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ONYX 29

ONYX 29 User's Guide

0029.00.900

The information contained in this User's Guide is the property of Air-Vac and shall not be repro-duced or published to a third party in whole or in part without prior written approval of Air-Vac. Please read this User's Guide carefully, to insure the optimal start-up and maintenance of the equipment and to help avoid the possible creation of danger points within the system. Every effort has been made to ensure that the information herein is complete and accurate. However, the information in this document is subject to change without notice. Air-Vac assumes no responsibility for any error or damages resulting from faulty operation or in observance of this manual. Trademark acknowledgements: HexSight, FireBlox and FireView are trademarks of Adept Technologies, Inc. Microsoft is a trademark of Microsoft Corporation, Inc. Visual C++, Visual Basic and Visual Studio are trademarks of Microsoft Corporation, Inc. Windows 2000 and Windows XP are trademarks of Microsoft Corporation, Inc. Visual Machines is a trademark of Infotech AG.


Art. Nr. 800.00.007 / Version 1.4 (ONYX 29 Series 5) / 10. August 2007 4 -226

General Delivery Terms (GDT) I. General Provisions

1. The present GDT applies to all Air-Vac services as long as no written differing agreements have been made.

2. Customer orders must be made in writing and, in order to be binding, require an order confirmation which only applies to the contents of the agree-ment (unless otherwise agreed).

3. Air-Vac retains all rights to proposals, drawings, and other documents as long as nothing to the contrary has been contractually agreed upon. In particular, documents from Air-Vac may only be made available to third parties after prior approval.

4. The delivered software remains the sole property of Air-Vac, even if license fees have been paid.

II. Prices and Methods of Payment

1. All prices are net prices in freely available Swiss Franks (CHF) - if there is no other agreement - and are ex works excluding packaging. All incidentals, including taxes, fees, etc. are the responsibility of the buyer, barring other agreements.

2. As long as nothing specific has been agreed upon, one third of the purchase price is payable upon or-der confirmation, and the balance upon delivery.

3. All invoices must be paid within 30 days of the invoice date. Discount deductions are not allowed. For late payments, interest will be charged starting on the 31

st day after the invoice date, without prior

reminder. The interest will be at least 4% above the rediscount rate of the Swiss National Bank.

4. The buyer may only offset such claims that are undisputed or legally binding.

III. Methods of Delivery

1. The time of delivery begins with the order confir-mation or after clarification of all technical details and any queries.

2. For as long as Air-Vac is hindered in executing or delivering the order due to force majeure, the deli-very deadline will be suspended. Force majeure also includes serious conditions without fault such as strike, fire, enactments of import embargos, or a considerable increase of import duties as well as considerable delays by suppliers that are essential to executing the order.

3. Partial deliveries are allowed, as long as their acceptance can be expected of the buyer.

4. Installation work will be charged separately, unless agreed upon otherwise.

IV. Retention of Ownership and Security

1. Air-Vac retains ownership of its delivery until the invoice has been paid in full and is authorized un-der its own onus to register the reservation with the responsible registry.

2. In the case of resale, even in an integrated condi-tion, the purchase price claim counts as being ceded to Air-Vac. The goods subject to retention of ownership may not be pledged nor conveyed as a security.

3. Furthermore, Air-Vac reserves the right to cede its invoices either in whole or part.

4. If a customer’s situation deteriorates considerably during the term of an order, Air-Vac has the right to make its services dependent on a security. If this remains undone, Air-Vac is authorized to withdraw from the contract and to claim the resulting dam-ages.

V. Risk Acceptance

1. The buyer assumes risk as follows:

a.) for deliveries without setup or installation: from point of shipping or pick up. Upon request and at the expense of the buyer, deliveries from Air-Vac will be insured against usual transpor-tation risks.

b.) for deliveries with setup or installation: on the day they are taken over in the buyer’s own company, or if agreed upon, after an error free probation period.

2. If the buyer ends up delaying acceptance, then he assumes all the risk.

VI. Warranty/Guarantee

1. Air-Vac offers a guarantee period of 12 months after the customer accepts responsibility.

2. The customer must check the delivery within 8 workdays and register any deficiencies in writing. Hidden deficiencies must be registered in writing within 8 workdays of their discovery. If this is not done, the goods are deemed to be approved.

3. Air-Vac must be awarded sufficient time and op-portunity to correct any deficiencies. If this is de-nied, then Air-Vac is released from the warranty.

4. The warranty does not cover natural wear and tear or damages that occur after responsibility accep-tance or as a result of incorrect or negligent treat-ment, excessive demand, unsuitable operational resources, and non-reproducible software errors, among others.

5. Under no circumstances does the buyer have a claim to compensation for damages that are not re-lated to the delivery, such as loss of production, loss of use, loss of orders, loss of profit, as well as other direct and indirect damages. This liability ex-clusion does not apply to illegal intent or gross negligence on the part of the supplier.

VII. Court of Jurisdiction and Applicable Law

1. The court of jurisdiction is Solothurn. However, Air-Vac has the right to summon the customer to his responsible court.

2. Swiss law is applicable (excluding the United Na-tions Convention on Contracts of the International Sale of Goods, CISG).

CE-Kennzeichnung CE-Zertifikation Arbeitssicherheit

EC-Declaration of conformity ONYX 29 Selective soldering system

[email protected] / [email protected] / www.pocon.ch / www.infotech-automation.com 1 -1

POCON T&T

Manufacturer EC-Declaration of conformity Manufacturer: Infotech AG, Vogelherdstrasse 4, CH-4500 Solothurn

www.infotech-automation.com Declares, that the design and the condition of the Type: ONYX 29 Selective soldering system Description: Semi automated, high precision and multifunctional positioning

and selective soldering system Serial number: 003.05.153 Certified: 4. February 2009 (according to machinery 98/37/EC) Validated with 2006/42/EC: 5. November 2009 meets the requirements according to the following EC directives:

Machinery 2006/42/EC, Low voltage 2006/95/EC, Electromagnetic compatibility 2004/108/EC, Pressure devices 97/23/EC, Noise 2003/10/EC.

