRS25 User Manual 0025 00 901 Load Function Jog Functions Machine Cooling System Status Memory EN EN m FootSw Air Force System 375 200 625 250 750 875 Cycle Busy Alarm 1000 Cooling Ring n Grams A T C Control 08 00 08 48 12 00 09 36 10 24 11 12 2 27 All active thermocouple channels must be connected to a thermocouple sensor before the process cycle is Section 5 Software Overview Force System This system monitors and controls the activities associated with component force placement force removal or force adjustment The Force System graphically displays the following control parameters e Force target set point A white number Force actual B blue number e Force range C white number Force System Grams A Set Point 120 B Actual 105 C Range Note During force controlled activity placement removal adjustment the operator should not touch any part of the machine DRS25 User Manual 0025 00 901 5 57 System Status Section 5 Software Overview The System Status provides the operator with a quick view of the cycle status This section also informs the operator if the machine is waiting for a response from the operator The Memory display A B C shows the free memory available to the DRS25 software These values will decrease over time and the system will automat
130. lect the Load Process Link File for the Soldering Program or Removal Program mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Mumerical Process Information Soldering Desoldering Site Cleaning Nozze System System Thermnocouple System UMEN 30 Set Point Set Point Set Point Actual Actual Actual Press the Start Stop Cycle icon to start another Removal cycle Press the Thumbs Up icon to exit the screen DRS25 User Manual 0025 00 901 7 24 7 5 Running A BGA Soldering Program Section 7 Operator Training After the Load Process Link File is selected the profile name at the top of the Run Screen will change to the Site Cleaning Program HH mm BGA Removal 60980001 DR5 LED Adjustment Graph Data Suto Scale Graph Load Process Link File Numerical Process Information Nozze System 50 60 Soldering Desoldering Site Cleaning mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File Numerical Process Information EE Nozze System Preheat System Set Point Set Point Set Point Actual Actual Actual Idle Idle Idle View Photo Links Export History Load Function Jog Functions Machine Cooling Thermocouple System Force System 375 500 1000 Cycle Busy Alarm oe e eo Cooling Ring To
131. lected before completing the Save As option Photo images must be stored in the following directory C WINDOWS DRS25 PHOTO default To save the bitmap enter the name of the bitmap in the File name edit box and click on the Save Button To exit the Save As screen click on Cancel Save As Save ir a Fhoto BGAZ25 balls BGA225_LOMF NENT BGAZ25 SITE BG4225 BOARD File name untitled Save type 255 Color Bitmap Cancel Exit To exit the Save Video Image option select the File menu and click on the Exit option About The About option will display the version number for the Save Live Video program DRS25 User Manual 0025 00 901 5 77 Section 5 Software Overview 5 5 2 Modify Video Image The Modify Video Image menu will allow the operator to load WINDOWS Paint tool a video snapshot from the default photo directory C WINDOWS DRS25 PHOTO These images can be modified by adding text or graphics to better clarify how the video snapshot can be used F compl Paint File Edit View Image Options Help 4917 Y Ww op Wa LJ k eh TOFP100T19 7 2 0 M EXE ar ir ee 2 E cB M age REO RETP EP RRR PR ERE ES sw uu DRS25 User Manual 0025 00 901 Section 5 Software Ove 5 6 Reset Cycle Counter rview The Reset Cycle Counter menu allows the op
132. level of nozzle to glass plate The left to right nozzle clearance to the glass plate must be 005 or less 7 To adjust raise the nozzle Go to the outside edge of the carrier assembly to make adjustments Loosen the four allen screws A that hold the carrier arms to the carrier rail Adjust the 3 32 allen screws B 1 8 turn at a time clockwise moves the carrier up 8 Snug the two allen screws A that hold the carrier arms Do not overtighten Repeat until the left to right nozzle clearance to the glass plate is 005 or less Check at center left and right sides Adjust as necessary 9 Turn nozzle 90 and repeat steps 6 8 for adjustment of carrier front to back B Preheater A DRS25 User Manual 0025 00 901 10 15 Section 10 Maintenance 10 4 Preheater Leveling TOOLS Free Standing Board Support 1M Inch Plate Glass 8x10 Inch Square 5 32 Inch Allen Wrench 3 32 Inch Allen Wrench Feeler Gauge e Place 1 4 plate glass in carrier Move glass over left side diffuser and lock in place e Place board support one not installed on the front left of the diffuser Note If board supports have been installed remove them so that there is no contact with the installed glass e Slide the board support under the glass Slide glass over right side preheater slide support under glass The preheater plate should be adjusted so the support contacts the glass consistently at these four corners e Use feeler gauge a
133. ll new filters NOTE Filter elements must cover holes on stem JLATOR HITROGEN e Manually lower vertical movement to bottom of travel Bearing may rise causing movement to not to extend fully Note De power vertical mechanism or machine prior to procedure e Firmly rotate left vertical movement knob A to lower heater until nozzle just passes board support segments 96 20060 oo9690055600099505969 009085900000095096909 o0000590006000095095969 00959005060009600909 M o0905900000095096969 lt gt 00902000000092699909 XS 009059 o590000009509690 oo969065500009505969 p 009605900000095096909 0505920000099090 7 200655000000 06525 User Manual 0025 00 901 10 5 Section 10 Maintenance Monthly e Check Upper Heater temperature verification Check flow rate verification Replace two nozzle vacuum filters A Unscrew glass jar Unscrew stem to remove and install new filters Note Filter must cover holes on stem e Drain water and oil from air supply filters B e Clean the fan cover filters on the rear of the upper box IGULATOR AIR LOW CALIBRATION T ER AIR RI DRS25 User Manual 0025 00 901 10 6 Section 10 Maintenance Three to four times per year as required To correct for play in carrier Y bearing e Bring the carrier to the forward most position center carrier and lock in place e Remove the four scre
134. machine Note Board preheating temperature may be programmed differently for various assemblies DRS25 User Manual 0025 00 901 7 31 Section 7 Operator Training Event 12 replaying thermal reflow sequence There is no operator involvement during this event The programmed heating of the BGA is automatic 0 This is a timed event The total time is displayed 00 00 00 48 01 36 Event Time at the bottom left of the Run screen EA Event 13 X EEEE EA A EEEE EESE EEEE This is a timed event The purpose of this event is to provide process repeatability for the next cycle At the end of the process the operator has three options Select the Load Process Link File for the Removal Program or Soldering Program HH mm BGA Removal amp 09880001 DR S LED Adjustment Graph Data Auto Scale Graph Load Process Link File View h Numerical Process Information Soldering Desoldering Site Cleaning Norrie System CN Press the Start Stop Cycle icon to start another Removal cycle Press the Thumbs Up icon to exit the screen DRS25 User Manual 0025 00 901 7 32 Section 7 Operator Training 7 6 Reference Run Screen Operator Controls xx mm BGA Removal 60980001 DRS Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling Soldering Desoldering Site Cleaning reheat System Thermocouple System Force System System Status
135. mber changes as new profiles are saved The file extension for all short file names must be DRS e Link Name Soldering Desoldering A soldering desoldering link B allows the operator to quickly open a related profile soldering or desoldering without leaving the Run screen The Link Name is not automatically generated The operator must enter this information The Link Name identifies points to to a previously created profile with process related functionality Typically a soldering profile has the desoldering Short Name entered as the Link Name e Link Name Site Cleaning After the component has been removed a Site Cleaning profile C is generally cycled to remove the excess solder from the site The Link Name is not automatically generated The operator must enter this information The Link Name identifies points to to a previously created profile with process related functionality Typically a desoldering profile has the site cleaning Short Name entered as the Link Name DRS25 User Manual 0025 00 901 5 13 Section 5 Software Overview e Long Name The Long Name D is used to describe the overall function purpose of the profile Long names are used by the Open option to help the operator accurately select a profile The Long Name can be up to 60 characters long The Long Name is not automatically generated The operator must enter this information Warning The operator should be careful not to enter exactly a long name
136. mp ER EN Date 09 26 2005 14 27 Temperature 150 0 100 0 50 0 Event Time Profile Time 7 00 48 01 36 0224 03 12 04 00 jmd Em Zi e t I mm BGA Removal 25profilenotesremoval b a DRS25 User Manual 0025 00 901 View Photo Links Export History Load Function Jog Functions Machine Cooling Farce System System Status 50 Memory 3m 500 25 EN mi 250 750 N2 FootSw Air Thermocouple System 875 Cycle Busy Alarm 1000 Cooling Ring n Grams Temperature vs Time T C Control 04 48 05 36 06 24 Time Z Power 07 12 08 00 08 48 Bord g 2 09 36 1024 11 12 12 00 2 27 PM 1 Section 5 Software Overview Menu Functions J This section of the Run screen displays the function menus that are available to the operator mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling Nozze System Preheat System Thermocouple System Force System System Status J 50 60 500 Memory 375 625 EN mi 250 750 Set Point Set Point Set Point 2 FootSw J gt mm 2 Actual Actual 1000 Cycle Busy Alarm Nozzle 6 Cooling Ring Set Point Actual Ramp Idie Idle o Date 09 26 2005 14 27 Temperature vs Time 450 0 400 0 350 0 300 0 T C Control 250 0 20