Used EN-standards: EN 12100-1, -2 EN 13849-1

EN 13850 EN 13857 EN 547-1 EN 55022/B EN 614 EN 60204-1, -2 EN 894-2 EN 61000-4-2 EN 983 EN 61000-4-4 EN 1037 EN 14121-1-2

We would like to point out, that the installation and the initial operation of the system has to be per-formed by our special educated personal. Only special trained personal is allowed to operate the equipment. When part of the system is being changed without our agreed permission, this declaration will be-come invalid. Solothurn, 5. November 2009 Solothurn, 5. November 2009 Infotech AG Pocon T&T

Ernest Fischer Rainer Fritzius General Manager Director


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ONYX29 User’s Guide Chapter 1: Introduction

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1: Introduction1: Introduction1: Introduction1: Introduction 1 Introduction ..............................................................................................................................................3 1.1 WELCOME ...............................................................................................................................................3 1.2 ONYX 29 SYSTEM OVERVIEW .................................................................................................................3 1.3 VISUAL MACHINESTM................................................................................................................................6


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1 Introduction

1.1 Welcome Please read this User's Guide carefully before the initial set-up of the system to insure the optimal start-up and maintenance of the equipment. This User's Guide has been compiled in accordance with ISO 9000 and the EC machine guideline regulations. It contains all information and instructions that are necessary for safe and trouble-free operation of the ONYX 29 machines. 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.

WARNING

HOWEVER, DUE TO THE TECHNICAL COMPLEXITY OF THIS SYSTEM, CERTIFIED PERSON-NEL MUST BE INVOLVED WITH THE INSTALLATION AND TRAINING OF YOUR NEW SYSTEM.

DO NOT ATTEMPT TO POWER UP THIS SYSTEM WITHOUT AIR-VAC PERSONNEL PRESENT.

This User's Guide must always be kept next to the machine. It is an essential part of the machine. The safety aspects have been tested in conformance to UL and CE standards.

1.2 ONYX 29 System Overview

Intended use of the ONYX 29 SEMI-AUTOMATED SOLDERING SYSTEM

THE ONYX 29 MACHINE PROVIDES SEMI-AUTOMATED REMOVAL, SITE CLEANING AND SOLDERING OF ADVANCED TECHNOLOGY COMPONENTS INCLUDING BGA'S, CSP'S, FLIP CHIP, MICRO-DISCRETES, SURFACE MOUNT CONNECTORS AND FINE PITCH QFP'S AS WELL AS TRADITIONAL LEADED DEVICES SUCH AS PLCC'S, SOIC'S AND SOCKETS.

THE ONYX 29 MACHINE IS CONFIGURED TO SUPPORT ALL LEAD FREE REWORK PROCESSES. ALL PERIPHERALS ARE MATCHED TO FULLFILL THE HIGHER TEMPERATURE AND TIGHTER TOLERANCE REQUIREMENTS.


0029.0

Machine overview of the standard Hot Gas System

ItemThe BothFron

B

C

E

D

A

0.900

A, B and C: identifies the board carrier and support features board carrier has two fixed (A) support arms and two adjustable rails movable arms are spring loaded to allow for board growth during heatit and rear knobs lock the movable arms in place.

H

(B) to hold the bng cycles.

G

F

1-4

oard.


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Each movable arm has three (3) sectional supports (C) to hold the edge of the board. These sup-ports should be positioned to provide maximum support under the targeted component. Move the sectional supports to the correct position(s) if edge components/clearance is an issue. Each sectional support has a swinging board lock to secure the board to the carrier. Bottom supports provide necessary rigidity to prevent board downward warping during the heating and component placement steps. The board carrier pivots upward to allow access to the underside of board. This feature simplifies board support positioning. It is important to position board supports clear of any bottom side com-ponents. Supports should be directly in contact with the board.

Item D: identifies a handle used to manually position the robot head. This handle is normally used during robot training. The assembly head can be moved manually.

Note

WHEN MOVING THE ROBOT HEAD MANUALLY, MAKE SURE THE NOZZLE IS AT A SAFE HEIGHT, OTHERWISE THE NOZZLE AND MACHINE PERIPHERALS MAY BE DAMAGED.

Item E: identifies the hot gas heater. The hot gas heater generates hot gas (air or nitrogen). The hot gas then is guided into the hot gas nozzles.

Note

THIS COVER SHIELDS THE HOT GAS HEATING ELEMENT FROM THE OPERATOR. THE HOT GAS TOOL CAN GET VERY HOT.

Item F: identifies the emergency stop button. Engage this button if any unplanned motion occurs. Do not use it to pause a running program. It should be used only in emergency situations.

Item G: identifies the board pre-heater panels. There are 4 independently programmable heater zones.

Item H: identifies the machine operator panel. The buttons located on this panel provide optional operator interaction during normal program execution.


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1.3 Visual MachinesTM The VISUAL MACHINESTM Software is used to support the ONYX 29 processes including removal, site cleaning and soldering. The base software VISUAL MACHINESTM is designed to put the focus on the application, not the programming. It is an object oriented, modular software environment that enables rapid implementation of complex motion, vision and process control modules. The soft-ware uses drag and drop VISUAL WIRES to allow easy application-specific changes. VISUAL MACHINESTM provides VIEWS, which represent possible actions the user may select for vari-ous operations. The principal views are:

Operating the machine, start and stop of production programs (Access level OPERATOR and higher) Creating new or modifying existing production programs (Access level PROCESS and higher) Defining the part type specific parameter and processes (Access level PROCESS and higher) Machine and peripheral calibrations (Access level MAINTENANCE and higher) Displaying actual states of the machine and the peripherals (Access level MAINTENANCE and higher) Machine and peripheral configuration (Access level ADMINISTRATOR and higher) Analysis and printing of Thermal Profile Chart/Data (Access level PROCESS and higher)


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Online help, the description of each page can be viewed directly within the page by clicking the question mark icon (Robo Help).


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ONYX29 User’s Guide Chapter 2: Safety

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2: Safety2: Safety2: Safety2: Safety 2 Safety ........................................................................................................................................................3 2.1 GENERAL SAFETY INSTRUCTIONS .............................................................................................................3 2.1.1 NOTES AND WARNINGS............................................................................................................................3 2.1.2 BASIC SAFETY INSTRUCTIONS ..................................................................................................................3 2.1.3 APPLICATION SPECIFIC SAFETY ASPECTS ..................................................................................................4 2.1.4 MACHINE WARNING LABELS ......................................................................................................................5


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0029.00.900 2-3

2 Safety

2.1 General Safety Instructions

2.1.1 Notes and Warnings

This manual contains safety instructions wherever required. These instructions are divided into two categories as follows:

WARNING

A WARNING INDICATES THAT INOBSERVANCE OF THE INSTRUCTIONS CAN RESULT IN PER-SONAL INJURY.

Note

A NOTE DESCRIBES SPECIAL ACTIONS, PROCEDURES, INSTRUCTIONS, AND INFORMATION THAT ARE RELEVANT TO THE SUBSEQUENT SECTION OR STEP. INOBSERVANCE OF THE INSTRUCTIONS CAN RESULT IN DAMAGE TO THE MACHINE OR TO THE PROCESS MATERIAL.

2.1.2 Basic Safety Instructions

In addition to the safety instructions in this document, the following guidelines must be observed to prevent personal injuries in general:

WARNING

BECAUSE STRONG MAGNETIC FIELDS ARE ASSOCIATED WITH THE SYSTEM MOTOR COILS AND MAGNET ASSEMBLY, PERSONS HAVING ACTIVE IMPLANTS (PACEMAKERS, ETC) OR HAVING ANY OTHER FERROMAGNETIC PRODUCTS SHOULD NOT OPERATE THE EQUIP-MENT OR ENTER WITHIN A 2 FOOT PERIMETER AROUND THE SYSTEM.

WARNING

THE HOT GAS TOOL AND THE PRE-HEATER REACH TEMPERATURES WELL ABOVE 60 DE-GREE C. HOT SURFACE WARNING LABELS ARE FOUND ON THE COVERS OF EACH HEATED SURFACE. DO NOT TOUCH THESE SURFACES AS SKIN CONTACT WITH THESE SURFACES WOULD RESULT IN A SHOCK REACTION AND THEREFORE PRESENTS AN IN-HERENT POTENTIAL THERMAL DANGER TO THE OPERATOR. IN ADDITION, OPERATOR SHOULD KEEP HAIR AND CLOTHING CLEAR OF THE PREHEATER AREA WHEN HOT.


0029.00.900 2-4

WARNING

IF FLUX IS USED DURING THE SOLDERING PROCESSES, THE OPTIONAL FUME EXTRACTION MANIFOLD SHOULD BE PURCHASED AND CONNECTED TO A FILTERING SYSTEM.

WARNING

ONLY QUALIFIED PERSONNEL ARE ALLOWED TO WORK ON THE PERIPHERALS WITH HIGH VOLTAGES.

Note

READ THIS MANUAL CAREFULLY BEFORE YOU OPERATE, SERVICE OR REPAIR THE MA-CHINE. THE MACHINE MAY ONLY BE OPERATED BY QUALIFIED PERSONNEL WHO HAVE RE-CEIVED APPROPRIATE TRAINING.

WHEN CLEANING PARTS AND PERIPHERALS OF THE MACHINE, USE ONLY THE SUB-STANCES RECOMMENDED. WHEN MAINTAINING AND SERVICING THE MACHINE, USE ONLY THE TOOLS SPECIFIED.

BEFORE YOU RE-START THE SYSTEM AFTER MAINTENANCE OR REPAIR, MAKE SURE THAT OTHER PERSONNEL, TOOLS AND FOREIGN MATERIALS ARE CLEAR OF THE MOTION AREA OF THE SUBSYSTEMS OF THE MACHINE.

WHEN REMOVING THE BOARD CARRIER, PRE-HEATER AND THE APPLICATION BASE PLATE, THE MAIN SWITCH IN THE BACK OF THE MACHINE MUST BE SWITCHED OFF AND LOCKED.

Note

WHEN PROCESSING ELECTRONIC BOARDS WITH ACTIVE DEVICES, THE OPERATOR MUST BE GROUNDED WITH THE MACHINE, TO AVOID DAMAGING THE ACTIVE COMPONENTS ON THE BOARD.

2.1.3 Application specific safety aspects

WARNING

ANY ADDITIONAL PERIPHERAL WHICH IS INTEGRATED INTO THE ONYX29 AND THE AP-PLICATION WHICH IS BEING APPLIED ONTO THE ONYX29 MUST BE DECLARED ACCORD-ING TO THE SAME SAFETY STANDARDS (EC DIRECTIVE MACHINERY (98/37/EC). WHEN USING DANGEROUS SUBSTANCES, WHICH ARE OF POTENTIAL RISK FOR THE OPERATOR, THEN ADDITIONAL SAFETY AND OPERATOR PROTECTION GUARDS OR OPERATING PRO-CEDURES MUST BE ADDED BY THE APPLICATION RESPONSIBLE COMPANY.


0029.00.900 2-5

2.1.4 Machine warning labels

Label Indication

This label indicates the presence of strong magnetic fields and is found on the X- and Y-axes motors. Because these magnetic fields are associated with the system motor coils and magnet track assembly, per-sons having active implants (pacemakers, etc) or having any other ferromagnetic products are not qualified and are not allowed either to operate the equipment or enter within a 0,5m perimeter around the system.

This label indicates hot surfaces well above 60 0C. The hot gas tool and the pre-heater are required to reach temperatures well above 60 0C. Hot surface warn-ing labels are found on the covers of each such heated surface. Skin contact with these surfaces would result in a shock reaction and therefore presents an inherent potential thermal danger to the operators.

This label indicates the presence of electrical equipment with voltages above 60 Volt. Labels are found beside all removable covers where electrical equipment is mounted and it is used to indi-cate a possible shock hazard.

This label indicates the presence of a Laser diode mod-ule with Laser class 2. Do not stare into the beam. Direct viewing into the beam or reflected beam can cause permanent eye damage. (Po = 1 mW, λ = 650 nm)

This label indicates the presence of an area that pre-sents a pinch point hazard when motion occurs. Keep hands and all objects clear of this area.


0029.00.900

Component Shuttle

1 label is attached to the front of the vision unit 1 label (pinch point) on the component shuttle

4 labels on the X/Y axes linear motor magnet tracks. 1 label on the base plate below the pre-heater. 1 label on the cover of the assembly head. 1 label on the hot gas cover 2 labels on the carrier rails.