137. mp Bottom Side Clearance No minimum size 2 0 square 1 0 height No minimum size 4 0 square 2 0 height DRS25 1 0 Bottom 1 0 DRS25T 2 3 Bottom 1 0 DRS25XL 1 0 Bottom 1 0 DRS25XLT 2 3 Bottom 1 0 NOTE Using microscope or camera to scan the perimeter of the devices for applications outside the range of the beamsplitter i e connectors and leaded devices 2 2 Maximum Vertical travel top to bottom Theta Adjustment X amp Y Table 2 3 Nozzle Vacuum Parts Handling Probe Solder Removal Tool Component Positioning Adjustments DRS25 25XL 5 0 DRS25T 25XLT 7 0 10 degrees 20 degrees total Manual control Cable driven backlash free design Fine adjustment with resolution of less than 0 0005 Internal Vacuum System 26 Hg at pump 20 Hg minimum at cup 25 Hg minimum 25 Hg minimum 2 4 Accuracy and Repeatability Placement Accuracy Repeatability 2 5 Component Placement Force 2 6 Computer System Processor Operating System Floppy Drive CD ROM Network Card Other 2 Voice Commands Verbal Instructions to Operator DRS25 User Manual 0025 00 901 0 001 at 3 Sigma This is defined as the ability for the machine to hit the target 0 0003 This is defined as the ability for the machine to return to the same spot Force Measurement System Up to 2000 grams in increments of 1 gram Target point and
138. nifold assembly section of the manual IGULATOR AIR LEE FLOW CALIBRATION EC un DES M o E DRS25 User Manual 0025 00 901 10 17 Section 10 Maintenance 10 6 DRS Z Axis Motor Belt Adjustment Adjustment Spring Spring Bracket Adjustment Screws ie Zn Pulley Z Motor Belt DRS25 User Manual 0025 00 901 10 18 Section 10 Maintenance 1 Remove Upper Casting of unit 2 Disconnect all power 3 Adjust belt by placing the edge of a scale on the centerline of the pulley Note the measurement 4 Belt tension is determined by pressing on belt as shown Once the pulley starts to move from the force take a reading Deflection should be set at 3 16 5 To adjust deflection loosen adjustment screws and pull up on spring bracket Retighten and check measurement DRS25 User Manual 0025 00 901 10 19 Section 10 Maintenance 10 7 Replacement of the Heating Element 10 1 3 Nozzle Heater Tools Needed Metric Allen Wrenches Multi Meter Perform these quick steps to ensure the new heater will not fail prematurely Please note that a burned out heater could possibly cause other parts of the system to fail NOTE To determine whether a heater is good or not check with a multi meter Terminal 2 and 6 53 0 5 0 coil Terminal 3 and 4 should have continuity thermocouple 1 Check heater for keyway and location of keyway at the connector Keyway Heat Sh
139. not to allow exactly a long name that already exists The system will allow identical long names to exist in the profile library DRS25 User Manual 0025 00 901 5 15 Section 5 Software Overview 5 2 5 Move This screen allows the operator to move profiles from a target group to a new or different destination group Hove Profile s Files CBGA 256 303 Removal 100 inch thick board a CBGA 256 303 Site Cleaning CBGA 256 303 Soldering 100 inch thick board CBGA CCGA 625 Removal 100 inch thick board N1 305 1305D CBGA CCGA 625 Site Cleaning CBGA CCGA 625 Soldering 100 inch thick board N1 305 1305D CCGA 44 mm Removal 100 inch thick board 301 7 30D CCGA 44 mm Site Cleaning CCGA 44 mm Soldering 100 inch thick board 1 301 7 30D CSP 46 Flux application directly on spheres N38DY G 3 CSP 46 Removal 062 inch thick board N36DYG 3 CSP 46 Site Cleaning CSP 46 Soldering 062 inch thick board N38D YG 3 PEGA 119 Removal 062 inch thick board 5 70065 PEGA 119 Site Cleaning PRGA 119 Soldering 062 inch thick board N570 885 PEGA 27 mm Removal 062 inch thick board N1081 1081 From Customer Group Air vac 1799 j source Groups rn 2222 v Destinations Groups _ From Board Group D on 2222 From Device Group Area Arrays 1 99 uum 2222 T Use Tree Listing I Sorting Long File Name wur La E Selection Steps The operator first highlights th
140. nt 1 Remove Nozzle Caution Hot Install Site Cleaning Nozzle Unlock table Press Footswitch to Continue The BGA removal nozzle will automatically be lowered 1 Raise or lower the nozzle using the z axis knob until the nozzle ring is just below the heater screen 2 Use the nozzle pliers supplied with the machine to hold the nozzle Rotate the nozzle ring counterclockwise to open the nozzle fingers 3 Place the Site Cleaning Nozzle into the upper heater Rotate the nozzle ring clockwise to close the nozzle fingers Note The nozzle fingers should not interfer with the collection chamber of the nozzle Position the vacuum hose so that it does not touch the bottom heater Event 2 Position Tip At Rear Left Corner of Site Focus Microscope Press Footswitch to Continue 1 Using the z axis knob lower the nozzle until the tip is just above the solder at the rear left corner of the site DRS25 User Manual 0025 00 901 7 19 Section 7 Operator Training Use the microscope to provide the best possible viewing for the operator It is important to have the operator ready to use the site cleaning nozzle prior to heat being applied to the board 6 3 5 5 2 4 2 Tilt the microscope until the site cleaning tip is in the center of the microscope viewing 3 Adjust oculars to operator 4 Lower rotate microscope to the lowest position to allow a better viewing angle o Focus microscope using the focus ring and adj
141. nt 13 10 3 Carrier Leveling 14 10 4 Preheater Leveling 16 10 5 Vacuum Ports System 17 10 6 DRS Z Axis Motor Belt Adjustment 18 10 7 Replacement of the Heating Element 20 DRS25 User Manual 0025 00 901 10 1 Section 10 Maintenance DRS25 User Manual 0025 00 901 10 2 10 Section 10 Maintenance Maintenance 10 0 Preventative Maintenance Checklist amp Schedule Note Please refer to the following pages for details Daily Weekly e Monthly Clean carrier area of fallen parts Wipe painted surfaces with cleaner Clean nozzles with flux remover and soft brush and replace vacuum cup or o ring if required Report any problem to supervisor or machine maintenance department Clean microscope and vision system optics Wipe flux from table arms and rails Apply a film of light oil to the X and Y rails to avoid corrosion Replace vacuum filter of Site Solder Removal System Manually lower vertical movement to bottom of travel Check Upper Heater temperature verification Check flow rate verification Replace nozzle vacuum filter Clean the fan cover filters on the two back fans Drain water and oil from air supply filters Three to four times per year Note Check for play in carrier Y bearing Check for play in carrier X bearing Check perpendicularity of carrier Check diffuser to carrier parallelism Clean and lubricate vertical shafts Check microscope lights Check for wobble in nozzle cone Che
142. o obtain precise board positioning in the X direction side to side Y Adjustment E rotates to obtain precise board positioning in the Y direction front to back Table Lock F secures X and Y position Board Supports G provide PC board support IR Preheater H B D F E DRS25 User Manual 0025 00 901 3 3 Section 3 Machine Overview Set Up amp Installation 3 2 Viewing Alignment System Vision System A superimposes component leads to PC board pads e Stereo Microscope B allows operator to view removal alignment and reflow processes Camera C optional allows operator to view removal alignment and reflow processes on computer monitor e Trolley Adjustment D sets the viewing angle for the microscope camera between 45 60 axially Top position is used for vision based alignment Bottom position is used for direct viewing at board level e Theta Adjust E rotates to obtain precise theta component position Nozzle Vacuum Switch F On Off vacuum to hold component e Manual Z Height Adjustment G adjusts nozzle height to PCB Software must disable motor power B G A C D DRS25 User Manual 0025 00 901 3 4 Section 3 Machine Overview Set Up amp Installation CAUTION REFER TO SECTION 2 FOR FACILITY REQUIREMENTS OF DRS25 All Pneumatic and electrical connections described in the following sections must be done prior to powering on the DRS25 3 3 Installation of Standa
143. o read or write to exists or if on a network is accessible look under Set up Customer amp Network for the default directory e Call Air Vac Technical Support 11 5 11 Run Export History This alarm occurs when there is an error when the software attempts to read or write to the export history file e Check that the directory you are trying to read or write to exists or if on a network is accessible look under Set up Customer amp Network for the default directory e Call Air Vac Technical Support 11 5 12 Process Cycle History This alarm occurs when there is an error when the software tries to read or write to the cycle history file e Check that the directory you are trying to read or write to exists or if on a network is accessible look under Set up Customer amp Network for the default directory e Call Air Vac Technical Support 11 5 13 Temperature Limits e Contact Air vac DRS25 User Manual 0025 00 901 11 6 Section 11 Troubleshooting 11 5 14 Flow Sensor This alarm occurs when the DRS25 nozzle flows are out of the pre set range of the set point default is 596 e Check air pressure e Calibrate nozzle flows e Modify the Default Flow Rate Limits in the Set up Limits and Defaults screen The factory default for the Nozzle Flow is 005 e Call Air Vac Technical Support 11 5 15 Low Pressure This alarm occurs when the DRS25 senses low pressure on either the ai