Fume Extraction

2-6

ONYX29 User’s Guide Chapter 3: Installation

0029.00.900 3-1

3: Installation3: Installation3: Installation3: Installation 3 Installation ................................................................................................................................................3 3.1 TRANSPORT ............................................................................................................................................3 3.2 UNPACKING .............................................................................................................................................3 3.3 REPACKING .............................................................................................................................................4 3.4 FACILITY REQUIREMENTS.........................................................................................................................5 3.5 WORKSTATION (OPTIONAL) ASSEMBLY .....................................................................................................7 3.5.1 MOVING THE SYSTEM ONTO THE FINAL TABLE LOCATION ..........................................................................10 3.5.2 REMOVE THE TRANSPORT SAFETY LOCKS ...............................................................................................11 3.5.3 IR OPTION AND SHIPPING BRACKET .......................................................................................................13 3.5.4 INSTALL THE PRE-HEATER .....................................................................................................................15 3.6 ELECTRICAL INSTALLATION.....................................................................................................................15 3.6.1 MAIN POWER.........................................................................................................................................16 3.6.2 ONYX29 DISPENSER OPTION (0029.08.010) INSTALLATION...................................................................19 3.7 PNEUMATIC INSTALLATION......................................................................................................................21 3.7.1 MAIN AIR SUPPLY ..................................................................................................................................21


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3 Installation

3.1 Transport The machines must be transported and stored in a temperature and humidity controlled environ-ment. The temperature range shall be within –20 oC to 50 oC, the humidity shall be within 5 – 90%, non-condensing. The machines must be transported and stored in the supplied packaging that is designed to pre-vent damage from normal shock and vibration. The packages must be handled carefully.

3.2 Unpacking Before unpacking carefully inspect all shipping crates for evidence of damage during transport. If any damage is indicated, make sure the transport agent is present during opening the crates. Carefully unpack the crate and compare the delivery papers with the contents in the crate, but also with your order papers.

Check the Machine ID-Label that is located on the right backside of the machine (when standing in front of the ma-chine). The serial number has to match the delivery papers (only the serial number of the machine is listed on the deliv-ery papers).

Systems which are equipped for countries with 208/120VAC the label must identify the proper volt-age configuration: U 3x208/120V I 16A f 60Hz S 5800VA P 6bar Store the package material carefully for further transports of the system. The space for the system has to be ready before the system can be moved. Make sure the table or lab bench where the system will be installed provides a stable flat surface.

ONYX 29 CE Serial Number: 003.02.003 Manufactured: 2004 U 3x400/230V I 16A f 50Hz S 6400VA P 6bar


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See the sections below for the installation guide.

WARNING

FOUR (4) PEOPLE ARE NEEDED TO MANUALLY MOVE THE MACHINE FROM THE CRATE TO ITS FINAL LOCATION. THE MACHINE WEIGHT IS 264 LBS.

THE WEIGHT IS UNBALANCED, THE LEFT SIDE (WHEN STANDING IN FRONT) OF THE MA-CHINE IS MUCH HEAVIER.

USE THE CORNER SPOTS ON THE BASE FOR LIFTING THE MACHINE, AS MARKED A, B, C AND D ON THE FOLLOWING DRAWING.

3.3 Repacking If the system needs to be transported to a new location, use the original packing material that has been supplied with the machine. If this packing material is not available any more, please contact your supplier for replacement packaging material. Improper packaging and handling during the transport of the system will reduce or void the war-ranty. Please follow the picture guides in Appendix C of this manual.

BA

C D


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3.4 Facility Requirements

Electrical:

• Machine Power: 208 VAC, 50/60 Hz, 3-phase, 25 A (max).

6’ of 12/4 power cord supplied. No plug supplied with system.

• Monitor Power: (208V) - Provided by convenience plug on machine.

• Computer Power: (208V) - Provided by convenience plug on machine.

Optional equipment:

• Time/Pressure dispense: 110/208 VAC, 50/60 Hz, 1A/.5 A, single phase.

Air/Nitrogen (Base Machine):

• Main Air Supply: 90-130 psi, 5 scfm, clean, dry air (non-condensing) source.

(Includes Board Cooling) 1/8”-18NPT with two 1/4” lines (supplied). Direct plumb.

Electrical: IMPORTANT

• This system is designed to operate on 208VAC, 3 phase.

• Under full load conditions, power must not drop below 205VAC. Verify all 3 phases.

• If the PC and monitor are connected to a separate power source, or connected through a volt-age regulator, the machine minimum voltage is 195V.

• Under no load conditions, power must not exceed 215VAC.

Air/Nitrogen:

• With top heater and board cooling system operating, system consumes up to 25 scfm @80 psi.With all systems activated, 70 psi. must be maintained. Requires both gas lines be directplumbed (no quick disconnect).

General: These requirements must be addressed prior to the installation and trainingvisit. This will assure you receive a productive training program within the scheduled installationtime.

Physical:

• ONYX29 Dimensions:

Base:

32W” x 32D” x 36H”

Operating with workstation:

78W” x 50”D x 55”H

• ONYX29 Weight:

ONYX29 (265 lbs.)

with workstation (365 lbs.)


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823

951

821.16

720101.16

772.5


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3.5 Workstation (optional) Assembly 36” x 60” ESD Bench


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Monitor Stand Nozzle Holder


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Triple Locking Drawer CPU Holder


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3.5.1 Moving the system onto the final table location

Before the machine can be moved, the machine table or a strong lab bench with a flat and hori-zontal surface must be installed. This table must be very stable to support the system. Move the machine on top of the machine support.

WARNING

A MINIMUM OF 4 PERSONS IS NEEDED TO MANUALLY MOVE OR CARRY THE MACHINE FROM THE CRATE TO ITS FINAL LOCATION. THE MACHINE WEIGHT IS 120 KG (264 LBS.)

THE WEIGHT IS UNBALANCED, THE LEFT SIDE (WHEN STANDING IN FRONT) OF THE MA-CHINE IS MUCH HEAVIER.

USE THE CORNER SPOTS ON THE BASE FOR LIFTING THE MACHINE, AS MARKED A, B, C AND D ON THE FOLLOWING DRAWING.

After the system has been moved to the proper location, the transport safety locks can be re-moved, the cables can be connected and the system can be made ready for operation.


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3.5.2 Remove the transport safety locks

After the system has been moved to the proper location, remove the X- and Y-axes transport safety locks: Remove the two screws. After the two screws have been removed, the X-axis can be moved carefully to the side. Do not slide back, when the Y-axis is not at the correct location, the Y-axis linear encoder scale may be damaged. Remove the bracket mounting screw and remove the transport safety lock bracket. Remove the X-carriage buffer from the bracket and attach it in the thread where the screw was removed. This buffer can be tightening by hand, without the need of any tools. Mount the screw into the location in the bracket where the buffer was removed. Re-attach the front Y-axis bracket with the screws from the transport safety bracket. Put the two original screws back into the threads from the bracket. This way these are not getting lost. These screws have different lengths. During the transport of the system, longer screws are used.