144. ocess Flow Off C Low Flow High Flow G F Zero Force Check Box D The force system is very sensitive to change A stable hands off no motion force sample must be present before any force placement activities are initiated Programming the Zero Force check box checked can be used to reset zero the actual force value that is measured after completing any event Run screen motion Z or Vision The Zero Force option can be combined with force placement option to minimize event complexity Force Destination and Range The force Destination B and Range C values allow the operator to fine tune the applied placement removal force A typical force placement example might be a target destination of 75 grams with a range of 20 grams Force can be measured in grams or newtons Display Only Check Box The Display Only check box E will allow the force value to be displayed programmed during the entire event Run screen There are no force control actions associated with this option DRS25 User Manual 0025 00 901 5 34 Section 5 Software Overview Placement Removat The Placement Removal check box G allows the operator to program a force placement removal event Force placement detects and controls a positive downward motion Force removal detects and controls a negative upward motion Typically negative force is created when a component is being lifted before the required solder reflow temperature
145. off vacuum for nozzle vacuum Device Nozzle Separation On off pressure for nozzle vacuum Site Cleaning Vacuum On off vacuum for the site solder removal system Camera Live Video Camera image is displayed over part of the Run screen DRS25 User Manual 0025 00 901 7 34 Section 7 Operator Training 7 1 8 Run Screen Advanced Operator Information xx mm BGA Removal 60980001 DRS LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling Soldering Desoldering DERE Site Cleaning Nozze System reheat System Thermocouple System Force System System Status lemory NER 375 500 625 30 80 250 750 20 0 Set Point Set Point Set Point 9 uf _ gt 100 0 0 110 Nozzle Date 09 26 2005 14 27 Temperature vs Time Control Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Time Z Power Board ae Ss omm i Site Clean Vac Nozzle System Upper Heater Nozzle Blue needle Indicates actual flow rate Yellow needle Indicates flow rate set to be reached Set Point Programmed temperature setting display white Actual Actual temperature setting display red Ramp Heater temperature per second rate red Bottom Heater Set Point Programmed temperature setting display white Actual Actual temp
146. old air through the nozzle use nozzle flow meter screen Setup Nozzle Flow Meter for 15 minutes to cool nozzle assembly e Go back and run Temp Scale Testing again and check offset between set temperature and actual at end of events 7 10 If temperatures are within 6C you are finished If not calculate differences and add to offsets to pull temperatures into spec Temperature vs Time Description 08 46 06 03 98 DRS24 Temperature Scale Testing 00000004 drs I ere BERGES FLUR FEINE l 1134 a s chad N ENC Temperature Po OR NE OO SEE NEE ADT EOP DES esami aa na a AS aiti en nn 00 00 00 51 01 42 02 33 03 24 04 15 06 06 08 57 06 48 07 39 08 30 09 2 10 12 11 03 41 54 12 45 Time DRS25 User Manual 0025 00 901 4 11 Section 4 Machine Function Verifications 4 5 Running the Operator Training QFP160 Align and Place Profile The training profile is intended to provide training of the DRS24 hardware and software Programming liberties have been taken to allow step by step instruction The settings are not intended for an actual program as no reflow occurs Please follow all instructions in the profile notes page below prior to running the training profile Op
147. om Link The communications link between your computer and your force board located in the left side box is not functioning e Check in the teach screen if you get a force reading and if it changes when weight is applied to the carrier e Make sure DB25 connector is plugged into the force board e Check the 3 wire yellow violet gray 10 pin connector is plugged into the COM2 pins on the motherboard gray wire closest to pin 1 e Shut down Windows95 re boot and test again e Check to see if the red LED power light is lit on the front bottom of the board If not make sure the white 4 pin wire connector JXX is connected If it is connected and the light is not on un plug and check for 12V DC across the black and yellow wire 165 amp 167 e Call Air Vac Technical Support 11 5 4 Temperature Com Link Verify that the temperature controllers have power Check to see if any error messages are displayed on the controller Load NO Error L Error H Verify 9 pin connector on COMS3 is plugged in Check 25 pin connectors on the B amp B converter Verify 12V DC to the power plug on the side of the B amp B Verify programming on the temperature controllers Check under Setup General System that the single double or no diffuser matches the configuration of the DRS e Call Air Vac Technical Support 11 5 5 Cycle Counter You have reached the maximum number of process cycles that has been pre set Reset cycle counter e Ch
148. on will be graphically displayed using a green button background OK Thumbs Up Profile Notes The Profile Notes button will display the application notes page This page is used to add any instructions that may be required to correctly process the application Limit Control The Limits button will display the profile limits page This page is used to control the maximum or minimum process limits related to flow rate temperature and force Home Z Vision Axis sei The Home Z Vision Axis button will reposition the 2 and Vision axis to their respective home locations LA This button executes a general motion utility This general motion utility cannot be directly programmed as a complete function however the results of this motion can be saved to an event Nozzle Load The Nozzle Load button will activate a series of predefined motion events This will allow the operator to semi automatically load the nozzle Initially the Z and Vision axis will be moved to their respective home locations Next the system will ask the operator to perform the following manual tasks 1 Open nozzle clamps 2 Load nozzle 3 Close nozzle clamps This button executes a general motion utility This general motion utility can not be directly programmed as a complete function Component Pickup The Component Pickup button will position the nozzle to a predefined set of Z and Vision coordinates T
149. ool to be efficiently applied to the pads when lowered Event 4 There is no operator involvement during this event thats This is a temperature based event System The thermocouple or temperature sensor will monitor the board temperature It is displayed under Thermocouple System The bottom heater is displayed and will heat the board until the set programmed temperature is reached The next event will occur automatically when the preheat temperature is reached Note Board preheating does time will vary depending on the initial temperature of the bottom heater board and machine Note Board preheating temperature may be programmed differently for various assemblies During this step there is no operator involvement The diffuser heats the board until the set programmed temperature is reached The next step will occur automatically when the preheat temperature is reached Preheating does take time but is important to consist operator procedures and reliable rework Note The time to heat the board will vary depending on the board DRS25 User Manual 0025 00 901 7 21 Section 7 Operator Training Event 5 There is no operator involvement during this event This is a timed event The nozzle will automatically be lowered to just above the board Note The tip must not hit the solder bumps or board Advise programmer to correct if this occurs Damage to tip and
150. operation DRS 4 Temperature Controllers Nozzle Temp Set 000 Flow Hate Set 000 Off Nozzle 5 9 8 Reset System Access To reset the system access to the production environment the operator must reset the operator Click on the Reset Operator option on the menu bar and the Operator Registration screen will be displayed Log in again followed with your security access code to gain access to the DRS25 machine Operator Registration DRS25 User Manual 0025 00 901 Section 7 Operator Training Table Of Contents 3 7 0 Overview BGA Removal Site Cleaning Soldering eee eee eere eee ee eee eee eene neon eee tette sees esee tette eese 3 74 oi D e 4 7 2 Mamm Sereen OVER VICW e 5 7 3 Opcom A RemoyalProgran me 6 7 4 Runnms A Typical Removal Pros a ea 12 7 5 Runnme A BGA Soldering Program T 25 7 6 Reference Run Screen Operator Controls uiis xsevesesssves codusv din dab vuduu dee aao aao oda ov Saas u aV NNA NANN 33 7 7 38 7 8 Preventative Maintenance Schedule Pr cedUte eee ees is
151. or board may result The heated air will melt the solder The time will vary depending on board Event 6 There is no operator involvement during this event This is a timed 5 seconds event The site cleaning vacuum will automatically be activated M d cA The tip will adjust according to programmed settings It is important that the tip does not contact the board during the process The distance from the bottom of the tip to the board may be different on various boards as determined by the programmer Event 7 Use X Y Wheels to Clean Site Press Footswitch When Finished Press Footswitch to Continue Use the x and y fine adjustment wheels to move the board under the tip The solder will be vacuumed into the nozzle It is advised to start at the rear left corner and move the x wheel only The table will move along the rear row of pads The large tip can remove approximately 3 rows of solder This is an important portion of BGA CSP rework as damage is most likely to occur if solder mask or pads are damaged It is important that the operator 1 Not allow the tip to touch the pads or board 2 Not leave the tip at an area for a long time 3 Not move the tip until the solder is definitely melted as damage may occur to the pads Do not move the tip to areas in which the operator cannot see DRS25 User Manual 0025 00 901 7 22 Section 7 Operator Training Event 8 Clean Inspect Site If Touch Up Is Necessary Flux Site an
152. oup into the existing list A To delete a group the operator must first highlight the group A Next the operator can click on the Delete Highlighted Entry button to remove the entry from the list To save these changes click on the Thumbs Up button To cancel any changes click on the Thumbs Down button Air Vac Engineering Company Svstem Files Board Group ES BGA Demo Board LEADED DEYICES Profile Library mu Device Group rea Arrays Demo Board Leaded Devices system Files AU OK Save Changes Exit Delete Highlighted Cancel Do Not Save Exit New Add DRS25 User Manual 0025 00 901 5 81 Section 5 Software Overview 5 7 5 Operator Setup Screen This screen is used is used to modify the registered operator list Operators are grouped into three categories High priority These operators have access to all screens Caution should be taken when defining these operators Critical machine parameters can be adjusted or corrupted Medium priority These operators can perform the following maintenance functions Vision calibration Backup restore e Diffuser idle In addition these operators can run existing profiles Hew Operator Operator Control Priority Low priority These operators can only run DIRE ZOW Pen omy MAINTENANCE existing profiles OPERATOR 5 7 6 Password This screen is used is used to modify the password associated
153. ozzle into the machine e Plug the nozzle thermocouple into channel 1 e Click on the Cycle Start icon A to start the profile The profile will run a scaled sequence of various temperatures and flow rates and will plot the Upper Heater temperature red line and the NCAL 1 Nozzle Temperature green line After the initial scale up sequence the profile executes a cool down stage and then scales up the temperature and flow rates a second time This is necessary to insure that the machine has been properly heated prior to verifying the temperature accuracy e Allow profile to run when complete click on Export History this saves the graph and data points to the Export directory for analysis e Thumbs up out of profile go to Control Import Graph Data Scroll DAT files in upper box to last file it should be a Temp Scale Testing DAT file Double click on this file so graph is displayed Now click on upper task bar Graph Data Scroll through to end of events 7 10 and look at temperature of T C 1 DRS25 User Manual 0025 00 901 4 10 Section 4 Machine Function Verifications e Subtract actual temperature of T C 1 from the target temperature and enter this number as the Offset for 75 tt each range in the Setup Communication screen Event 7 180 T C 1 Temp Offset 001 200 C Event 8 250 T C 1 Temp Offset 201 270 C Event 9 300 T C 1 Temp Offset 271 340 C Event 10 350 T C 1 Temp Offset 341 420 C Run c
154. p Incr 000 L Temp M Temp C R Temp Flow Off C Low Flow High Flow DRS25 User Manual 0025 00 901 5 36 Section 5 Software Overview Nozzle Heater Temperature Flow Rate and Temperature and Ramp The nozzle heater temperature Temp C B can be programmed from 0 C to 420 C The nozzle flow rate Rate A can be programmed from 15 to 110 100 represents 2 75 scfm A flow rate range between 15 and 19 allows a maximum temperature of 325 C Temperature ramp C Sec C controls the temperature set point increase per second The default setting for this control parameter is zero not in use The maximum temperature ramp is 50 C Sec Air Nitrogen Option The pressure source connection for the upper heater can be Air or Nitrogen D Selecting the Air option automatically connects to the upper heater to the main air source large blue hose The main air source is also used by the vacuum and cooling systems Selecting the Nitrogen option automatically connects the upper heater to the secondary pressure connection smaller blue hose or yellow black hose This secondary pressure source is generally connected to nitrogen If nitrogen is not available this required connection must be made to air Note The secondary pressure connection typically provides a more stable flow rate environment and should be considered for all placement soldering events Note If nitrogen conservation is a cr
155. plate if not check to see if the gold vertical linear bearings are bottoming out on the shafts before the housing reaches the bottom If this is the case these linear bearings must be pushed up with a screwdriver or similar prying device e Enter Set up Force Measurement and VIEW the Force Sample value in the box This should be fluxuating around a certain point by 300 Apply a downward force to the preheater directly under the nozzle and see if this value increases If you see characters other than numbers this means the force board needs re programming Call Air Vac Technical Support Note Make NO attempt to calibrate the force system This requires a special calibration weight and a procedure that must be followed TO THE LETTER e Call Air Vac Technical Support DRS25 User Manual 0025 00 901 11 7 Section 11 Troubleshooting 11 6 Force Measurement Problems If the force measurement system does not reach the specified force value e Verify in the Teach screen for that event that proper force values are entered properly e sure the nozzle is approximately 50 thousandths of an inch above the PC board prior to beginning the force placement Note If the nozzle is too high above the board there will not be enough pulses to properly perform the placement e Check that the number of adjustment pulses in the Motion Setup screen has not been altered The number should be 25 e Communications verification can be
156. plication process limits Each profile have a unique Nozzle Range This parameter controls the acceptable profile temperature range target actual for the nozzle temperature controller L Diffuser This parameter controls the acceptable profile temperature range target actual for the left diffuser temperature controller R Diffuser This parameter controls the acceptable profile temperature range target actual for the right diffuser temperature controller Nozzle Flow Sensor This parameter controls the acceptable profile flow rate range target actual for the nozzle flow controller Maximum Force This parameter controls the maximum force actual that is allowed during a force event Run ocreen Top Bottom Vision LED DRS25 machine has an LED based lighting system which provides independent top and bottom intensity adjustment The top LED system uses green lighting to illuminate the component The bottom LED system uses white lighting to illuminate the board Limit Control Process Limits Nozzle C Nozzle Flow Sensor Range Range fi u 005 L Diffuser C H Diffuser C Range Range 1 00 100 Maximum Force Top Vision LED Bottom Vision LED DRS25 User Manual 0025 00 901 5 28 Section 5 Software Overview Motion Control Teach LED Adjustment Build Photo Links Events have three basic elements of Options ee Nozzle System el Tempe operation Dest 0
157. r Training Event 4 Lock Table Position Temperature Sensor Approximately 3 inches from Site Press Footswitch to Continue Lock table using the carrier lock knob Db NENNT UC Ad Rotate the temperature sensor over the board OR be sure a thermocouple is taped to the board ai ay Note The temperature sensor is meant to read the board temperature It is important to position the temperature sensor thermocouple away from the nozzle and not on or over another device or at the edge of the board Press the footswitch to continue Event 5 There is no operator involvement during this event The nozzle automatically move up to approximately 1 16 of an inch from the BGA Note A relative move will move the programmed distance from where The operator last leaves the nozzle z axis It is important that the nozzle be positioned at the right height In this case slightly touching the BGA During operation the heated air heats the component and exhausts Space is required for the heated air to exhaust DRS25 User Manual 0025 00 901 7 14 Section 7 Operator Training Event 6 There is no operator involvement during this event This is a temperature based event The thermocouple or temperature sensor will monitor the board temperature It is displayed under Thermocouple System The bottom heater is displayed and will heat the board until the set programmed temperature is reac
158. r coordinates represent the destination event position for the Z and Vision axis These coordinates are taught during the profile motion development phase B Usage When the Motion check box is clear default the destination positions B will not be adjusted each time a Teach function is performed This mode allows the operator to quickly scroll through the events without having to wait for motor synchronization Don I DM When the Motion check box is selected checked the destination positions B will be adjusted each time a Teach function is performed Caution should be used during this mode of operation because motion may occur and destination motor positions will be adjusted by Teach function When the Motion check box is toggled from a clear state to a checked state the Z and Vision axis will be repositioned using the destination coordinates This motion will include a complete Z and Vision home axis procedure A Warning Message is displayed to the operator before any motion is initiated Note The Motion check box protects the destination coordinates from accidental modification C If the Motion check box is clear the motion function buttons C located in the Options section will remain gray and inactive This mode also allows the operator to use the scroll buttons to advance the event counter to a new event 3 of 2 Options If the Motion check box is selected checked the operator can not scroll b
159. r or inputs e Check pressure gauges on the rear of the DRS25 They must be set with no air flowing to the proper specs in your manual Check to see if your air pressure drops significantly below 65psi when nozzle diffuser and vacuums are all turned on high flow e Call Air Vac Technical Support 11 5 16 No Activity Time Out This error occurs when you have the Run screen up and after a pre determined length of time with no activity the screen times out e When not running a profile exit out of the Run screen and keep on the Main DRS25 screen e Enter Set up General System and modify the Screen Time Out number factory set to 20 000 e Call Air Vac Technical Support 11 5 17 Force Placement This alarm occurs when the force applied to a part is out of the specified range that was set in the profile Make sure that no one touches the DRS25 or the table it sits on when force placement is occurring e Check that the vertical tension brake screw is properly adjusted With the machine powered down manually raise the Z axis to the top of the travel Tighten or loosen the adjustment screw so that the nozzle head just starts to drop down under its own weight then tighten just enough so it won t slip down e Check the vertical bearings on the Z axis shaft s Remove the heat shield and manually lower the Z heads all the way to the bottom of the travel The black bearing housing bracket should contact the bottom stainless