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WARNING

NEVER USE THE SHORT SCEWS TO ATTACH THE SAFETY BRACKET. THESE WOULD GET LOOSE ON THE TRANSPORT.

Note

PUT THE SAFETY BRACKET WITH THE LONGER SCREWS AND THE BUFFER REPLACEMENT SCREW INTO A SAFE LOCATION. IT WILL BE USED EACH TIME THE SYSTEM IS BEING MOVED.

MOVE THE X-AXIS AND THE Y-AXIS FROM ONE END TO THE OTHER END, THEN MOVE BOTH AXIS TO ABOUT THE CENTER LOCATION. THESE TWO MAIN AXIS CAN BE MOVED EASY, WHEN THERE IS NO POWER TO THE SYSTEM, AS LINEAR MOTORS AND LINEAR ENCODERS ARE USED.

Remove the Vision X-axis transport safety lock by removing two screws. Re-attach them in the same location but facing up. This way the locks are always present when needed.

Note

THE VISION X- AND Y-AXIS CANNOT BE MOVED EASY. CAREFULLY MOVE THE VISION Y-AXIS SLIGHTLY TO THE FRONT.


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3.5.3 IR Option and Shipping Bracket

1. Locate shipping bracket on vision assembly.

2. IR Probe will need to be removed in order to remove shipping bracket. 3. Remove the mounting screws (5) for the IR probe.

IR Probe Assembly

Shipping Bracket

Vision Assembly

Shipping Bracket

IR mounting screws (5)


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4. Move IR to the side in order to remove the shipping bracket.

5. Re-mount shipping bracket as shown for future use. 6. Re-mount IR probe.

IR Probe

IR Probe


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3.5.4 Install the Pre-Heater

The pre-heater is transported inside its separate packaging. Unpack the pre-heater and remove the isolation material. Make sure that there is no isolation material left on the pre-heater or the application base plate. The pre-heater feet have to be located in the appropriate holes of the base plate. The connections are shown from the back side:

4 3 2 1 The cables of the pre-heaters can be installed in the back of the system. Install cables into the diffuser port as required (1-4).

3.6 Electrical Installation

Note

ONLY QUALIFIED PERSONNEL ARE ALLOWED TO WORK ON THE PERIPHERALS WITH HIGH VOLTAGES. THE GOVERNING LAWS AND REGULATIONS MUST BE OBSERVED.

WHEN WORKING WITH HIGH VOLTAGES, ALWAYS ENSURE THAT ANOTHER PERSON IS NEAR YOU WHO IS FAMILIAR WITH ALL EMERGENCY POWER OFF CONTROLS.

MAKE SURE TO CHECK THE ELECTRICAL SCHEMATICS SUPPLIED WITH THE MACHINE.

THE MACHINE EXISTS IN 2 DIFFERENT, COUNTRY VOLTAGE SPECIFIC VERSIONS (3PE 208V AND VERSION 3PNE 400V).


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3.6.1 Main Power

IMPORTANT:

MAKE SURE THE MAIN SWITCH IS SWITCHED TO OFF (0).

The main 3-phase power cable is already con-nected inside the base chassis. Use this cord to connect to a facility power outlet.

WARNING

THE POWER SUPPLIED ON THESE PC- AND MONITOR POWER PORTS PROVIDE A VOLTAGE OF 208 – 240 VAC, MAKE SURE THE PC AND THE MONITOR ARE CONFIGURED FOR THIS VOLTAGE SUPPLY. OTHERWISE THE PC AND MONITOR CAN BE DAMAGED.

Main power Input of the machine support 3x 208VAC 3PE Phase 1 & phase 2 = 208-240VAC Phase 2 & phase 3 = 208-240VAC Phase 1 & phase 3 = 208-240VAC Each phase & earth ground = 110-126VAC

Phase 1 L1

Phase 2 L2

Phase 3 L3

Earth Ground PE

208V

AC

208V

AC20

8VA

C

110V

AC

110V

AC

110V

AC


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1. Connect the 6-pin FireWire IEEE-1394 connector cable to the FireWire port on the back of the

machine and connect the other side to one free FireWire IEEE-1394 port of the PC. 2. Connect Ethernet cable here, then to PC.

Attach the S-video cable to the camera and connect the other side of the S-video cable into the PC. Attach the camera power plug provided here, then to the cam-era power outlet as shown above.

Camera Power

(option)

Camera Light Ring

Power (option)

Accura Dispenser

Power (option)

1 2

Direct View Camera (option)


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S-Video cable from Direct View camera (option)

Ethernet to back of ONYX

FireWire to back of ONYX

PC Power to back of ONYX


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3.6.2 ONYX29 Dispenser Option (0029.08.010) Installation

Setup:

Dispenser – front and rear connections Pressure – Set to 100 Kpa unless otherwise determined/directed Time Set – 000 Mode Button – In (steady state) Shot Button – Out (Off)

Dispenser Front

Dispense Head


0029.00.900 3-20

Dispenser Rear:

ONYX29 Rear Pneumatic Connection: ONYX29 Rear:

To air filter To right rear of machine

To 110V

Connection from control cable (rear of Accura dispenser)

to rear of ONYX29.


0029.00.900 3-21

3.7 Pneumatic Installation The upper unit can either be connected to a nitrogen source or tied into the lower, main air source.

3.7.1 Main Air Supply

The machine has to be supplied with clean, dry and non-condensing air.

Connect the air hose to the Pneumatic maintenance unit located at the back left side of the machine. The lower unit is the main air source. Make sure to use a straight connection to the main pneumatic mainte-nance unit and not a 90 degree connection. Use at minimum a hose with a diameter of 8mm (1/3 Inch tube). Adjust the air pressure with the air pressure regulator until the gauge shows 0.55 mpa (80PSI). If a second maintenance unit is installed, this unit must be connected as well. Normally this unit is supplied with nitrogen, however if nitrogen is not available, then it must be connected to the compressed air source. Otherwise it will not be possible to use the hot gas tool. Adjust the gas pressure at the second gas pressure regulator until the gauge shows 0.55 mpa (80PSI).