160. ration ion Lights Noz Probe Video Jog Aere NE B Miscellaneous Control Site Cleaning System Alert Adj Z Pos Vac Clear Pulses Solder Reflow 183 Range 000 Adj Pulse 000 Clogged 000 Vacuum 000 A Force Placement System Actual Dest Range 0000 00 0000 00 0010 00 m cm Vacuum Sensor Stop Force Placement Auto Adjust M Display Only Cooling Ring Rate Removal System Lower Heating System LTemp C M Temp C R Temp Vaetum Retry 000 000 oo Actual Sensor Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 Action C Disable Standard BB je Replace o Add C Subtract Data If ERROR Stop Process Flow Off C Low Flow Hic DRS25 User Manual 0025 00 901 5 40 Section 5 Software Overview Site Cleaning The Site Cleaning System A allows the operator to program a special vacuum port used for site cleaning The site cleaning tool requires a vacuum source to remove the molten solder from the site Programming this check box checked will activate the vacuum for the current event Run screen A clear check box will deactivate the vacuum for the current event Run screen Speech Check Box The Speech check box B allows the operator to program the text to speech synthesizer for even
161. rator xx mm BGA Soldering Customer Group Air Vac Engineering Board Group Air Vac Engineering Device Group Air Vac Engineering Use Tree Listing Iv Sorting Long File Name www alr vac eng com 1 Select Directory The operator must select the correct Customer Board and Device Group directory Using the Up Down Arrows at the right side of the each group box to select aBGA removal file 2 Select Program Under files highlight a BGA removal program file i e BGA 27mm Removal 3 Click on Thumbs Up icon Advanced Operator Training e Use Tree Listing Allows a short cut to find the only Board and Device Groups under a specific Customer Group For example if a customer group were selected the only listings for board or device group would be what is available programmed as no other directory paths exist Note This is a good method for operators if they want to simply finding a program e Sorting Long File Name Displays the computer program number assigned to each file program in that directory This is used by the software programmer DRS25 User Manual 0025 00 901 7 6 Section 7 Operator Training The Open Profile Note screen will appear It provides information prior to running the program xx mm BGA Removal 60980001 DRS BE y Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Open Profile Notes Description COMPONENT REM
162. rce System System Status Memory 50 60 315 900 625 gp 750 a ER 20 90 Set Point Set Point Set Point FootSw Air nf EN EN i 0 0 110 Actual Actual 1000 SES oe 2 ee Cooling Ring Set Point Actual Ramp Idle Idle Idle E ER DIENEN T 1 E Click On The Cycle Start Button To Begin Process Date 09 26 2005 14 27 Temperature vs Time T C Control Temperature 50 0 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Time Event Time Profile Time 2 Board it Jede Kl stort CZ a t I mm BGA Removal 25profilenotesremoval b qma 2 27PM Messages may be programmed to use the text to speech synthesizer The languages which are available include English Spanish German and French DRS25 User Manual 0025 00 901 5 59 Graph Process Information C Section 5 Software Overview This section of the Run screen displays the Temperature vs Time graph This window only displays a 12 minute view of the process cycle To display the entire graph after the cycle is complete the operator can select the Auto Scale Graph menu option see Menu section for more information mm BGA Removal 60980001 DRS Auto Scale Graph Load Process Link File View Photo Links Export History Nozze System 50 60 7 Preheat System Thermocouple System Set Point Set Point S
163. rd Machine Hardware 3 3 1 Pneumatic Connections Top and Bottom Heater Upper Heater Pneumatics e Connection 1 4 diameter hose 1 8 NPT male fitting e Pressure Setting B 80 psi adjust as required C e Air Nitrogen Consumption 3 scfm Other Pneumatics nozzle vacuum site cleaning vacuum board cooling option e Connection D 3 8 diameter hose 1 4 NPT male fitting e Pressure Setting E 80 psi adjust as required F e Air Consumption 15 scfm D F E C B A DRS25 User Manual 0025 00 901 3 5 Section 3 Machine Overview Set Up amp Installation 3 3 2 Electrical Connections Machine Power A Monitor Power B CPU Power C CPU Cable FireWire Interface D D C B NOTE CPU and Monitor are both powered with 220V C DRS25 User Manual 0025 00 901 3 6 Section 3 Machine Overview Set Up amp Installation 3 3 3 Re Installation of Main Fuses e The two 2 20 amp main fuses are removed by Air Vac prior to shipment e Remove the orange caution label covering the Main Fuse Holders A and insert the Two Main Fuses B from accessories kit into the main fuse holders e Close the right white box but do not install the locking screw at this time A 3 3 4 Power Up Sequence IMPORTANT With both PC and Machine power off e Turn PC on and let it boot up to the Air Vac password screen e Turn Machine power on e Enter password and start Air Vac
164. re disabled DRS25 User Manual 0025 00 901 5 3 Section 5 Software Overview 5 1 2 Edit Boxes Edit Boxes allow information to be entered by placing the cursor over the top of the box and clicking on the left mouse button Characters are entered directly from the keyboard or from the pop up keyboard keypad Clicking on selected edit generate a popup keyboard keypad Characters may be entered directly from the physical keyboard or by clicking on the screen key buttons After the desired information is entered the operator must press the enter key physical keyboard or click on the thumbs up button to complete the entry Screen Keyboard HET mer LEE UM E KEME Jalal dal jd ELI 2 Space Bar Screen Keypad KeyPad Backspace DRS25 User Manual 0025 00 901 5 4 Section 5 Software Overview 5 1 3 Spin Buttons opin Buttons are used to directly modify information within an edit box By clicking left button on or holding down repeat the up or down button the edit box value will increase or decrease respectively Note If desired the operator can alternatively use the popup keyboard keypad to directly enter a value 5 1 4 Check Boxes Check boxes are generally used to program a DRS25 function or activity e Inactive Clear state E A blank check box indicates the Off or the inactive state e Active Black state W A black check mark indicates the On condition or the active state For Ex
165. ressure Verification profile and click on the Thumbs Up icon Click on Thumbs Up again to advance to the Run screen Lift the right white box cover with Air Vac logo Verify that the machine voltage reads 208 or higher A Click on the Cycle Start button to begin the process Re check the machine voltage while the process is running to verify that the voltage is not dropping below 208 while in process Check the pressure regulators on the back of the machine to insure they read a minimum of 70 psi while the profile is running e Click on the Cycle Start button to stop the process e Close the right cover and fasten the rear hold down screw A DRS25 User Manual 0025 00 901 4 5 Section 4 Machine Function Verifications 4 3 Flow Rate Verification and Adjustment Once the pressure verification is complete the gas flow rate should be verified Accurate gas flow through the nozzle is critical for achieving repeatable results The DRS25 incorporates a Mass Flow Controller with closed loop control to monitor and regulate gas flow rates The two areas of flow verification include the Nozzle Flow Controller which controls actual flow rates and the Nozzle Flow Sensor which controls the Computer Digital Flow Display Nozzle flow verification is required for initial installation or any time the machine is disconnected and or moved 4 3 1 Nozzle Flow Controller Verification and Adjustment 100 only Materials required Scrib
166. review the Application Notes for the Soldering Program 00 48 01 36 02 24 select the Application Notes icon m The Open Profile Note screen will appear It provides information prior to running the program mm BGA Soldering 60980002 DR5 BET Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Open Profile Notes Description P MM BGA SOLDERING Component Location Flux Typ PASTEFLUC XX Nozzle T eaae a INSTALL INSTALL BOARD SUPPORTS UNDER Application Notes REFERENCE PLUG TEMPERATURE SENSOR OR THERMOCOUPLE INTO CHANNEL 1 Iv Continue to Run Screen WWVW alI Vac erig corri Select the Cycle Start Stop icon to begin the site cleaning program DRS25 User Manual 0025 00 901 7 25 Section 7 Operator Training Typical Soldering Program Event 1 UE There is no operator involvement during this event It is a timed event This is shown at the bottom left side of the Run Screen After programmed timed has occurred Event 2 will automatically 00 00 00 48 0136 02 2 be actived Event 2 The loading tray will move forward to the operator Place component into loading tray Note Component orientation polarity must be correct Note The parts handling vacuum will turned on If the nl Component is delicate or it is company policy not to p have operators handle components with their