0029.00.900 3-22

ONYX29 User’s Guide Chapter 4: System Power Up/Down

0029.00.900 4-1

4: System Power Up/Down4: System Power Up/Down4: System Power Up/Down4: System Power Up/Down 4 System Power Up / Down........................................................................................................................3 4.1 SYSTEM POWER UP..................................................................................................................................3 4.1.1 SWITCH ON THE MAIN 3-PHASE POWER .....................................................................................................3 4.1.2 RELEASE THE E-STOP BUTTON .................................................................................................................3 4.1.3 SWITCH ON THE SYSTEM POWER I/O AT THE ONYX 29 .............................................................................4 4.1.4 SWITCH ON MONITOR, THE PC AND LOAD THE OPERATING SYSTEM ............................................................4 4.1.5 START THE VISUAL MACHINESTM SOFTWARE.............................................................................................4 4.1.6 LOG ON WITH THE USER NAME AND PASSWORD .........................................................................................5 4.2 STATUS BAR AND SAFETY PROTECTION WARNINGS ..................................................................................5 4.2.1 EXECUTE THE CALIBRATION PROGRAM ......................................................................................................6 4.3 SYSTEM POWER DOWN ...........................................................................................................................6


0029.00.900 4-2


0029.00.900 4-3

4 System Power Up / Down

4.1 System power up The steps for starting up the system are summarized below and discussed in detail on the pages that follow: • Switch on the main 3-phase power (normally not necessary) • Release the E-stop button and enable power to the axes • Switch on the system power I/O at the ONYX 29 • Switch on the monitor, the PC and load the operating system (Windows 2000 or XP) • Start the Visual MachinesTM Software • Log on with the user name and password • Execute the calibration program • Operate the system

4.1.1 Switch on the main 3-phase power

Turn on the main 3-phase power switch which is located behind the system (90° clockwise to on). Normally this switch is not switched off. It is switched off only if maintenance personnel need to have access to the power control modules in the base of the system.

Note

PLEASE BE AWARE THAT SWITCHING OFF THIS MAIN 3-PHASE POWER SWITCH WILL SWITCH OFF THE PC AND MONITOR AS WELL. SHUT DOWN THE PC FIRST BEFORE MA-NIPULATING THIS SWITCH TO OFF (0).

4.1.2 Release the E-stop button

The button has to be rotated clock-wise for about 20O then it releases itself. When the E-stop button is released, the axes have no power yet. The power will be enabled automatically during the axes calibration sequence.


0029.00.900 4-4

4.1.3 Switch on the system power I/O at the ONYX 29

Turn on the system power switch I/O of the ONYX 29, which is located at the front to the left side.

4.1.4 Switch on monitor, the PC and load the operating system

Switch on the monitor, the PC and load the operating system Windows 2000 or Windows XP.

4.1.5 Start the Visual MachinesTM Software

Note

WAIT UNTIL THE PC HAS LOADED THE WINDOWS OPERATING SYSTEM. THIS MAY TAKE UP TO 5 MINUTES.

As soon as the Windows operating system has been loaded, double click the Icon VISUAL MACHINESTM and the

software will be started. The system can be configured, that VISUAL MACHINESTM starts automatically. Refer to the Windows operator system manual.

NOTE:

IF THE MACHINE WAS NOT POWERED ON PRIOR TO STARTING THE VISUALMACHINESTM SOFTWARE, THE FOLLOWING MESSAGE WILL APPEAR.

SWITCH ON THE SYSTEM POWER I/O SWITCH. CLICK ON THE “CONTINUE ONLINE” BOX.

VisualMachines.lnk


0029.00.900 4-5

4.1.6 Log on with the user name and password

Enter the User Name and Password.

4.2 Status Bar and Safety Protection Warnings The status line at the bottom of the monitor is always displayed:

Operator name

Access

level

Shows Robot

status Calibrated

Not calibrated

Shows which Tool holds which Nozzle on which

Head

Runtime

Idle Paused Running E-Stop

Online Online Offline

Pre-heater

HOT Warning When above 60oC,

blinking warning text

Hot Gas Tool HOT Warning

When above 60oC, blinking warning text

The status bar is machine configuration specific and may appear different on your system.

WARNING

FOR THE PRE-HEATERS AND FOR THE HOT GAS SYSTEMS, HOT TEMPERATURE WARNING LABELS ARE DISPLAYED WITHIN THE STATUS LINE AS SOON AS THE TEMPERATURE OF ONE OF THESE DEVICES EXCEEDS 600C.

THE ACTUAL TEMPERATURE IS DISPLAYED IN A RED, BLINKING BOX.


0029.00.900 4-6

4.2.1 Execute the calibration program

The VISUAL MACHINESTM Software will prompt the operator to execute the calibration program. • Select Yes.

Note

THE SYSTEM WILL MOVE ALL THE AXES DURING CALIBRATION. MAKE SURE THERE ARE NO TOOLS OR ANY OTHER PARTS IN THE WORKING AREA.

The system is now ready for operation.

4.3 System Power Down To power-down the system follow the power-up sequence in the reversed order:

• Complete the operation with the machine • Exit the VISUAL MACHINESTM Software, the databases are saved automatically • Switch off the system power I/O at the ONYX 29 • Shut down the operating system Windows 2000 or XP at the PC • Switch off the PC and monitor

Note

WHEN EXITING THE VISUALMACHINESTM SOFTWARE, AN AUTOMATIC BACKUP OF ALL PROGRAMS AND PART TYPES IS MADE.

IN ADDITION, IF THE TOP AND BOTTOM HEATERS ARE ABOVE 600C. THE MACHINE WILL CONTINUE TO COOL DOWN THE HEATERS UNLESS YOU INSTRUCT IT OTHERWISE.

ONYX29 User’s Guide Chapter 5: Verification/Calibration

0029.00.900 5-1

5: Verification/Calibration5 Verification/Calibration.................................................................................................................3

5.0 VERIFICATION/CALIBRATION MATRIX .................................................................................................3

5.1 ROBOT CALIBRATION......................................................................................................................4

5.2 FLOW RATE VERIFICATION ..............................................................................................................5

5.3 HOT GAS TOOL TEMPERATURE VERIFICATION.....................................................................................6

5.4 HOT GAS TOOL CALIBRATION...........................................................................................................7

5.5 BOTTOM HEATER VERIFICATION.......................................................................................................8

5.6 PLACEMENT VERIFICATION..............................................................................................................8

5.7 VISION SYSTEM CALIBRATION ..........................................................................................................9

5.8 IR SENSOR VERIFICATION ............................................................................................................10

5.9 IR SENSOR CALIBRATION..............................................................................................................10

5.10 THERMOCOUPLE CHANNELS..........................................................................................................11

5.11 FORCE TABLE VERIFICATION..........................................................................................................11

5.12 FORCE TABLE CALIBRATION...........................................................................................................12


0029.00.900 5-2


0029.00.900 5-3

5 Verification/Calibration

The ONYX29 is factory calibrated. This section provides information regarding calibration and verifi-cation processes.