167. ring 062 inch thick board N570X885 0 PBGA 27 mm Removal 062 inch thick board 1081 1081 PRGA 2 mm Removal 062 inch thick board M2 7E 7 Customer Group Air vac 1799 Board Group Profile Library 1 99 Device Group Area Arrays 1 99 Use Tree Listing Sorting Long File Name DRS25 User Manual 0025 00 901 5 18 Restore Profile Screen Restore Profile Files 27 Site Cleaning auto adjust CEGA 256 303 Removal 100 inch thick board CBGA 256 303 Soldering 100 inch thick board CBGA CCGA 625 Removal 100 inch thick board N1305 1305D7 CBGA CCGA 625 Soldering 100 inch thick board N1305X1305D Section 5 Software Overview CSP 46 Removal 062 inch thick board NbOODVG 4 CSP 46 Soldering 062 inch thick board N38DVG 3 CSP 46 Soldering 062 inch thick board N500DYG 4 Site Cleaning auto adjust Site Cleaning auto adjust Site Cleaning auto adjust Sorting Long File Name PRGA 27 mm Removal 062 inch thick board N1061 1081 PEGA 27 mm Soldering 062 inch thick board N1081X1081 Restore Drive From user can copy multiple files simultaneously e The user can select any profile from and existing groups e Missing Customer Board or Device groups are automatically added during the rebuild index message Open Delete Backup and Restore options e The user can select any d
168. rmation Profile Event Alert Foot Switch Messages Graph Process Information Event Time Event Counter Process Time Button Functions Software Hardware Communication Link Error Status Bar Code Board Serial Number Tracking Menu Functions LED Adjustment Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Machine Cooling System Preheat System Thermocouple System Force System System Status 50 60 500 40 70 375 625 H so 250 750 KE ES 20 00 Set Point Set Point Set Point FootSw Air 125 875 ERERER Veen Cycle Busy Alarm 0 N le 110 Actual Actual Actual 0 1000 ozzle Cooling Ring Grams m Set Point Actual Heo aph Process I Date 09 26 2005 14 27 Temperature vs Time 500 0 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 T C Control Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Time Event Time Profile Time Z Power Board 4 Isa Mer d e ca IA mm BGA Removal 25profilenotesremoval b Al qaa 2 27 PM DRS25 User Manual 0025 00 901 Numeric Process Information A Section 5 Software Overview This section of the Run screen displays numeric information associated with process temperature flow rate force and thermocouples xx mm BGA Removal 60980001 DRS LED
169. roller value has been set For each of the remaining radio buttons 20 90 location C the operator should run through the same verification and adjustment procedure that was just completed for the 100 Nozzle Flow Controller value If the flow meter reads too high decrease the value by increments of 5 in the appropriate 20 90 Nozzle Flow Controller box location D If the flow meter reads too low increase the value by increments of 5 in the appropriate 20 90 Nozzle Flow Controller box location D Nozzle Flow Sensor Verification and Adjustment 100 only Making Flow Sensor 100 Verifications and Adjustments Click on the 100 radio button A The air flow will activate after 1 4 seconds Wait 45 seconds before making any adjustments The software screen displays to the operator a Yellow Needle E flow rate set point and a Blue Needle F actual flow rate sensor reading Check the blue needle that is being displayed on the software screen This needle represents the actual flow rate sensor output from the flow controller The blue needle should bounce between 99 101 If the blue needle is not within this range adjustments can be made to the 100 Nozzle Flow Sensor value If the blue needle is too high increase the value by increments of 5 in the 100 Nozzle Flow Sensor box G If the blue needle is too low decrease the value by increments of 5 in the 100 Nozzle Flow Sensor box G Note This is OPPOSITE from
170. rrier and vision systems Fill out and return cpu and monitor warranty cards DRS25 User Manual 0025 00 901 1 5 Section 1 Introduction Getting Started 1 3 Material Check List The following are checklists of items shipped with all DRS25 systems Machine Serial Number Part Number Hot Gas Reflow Module Standard DRS25 Hot Gas Reflow Module Large Boards DRS25XL Hot Gas Reflow Module Extra top side clearance DRS25T Hot Gas Reflow Module Large Boards and extra 1 DRS25XLT Top side clearance Accessories Tool Kit Calibration Kit 1 1 002400040 FireWireCard CPU 21 90022805 Footswtch 1 1 00244040 Air Hose 10 SIB 2 Hoses blue 3 8 yel blk 1 4 1 900145013 MicroscopeAssembly 1 1 220020 200M Lens 1 90050300 X Computerw Monitor 1 900208003 Keyboard Extension Cable 17 1 900208051 Manual 1 002500901 Spare Parts The following is Air Vac s list of recommended spare parts The recommended spare parts will only be included with the shipment if they have been ordered by the customer Air Vac recommends that all customers have these items on hand HalogenBulb Osram 1 14045 SwithBubs28vot 1 2 1632101 Assortment of silicon cups 1 1 VCASST Assortment of silicone o rings 1 1 ORASST Heating Element 1000W Nozzle 71 0049046 2 Vacuum Tube 11 002491103 Filter Element setof 10 1 F1AaE
171. s e Use original spare parts only DRS25 User Manual 0025 00 901 8 4 Section 8 Safety 8 2 Additional Safety Precautions e Upper heater housing protects the upper heating element marked with hot label e Diffuser plate surface can be hot protective covers are marked with hot label e Flux vapors can be hazardous to operators fume extraction should be employed e Flux liquid is flammable and hazardous to operator health and safety Nozzle and vision motion can cause injury to the operator 8 2 1 Handling of Hazardous Solder and Flux Products AIR VAC does not supply the solder or flux products with the DRS25 system The end user of the DRS25 system should follow proper handling and disposal instructions for the materials as supplied by their vendors 8 2 2 Nozzle Changeover Safety Equipment Requirements When changing out the part specific gas nozzle use the special nozzle removal tools GNT1 GNT4 that are supplied in the tool kit of the system whenever handling a hot nozzle Removing a nozzle e Hold the hot nozzle with the nozzle removal tool e Turn the nozzle locking jaws counter clockwise and the nozzle fingers will open to free the nozzle e With the hot nozzle held firmly in the removal tool place the nozzle in a container that can handle the heat of the nozzle To install a nozzle reverse the above procedure DRS25 User Manual 0025 00 901 8 5 Section 8 Safety 8 3 Label Description and Placement Th
172. s reference Note The support should just touch the glass and still be free to move e Remove the board support adjust loosen the four 5 32 allen screws on both left and right side of preheater e Tighten or loosen the four 3 32 allen screws B to adjust height of the board support to the glass Note Adjust up only until four corners are touching then back off Raising front lowers back e Tighten the 2 118 allen screws Note Do not over tighten screws This will warp preheater mounting plate e Place the board support back on the preheater and slide under the glass Check for contact with the glass in four corners Repeat steps on all 4 corners of the preheater until no more adjustment is needed Preheater A DRS25 User Manual 0025 00 901 10 16 Section 10 Maintenance 10 5 Vacuum Ports System Input Regulators both nitrogen and air inputs Heater Condensation Chamber A and Nozzle Condensation Chamber B e Bleed off any water built up in the condensation chamber e Inspect the chamber for excessive dirt Take corrective action on the input air line if excessive dirt is found Nozzle Vacuum Filter C Keep the nozzle vacuum glass tube free of contaminants Change felt filter F1AE as needed Site Clean Vacuum Filter D Keep the site clean glass tube free of contaminants Change felt filter FIAE as needed For internal vacuum pump locations and part see the ma
173. same site Use as many board supports as possible Gas Nozzles Select the proper gas nozzle Use the GNT handling tools to hold hot nozzles e Store nozzles in tray Do not drop nozzles Remove arrows from repair components Vacuum port will clog and device will not pick up e Remove o ring or vacuum cup to clean nozzle in cleaning solution ooftware Alert supervisor to correct profile if flawed rather than bypassing the process e Please note the correct removal and site preparation process must occur for the correct soldering process It is advised to use the DRS programs for removal and site preparation for all applications Open the appropriate software profile and be sure to follow all set up notes Footswitch must be held until yellow radio button goes out Microscope Vision System Always use the microscope whenever possible for process work including inspection of pads and mask prior to soldering process the application of flux site preparation soldering solder removal viewing nozzle positioned to device nozzle at correct board height inspecting overall site and assembly etc Correct eyecup focus eyepiece width opening and tilt to individual Keep all optics clean for crisp clean viewing e Always use maximum magnification to maximize accuracy Turning off the DRS25 Important Do not turn off the machine without following the proper sequence Exit the program using the Thumbs Up icon Clic
174. sents the diffuser temperature Column 4 D represents the nozzle temperature Columns 5 12 E represent the thermocouple temperatures B D E Graph Data Matrix A TIC 1 Max Temp C Min Temp C Temp Slope Time Above 183 Time Above 8 000 2 MaxTemp C a TempSlope a Time Above 183 C Time Above aearc TIC 3 Max Temp C 1 mintempc 1 Temp Stope V TimeAbove Time Above a c TIC 4 Max Temp C Mintempc TempStope Time Above 183c Time Above 08 TIC 5 Max Temp C MinTemp c VTempstope Time Above 183 Time Above 08 MaxTemp C Mintemp c Telnp stope tine Above 183 Time above zeae L F G H 0 The summary section of this screen provides the operator with the cycle analysis details This information is organized separately for each thermocouple channel The following categories are calculated e Maximum and minimum F G temperature Max Temp C Min Temp C e Temperature slope H C Sec Time above reflow 1 Time Above 183 C In addition a programmable temperature analysis column Time Above C allows the operator to temporarily modify adjust the time above reflow analysis calculation Selecting the Resample Data button K will re process the cycle data using the new analysis data J Selecting the Up Thumb button