• Verification is the process whereby calibration is verified.

• Verification procedures can be done by anyone.

• Calibration is the process whereby machine settings are actually changed.

• Calibration procedures are user/password restricted.

5.0 Verification/Calibration Matrix

Category

Robot

Hot Gas Tool

Bottom Heater

Placement Accuracy

IR Sensor

TC Channels

Force Table

Verification

Not required.

Every 3 months

Not required

Every 3 months

Every 3 months

Not required

Every 3 months

Calibration

Done automatically each time

VisualMachinesTM software is started

Only if verification check indicates that

calibration is required

Not required





Not required




0029.00.900 5-4

5.1 Robot Calibration

Upon entry into VisualMachinesTM software, the operator will be prompted to calibrate the robot.

All motorized axes will “home” and the robot will move. When complete, the toolbar at the bottom ofthe screen will show “Robot Calibrated”.

NOTE:

PROGRAMS CANNOT BE EXECUTED IF THE ROBOT IS NOT AUTO-CALIBRATED.

IF YOU EXIT AND RE-ENTER VISUALMACHINESTM SOFTWARE, BUT LEAVE THE ROBOT ON,THE CALIBRATION MESSAGE WILL STILL APPEAR, BUT THE ROBOT WILL NOT MOVE AS RE-CALIBRATION IS NOT REQUIRED, UNLESS THE ROBOT IS DE-POWERED THEN RE-POWERED.THE KEY IS TO CONFIRM THAT THE ”ROBOT CALIBRATED” MESSAGE SHOWS IN THETOOLBAR.

IF THE ROBOT FAILS TO CALIBRATE, CONTACT AIR-VAC FOR TECHNICAL ASSISTANCE.

YOU WILL SEE A CALIBRATION RETRY MESSAGE. RETRY THE CALIBRATION. IF THE RETRYFAILS, CONTACT AIR-VAC.


0029.00.900 5-5

5.2 Flow Rate Verification

NOTE:

THE ONYX29 INCORPORATES A PRECISION MASS FLOW CONTROLLER TO REGULATE THEHOT AIR FLOW. THE FLOW OF THIS DEVICE IS VERIFIED PRIOR TO SHIPMENT ON ONYXUNITS BY THE MANUFACTURER AND DOES NOT NEED ADJUSTMENT.

HOWEVER, IF VERIFICATION/CALIBRATION OF THE MASS FLOW VALVE IS A REQUIREMENTBEFORE RELEASING THE MACHINE TO PRODUCTION, (1) THE VALVE CAN BE REMOVEDFROM THE MACHINE AND SENT BACK TO THE MANUFACTURER FOR CERTIFICATION, (2)CUSTOMERS CAN PURCHASE A CALIBRATION KIT #1016.02.010 FROM AIR-VAC TOPERFORM THE CALIBRATION. ONCE PURCHASED, CUSTOMER WOULD THEN MAINTAIN THECALIBRATION OF THIS KIT FOR FUTURE USE.

1. Go into the Maintenance view

(operator/password restricted)

and double click “Hot Gas Tool”.

2. Increase the flow rate and check the actual flow output (A)versus the set point (B) at 10 SLM intervals between 20and 80 SLM.

• The actual rate should be +/- 3 SLM. If the flow rate ex-ceeds this tolerance, contact Air-Vac.

A

B


0029.00.900 5-6

5.3 Hot Gas Tool Temperature Verification

Tools required: NCAL1 Temperature nozzle

1. Open the temperature verification profile in the Air-Vac directory.

Go to Execution; Open Program folder; Open AV folder;

Select “Temperature Calibration Check – NCAL1 <date code>.itp”

2. Select basic view

3. Load NCAL1 nozzle into the Solder Head and plug the T/C of the nozzle into T/C #1.

4. Execute this program following the step-by-step prompts.

5. The actual temperature output through T/C #1 (NCAL1 nozzle) at 300 seconds should be manu-ally recorded. (Select basic view to read board thermocouple temperature). Note that thereis a CSV file created as a part of this program so the temperature at 300 seconds can be deter-mined from that after the run is complete.

6. If the actual temperature is within 300c +/-3 degrees (ie. 297c to 303c), re-calibration of the topheater is not required.

7. If recalibration is required, using the value just recorded proceed to Hot Gas Tool Calibration step#5.


0029.00.900 5-7

5.4 Hot Gas Tool Calibration

Tools required: NCAL1 Temperature nozzle

1. Open the temperature verification profile in the Air-Vac directory.

Go to Execution; Open Program folder; Open AV folder;

Select “Temperature Calibration Check – NCAL1 <date code>.itp”

2. Load NCAL1 nozzle into the Solder Head and plug the T/C of the nozzle into T/C #1.

3. Execute the program following the step-by-step prompts. Record the Ncal1 temperature at 300seconds. A CSV file is created and can be reviewed to get the temperature after the program hasbeen run.

4. Verify that the target temperature is 300c +/- 3c. If the temperature is not within the tolerance

continue.

Go to Calibration View; Hot Gas ToolCalibration; Calibration Calculator

5. At step 3, of the calibration calculator (5 min-300@60slm temp) enter the value from the

previous run. Example: If recorded temp is 315 thenenter 315. Then Click on Compute Calibration, Apply,Okay.

6. Repeat steps 3 – 5 as required to obtain 300c +/-3c.


0029.00.900 5-8

5.5 Bottom Heater Verification

NOTE:

NOT REQUIRED. ACHIEVEMENT OF THE SAME BOARD PREHEAT TARGET TEMPERATURE ISDONE DURING EVERY PROCESS TO INSURE REPEATABLE RESULTS.

5.6 Placement Verification

NOTE:

PLACEMENT VERIFICATION SHOULD BE DONE EVERY THREE MONTHS.

1. Open and execute the Placement Test Program in the Air-Vac directory.

2. Align and place a QFP160 onto a bare site using double-sided tape, device, board, and nozzlethat are supplied with the machine.