175. st not touch machine If machine senses pressure on the board carrier it will automatically go to the next event The nozzle vacuum will be turned off and the component will be dropped out of alignment DRS25 User Manual 0025 00 901 7 30 Section 7 Operator Training Event 9 vacuum off nozzle pressure on The nozzle vacuum is automatically turned off and nozzle pressure is applied Event 10 There is no operator involvement during this event The nozzle automatically move up to approximately 1 16 of an inch from the BGA Note A relative move will move the programmed distance from where The operator last leaves the nozzle z axis It is important that the nozzle be positioned at the right height In this case slightly touching the BGA During operation the heated air heats the component and exhausts opace is required for the heated air to exhaust Event 11 preheating board There is no operator involvement during this event This is a temperature based event The thermocouple or temperature sensor will monitor the board temperature It is displayed under Thermocouple System The bottom heater is displayed and will heat the board until the set programmed temperature is reached The next event will occur automatically when the preheat temperature is reached Note Board preheating does time will vary depending on the initial temperature of the bottom heater board and
176. sue vae eaa epe Fun e een 39 DRS25 User Manual 0025 00 901 7 1 Section 7 Operator Training DRS25 User Manual 0025 00 901 7 2 Section 7 Operator Training 7 Operator Training 7 0 Overview BGA Removal Site Cleaning Soldering The following outline is an illustration of typical steps performed for BGA removal site cleaning and soldering 1 Register as an operator 2 Select the appropriate profile 3 Follow the instructions of the first note detail screen such as load nozzle load PCB and position board supports 7 1 1 Removal Program 1 Press the cycle start icon Follow message prompts 2 Position nozzle on BGA Position temperature sensor or tape thermocouple to board 3 Select linking file function to go to site cleaning program 7 1 2 Site Cleaning Program 1 Press the cycle start icon Follow message prompts 2 Remove removal program nozzle install site cleaning nozzle 3 Position nozzle tip at site focus microscope and flux site 4 Move table as solder melts to clean site 5 Clean area and inspect 7 1 3 Soldering Program 1 Place device into loading tray 2 Align device and flux site 3 Remove board when complete WARNING The DRS machine is configured to run on the dedicated PC provided The custom software is configured for optimum machine performance in conjunction with the Windows operating system Additional software loaded for Windows system changes may affect performan
177. t messages Alert Message edit boxes Programming this check box checked will activate the speech system for the current event A clear check box will deactivate the speech system for the current event There are 4 languages available English Spanish German and French Alert Check Box The Alert check box C allows the operator to program an audible tone 5 seconds before the end of a time based event Programming this check box checked will activate the audible tone An active audible tone will be automatically deactivated during an event change Teach LED Adjustment Build Photo Links Vision and Nozzle System Temp C C Sec Pos Pos Rate Dest 00 000 Dest 00000 Fon Be l Replay Thermal Sequence B i x l ZMove ABS Air C mm A 0 L C ZMove REL Event Control N C Do Not Move Nitrogen inch Vision Lights Noz P 100 100 100 Cool Air ei Ale Be Device Nozzle Site Cleaning System Actual Sensor Auto Adj 2 Vacuum Alert Pulses Solder Reflow 183 Sines Range 000 Adj Pulse Clear EA Msg Clogged 000 Vacuum 000 Thermocouple System Force Placement System Actual Dest Range 0000 00 0000 00 0010 00 mesec F Motion 7 Z Power Events um oot Time EN Fer Hii Miscellaneous Control
178. t overtighten preheater plate and carrier can be distorted Check board carrier and preheater leveling DRS25 User Manual 0025 00 901 10 13 Section 10 Maintenance 10 3 Carrier Leveling TOOLS e NCal4 Nozzle e Glass Plate 8 x 10 x 1 4 e Allen wrench set e Feeler Gauge Warm Up e From the Main DRS25 Screen select Setup e Set both heaters to 200 C and high flow Let heaters stay on until heater is heat soaked 5 10 minutes e Change heater temp to 200 C at low flow DRS Software System Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator DRS25 Lead Free Rework Repair amp Assembly WWNW air vac eng com DRS25 User Manual 0025 00 901 10 14 Section 10 Maintenance Carrier Leveling 1 Attach the NCAL4 nozzle knife blade to the DRS De power vertical motor if required 2 Place the glass plate in the carrier arms 3 Center the glass from front to back of the carrier arms Lock the glass to the carrier 4 Center the glass under the nozzle from front to back and left to right Lock the carrier The blade of the nozzle should run from left to right as viewed from the front of the DRS 5 Lower the nozzle until the blade is just above the glass Do not hit the glass with the blade of the nozzle Note If the nozzle hits the glass plate raise the nozzle release the nozzle clamp and then re clamp the nozzle into place 6 Using the feeler gauge check
179. t the communication needs of all the operators If a language other than English is selected this file can be converted DRS25 User Manual 0025 00 901 5 84 Section 5 Software Overview 5 8 Reset Operator To reset the system access to the production environment the operator must reset the operator Click on the Reset Operator option on the menu bar and the Operator Registration screen will be displayed Log in again followed with your security access code to gain access to the DRS25 machine Operator Registration DRS25 User Manual 0025 00 901 Section 5 Software Overview 5 9 Protected System Security Access To access the Protected System Menu the operator must click on the Air Vac logo with the right mouse button Right Click here DRS Software System Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator S A R VAC ac e zig Q 918128 This will load the Protected System Menu Options DRS Software system Options Control History video Screen Utilities Reset Cycle Counter Setup Reset Operator DRS25 User Manual 0025 00 901 5 86 Section 5 Software Overview 5 9 1 Setup Menu The options in the menu bar will change slightly The new options will have access to the protected system setup controls General System The General System setup page is used to configure the software to match the type of DRS25 system hardware 5 9 2 Communications
180. the Locking Jaws F in the same fashion as a regular nozzle DRS25 User Manual 0025 00 901 3 13 DRS25 User Manual 0025 00 901 Section 3 Machine Overview Set Up amp Installation Table Of Contents 4 Machine Function Verifications 4 0 4 1 4 2 4 3 4 4 4 5 Verification Overview Pressure Verification Post Power Up Voltage and Pressure Verification Flow Rate Verification and Adjustment Temperature Verification Running the Operator Training QFP160 Align and Place Profile DRS25 User Manual 0025 00 901 Section 4 Machine Function Verifications A Un A 99 Q 10 12 Section 4 Machine Function Verifications DRS25 User Manual 0025 00 901 4 2 Section 4 Machine Function Verifications 4 Machine Function Verifications 4 0 Verification Overview DRS Software System Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator DHS525 Lead Free Hework Repair amp Assembly WWW air vac eng com Once the DRS25 has been setup according to the instructions as outlined in section 3 critical machine functions including pressure gas flow rate temperature and vision must now be verified to ensure proper machine performance It is important that the verification procedures be done sequentially as outlined in this section Machine verification should be done after initial setup anytime the system is physically moved or disconnected and at regularly scheduled intervals such as ever
181. the four screws holding the board carrier set aside Remove preheater mounting plate Locate the 4 access holes to the x bearing plate Use a 3mm allen wrench to completely loosen the screws holding the x bearing rail to the y bearing block The x bearing rail and assembly are now free of the y bearing block Lift and move the carrier assembly to the back of the DRS along the cables in order to access the y bearing block Tighten the two 3mm allen screws holding the left bearing to the y bearing block To adjust the y bearings loosen the two 3mm allen screws that hold the right side bearing to the y bearing block Tighten a small amount on the 3mm allen an adjustment cam in the center of the right side bearing Retighten the two 3mm allen screws holding the right bearing Check the y bearing assembly for excessive play by twisting the bearing plate left and right There should be less than 1116 play in the assembly Do not over tighten Table will not move with y drive or bearing will be damaged if it is too tight The bearing assembly is adjusted correctly when the left to right play is less than 1116 Also check that the bearing assembly moves freely from front to back Repeat steps 6 8 until no more adjustment is necessary Reattach the carrier and x bearing rail to the y bearing block make sure carrier is perpendicular to y axis rail before tightening Attach the preheater assembly and board carrier to the x axis plate Do no
182. ture window Ask supervisor to call default to 100 C on either side of the set point is Air Vac technical not reached by one or more of the heaters after 30 seconds Flow Sensor Occurs when the nozzle flow is out of the pre set range of the Check that air pressure set point is 80 psi at both inputs e Call supervisor to call maintenance to correct or Air Vac Technical Support Low Pressure Occurs when the machine senses low pressure at the upper or Check that air pressure lower heater inputs is 80 psi at both inputs e Call supervisor to call maintenance to correct or Air Vac Technical Support No Activity Time Out Occurs when you have Run screen up and after a When not running a predetermined length of time with no activity profile exit Run screen the screen times out Normally 45 minutes to Main screen Ask supervisor to call Air Vac technical support DRS25 User Manual 0025 00 901 7 37 Section 7 Operator Training 7 7 Process Tips General Use height adjustable chair to allow comfortable viewing of microscope at the top and bottom position It is advisable to run the warm up cycle every 6 8 hours if the machine is not used Machine must be recalibrated if moved or air or electrical lines have been changed If bridging occurs examine for mask damage It is important to use the DRS25 for removal and site cleaning Use minimal amounts of flux Do not open electrical compartments Do not mix flux or solder types for the
183. uch products are to Air Vac s satisfaction determined to be defective When contacting Air Vac for warranty inquiries please provide the following information Order number under which the parts were shipped Model and serial number of the product Reason for warranty Products cannot be returned to Air Vac without authorization please call for an RMA ft DRS25 User Manual 0025 00 901 1 4 1 2 Shipping Weight including monitor 425 lbs Shipping Dimensions 47 x 37 x 56 Shipping Cartons The system is shipped in a wooden crate Accessories are individually packaged and secured inside the crate covering the system or in separate containers Please keep crate in upright position when moving Save crate for future shipping Removing Module DO LIFT BY TROLLEY BOARD CARRIER SYSTEM OR UPPER BOX SECTIONS AS DAMAGE WILL OCCUR Section 1 Introduction Getting Started Unpacking Remove screws A in side of crate and take out boards 3 Break down crate sides amp top Lift by openings in casting B on both sides Note Module weighs 255 Ibs Please provide CAUTION and adequate capability when lifting Note Weight is unbalanced Back end of unit is Y heaviest Please be careful of delicate electrical cable and pneumatic connections Position module on a level surface which can provide adequate support for weight Remove any strapping and or packing securing board ca
184. uence number represents the last recorded data set The Long Name and the board serial number if available are also displayed to help the operator select the correct historical graph data set Import Graph Data Files x Graph Data NotePad Print Options 00000204 dat PBGA 225 Soldering Air Yac demo board N1081X1081 00000205 dat PBGA 225 Soldering Air Yac demo board N1081X1081 00000206 dat QFP 160 Removal Air Yac demo board an 10381103 59 00000207 160 Soldering Air V Graph Import information Lines Page ns vs Time 2000 Description 15 24 03 05 98 DRS24 PBGA 225 Soldering Air Vac demo board N1081X1081 1011134 DRS 450 0 400 0 350 0 300 0 250 0 Temperature 200 0 150 0 100 0 50 0 0 00 00 00 24 00 48 01 12 01 36 02 00 02 24 02 48 03 12 03 36 04 00 04 24 04 48 05 12 05 36 06 00 Time Note Graph data can be automatically or manually captured during the Run cycle DRS25 User Manual 0025 00 901 5 68 Section 5 Software Overview Graph Data Menu Option The Graph Data menu allows the operator to load the current cycle graph data into an analysis matrix This information is organized and displayed based on seconds Each row captures one second of the overall profile cycle This menu option is only available when the process is not cycling e Column 1 A represents seconds Column 2 B represents the current event Column 3 C repre
185. ustable eyepieces 6 Adjust the zoom lens to the maximum setting for magnification of the site cleaning operation Refocus as needed 7 Use the x and y thumb wheels of the carrier to move to the left corner of the site under the site cleaning tip Option A camera may be provided for operator viewing on the computer screen DRS25 User Manual 0025 00 901 7 20 Section 7 Operator Training Apply Flux Paste Position Temperature Sensor Nozzle preheat Press Footswitch to Continue The nozzle will automatically move up Event 3 This is a timed event 60 seconds with the nozzle being heated during this time as the operator applies flux and positions the thermocouple temperature sensor This is normally sufficient time If it is not advise supervisor to reprogram to a longer timed event or provide an extra footswitch event 1 Apply flux paste generously over the entire site Do not use a low solids flux 3 Re position the temperature sensor over the board If a thermocouple is used use Kapton tape to attach it to the board material This should have been done prior the program being activated when reviewing the application notes Note The sensor is meant to read the board temperature It is important to position the sensor thermocouple away from the nozzle and on or over another device or at the edge of the board IMPORTANT The nozzle must heat soak prior to positioning at the board level This will allow the heat of the t
186. ws A left amp right sides holding the board carrier set carrier aside e Remove the four screws B left amp right sides holding the diffuser mounting plate double diffuser or dovetail single e Lift straight up and slide to back Lay on top of diffuser Inspect cable Make sure cable clamps are tight e Clean rail e Remove the four screws C holding the x bearing rail e Lift and move the carrier assembly to the back of the machine O O e DRS25 User Manual 0025 00 901 10 7 Section 10 Maintenance e Remove left bearing A Be careful so that balls do not fall out e Remove right bearing B Do not loosen center screw cam e Use 3 in one oil or similar to lightly lubricate bearing A B Reinstall right bearing Do not tighten completely Slide back and forth Reinstall left bearing from front of machine Slide back and forth Tighten Press right bearing against rail Set cam until almost tight Tighten top and bottom screws Check the y bearing for excessive play by twisting the bearing plate left and right There should be less than 1 16 play in the assembly Do not over tighten Table will not move with y drive or bearing will be damaged if it is too tight e Continue to X bearing procedure DRS25 User Manual 0025 00 901 10 8 Section 10 Maintenance Three to four times per year as required To correct for play in carrier X bearing To correct wobble in nozzle con
187. y 8 Safety 8 0 Safety System Overview The DRS25 system was designed with safety of the operator in mind The operation and maintenance of the system must be performed cautiously due to the nature of the hot surfaces and the hazardous chemicals involved in the assembly and rework of printed circuit cards NOTE When operating the AIR VAC DRS25 system follow all local codes for safe operation of the machine Disposal of materials used in the processing of Printed circuit boards must be done in compliance with each Manufacturers recommendation in accordance with local codes The DRS25 machine employs a motherboard and control PCB s for the control system While the system is in operation the embedded computer will provide the first level of operator safety The controller will not allow the system to operate unless all air and electrical input requirements are connected and working System alarms are employed by the controller to minimize dangerous or non compliant operation of the machine Other safety mechanisms include e Alatching E stop Operator safety warning labels and markings are employed e Diffuser safety shields have been included to minimize operator exposure to the heated diffuser plates e Gas nozzle handling tools has been included and should be used when handling hot nozzles DRS25 User Manual 0025 00 901 8 3 Section 8 Safety 8 1 General Safety Machines and tools of Air Vac can only be used with maximum efficien
188. y six 6 months DRS25 User Manual 0025 00 901 4 3 Section 4 Machine Function Verifications 4 1 Pressure Verification Check the pressure requlators on the back of the machine to insure they read a minimum of 70 psi while the profile is running The Pressure Gauge for the Upper Heater A should read 80 psi 5 psi 70 psi minimum while post power up profile is running Please verify these pressure readings and if either gauge reads something other than 80 psi change the pressure by e Unlocking by pulling upwards the Pressure Regulator Adjustment Controls B e Turning the control clockwise to increase the pressure and counter clockwise to reduce the pressure Once the Pressure Gauge reads 80 psi lock by pushing downward the Adjustment Control e Gotothe hidden menu and then open Post Power Up Profile e Click on the Cycle Start button to stop the process e Close the right cover and fasten the rear hold down screw Note Both the Upper Heater and Bottom Heater must be off during this process B A t 2 1 s T see 2 a ra 4 3 gt 4 50 a By 7 DRS25 User Manual 0025 00 901 4 4 Section 4 Machine Function Verifications 4 2 Post Power Up Voltage and Pressure Verification IMPORTANT REFER TO SECTION 2 FOR FACILITY REQUIREMENTS OF DRS25 Select Options from the menu bar Select Open File Group System System System Select the Post Power Up Voltage and P
189. yboard may be used Bl a 5 o E E Move the cursor to the Thumbs Up icon and click the left side of the mouse to save the information Click on the Thumbs Up icon again to go to the next screen If access is denied consult supervisor Note It is advised that each operator have an individualized operator name and password The operator name and password must be registered by an individual with high clearance within the software programming 2 Turn on machine power Disengage e stop and turn power key 3 Enter Password The Password screen will automatically appear after the Operator Registration Operator Registration screen Y Password 4 Click on Thumbs up icon to go to the next screen Note The module is shipped with no password If access is denied consult supervisor Note Passwords are installed and must be correct to access software Low priority will only allow access to minimal screens The machine is shipped with operator and no password blank under low priority limited access DRS25 User Manual 0025 00 901 7 4 Section 7 Operator Training 7 2 Main Screen Overview DRS Software System Cek DRS25 Options Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Lead Free Rework Rep ir amp Assembly WWW air vac eng com Note Using the low priority password limits the oper

Air-Vac DRS25 manual 1.00

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