IMPORTANT:

THE LEADS ON THE QFP160 MUST NOT BE BENT OR DAMAGED. DO NOT TOUCH THELEADS DURING THIS PROCESS.

3. Remove the board. Inspect the placement accuracy on all four sides using a microscope. Re-cord any “X”, “Y” errors.

4. Carefully remove the QFP without touching the leads (use the nozzle vacuum).

5. Repeat the Placement Profile a second time to verify that the results match the initial findings. Ifrepeated placements show the same “X” or “Y” errors, follow the instructions for calibrating theVision System.


0029.00.900 5-9

5.7 Vision System Calibration

NOTE:

CALIBRATION OF THE ONYX29 VISION SYSTEM DOES NOT REQUIRE ANY MECHANICALADJUSTMENT. CALIBRATION MUST BE DONE BY AUTHORIZED PERSONNEL.

1. Go to the Calibration View (operator/password restricted).

2. Double click on Vision Unit to access the vision system “X” and “Y” offsets.

• The 0,0 position on the ONYX29 is front left.

3. If the QFP leads need to move toward 0,0 in the X or Y direction, a small adjustment should bemade to the existing offset values.

4. If the QFP leads need to move away from 0,0 in the X or Y direction, a small adjustment shouldbe made to the existing offset values.

IMPORTANT:

THE AMOUNT OF THE OFFSET ADJUSTMENT SHOULD BE VERY SMALL, TYPICALLY .25 MM.

5. Repeat the Placement Verification Process after the offset adjustments are made. Reiterate untilthe desired placement results are achieved.


0029.00.900 5-10

5.8 IR Sensor Verification

NOTE:

THE IR SENSOR IS FACTORY CALIBRATED. VERIFICATION OF THE IR SENSOR ISRECOMMENDED EVERY 3 MONTHS.

1. Attach a K-type thermocouple to a test board with Kapton tape.

2. Teach the IR Sensor position (integrated head version) or move the IR Sensor arm to the sameposition.

3. Run the IR Sensor Verification program in the Air-Vac directory. Write down the IR Sensor andK-type thermocouple readings at 80, 100, 120 and 150 degrees.

4. If the IR Sensor is more than +/- 7.5 degrees different from the IR Sensor, proceed to the IRSensor Calibration section.

5.9 IR Sensor Calibration

NOTE:

CALIBRATION SHOULD BE PERFORMED BY AUTHORIZED PERSONNEL.

1. Select the Calibration View (operator/password restricted) and double-click on Vision System.

2. Adjust the IR offset value up or down, based on the average temperature differential identifiedin the IR Sensor Verification section.


0029.00.900 5-11

5.10 Thermocouple Channels

NOTE:

THE THERMOCOUPLE CHANNELS ARE FACTORY CALIBRATED AND REQUIRE NO ADDITIONALVERIFICATION OR CALIBRATION.

5.11 Force Table Verification

NOTE:

A FORCE CALIBRATION WEIGHT (METAL “HOCKEY PUCK”) IS PROVIDED WITH EACHONYX29 SYSTEM.

1. Select the Maintenance view and double-click on Force Table.

2. Zero the force table, then place the calibration weight in various positions above the metal plate.The reading should be 5.1 +/- 0.5.


0029.00.900 5-12

5.12 Force Table Calibration

Contact Air-Vac.

ONYX29 User’s Guide Chapter 6: Maintenance

0029.00.900 6-1

6: Maintenance6: Maintenance6: Maintenance6: Maintenance 6 Maintenance .............................................................................................................................................3 6.0 PREVENTIVE MAINTENANCE SCHEDULE ....................................................................................................3 6.1 MAINTENANCE VIEW ................................................................................................................................5 6.1.1 MACHINE MAINTENANCE ..........................................................................................................................5 6.1.2 HEAD MAINTENANCE................................................................................................................................6 6.1.3 FORCE SENSOR MAINTENANCE ................................................................................................................6 6.1.4 MACHINE OPERATOR PANEL MAINTENANCE VIEW .....................................................................................7 6.1.5 VISION UNIT ............................................................................................................................................7 6.1.6 HOT GAS TOOL .......................................................................................................................................9 6.2 SOFTWARE BACKUP...............................................................................................................................10 6.3 CREATE SOFTWARE ARCHIVE ................................................................................................................12 6.3.1 BLOW-OFF AIR ADJUSTMENT...................................................................................................................13 6.3.2 VACUUM FILTER .....................................................................................................................................13 6.3.3 UPPER HEATING ELEMENT REPLACEMENT..............................................................................................14 6.4 SPARE PART LIST ..................................................................................................................................22 6.4.1 ONYX 29 SELECTIVE SOLDERING SYSTEM .............................................................................................22 6.4.2 ONYX 29 BASE IP-500 PLATFORM 300.01.010.....................................................................................23 6.4.3 X-Z AXIS 150MM ONYX 29 300.01.024 (OBC 30MM) ...........................................................................30 6.4.4 X-Z-AXIS 230MM ONYX 29 300.01.026 (OBC 70MM) ...........................................................................32 6.4.5 MANUALMOTION 300.00.394 .................................................................................................................34 6.4.6 THERMO COUPLE MODULE WITH 4 PORTS 300.01.040.............................................................................35 6.4.7 THERMO COUPLE MODULE WITH 8 PORTS 300.01.058.............................................................................35 6.4.8 FIELD ILLUMINATION 300.00.397 ............................................................................................................36 6.4.9 FIELD ILLUMINATION LAMP 300.00.438 ...................................................................................................36 6.4.10 ADVANCED SOLDER HEAD ONYX 29 300.01.007 ...............................................................................37 6.4.11 VISION SYSTEM WITH MFOV 300.01.050...........................................................................................45 6.4.12 BOARD HOLDER 500 MM 300.00.483 .................................................................................................51 6.4.13 PREHEATER – 5600 WATT, 19” SQUARE – 0029.06.041.....................................................................52 6.4.14 BOARD COOLING 490 MM 300.00.409 ................................................................................................55 6.4.15 DIRECT VIEW CAMERA 300.01.045.....................................................................................................56


0029.00.900 6-2


0029.00.900 6-3

6 Maintenance

6.0 Preventive Maintenance Schedule

Machine

Component

Maintenance Activity Notes Frequency

Daily Weekly Monthly

Data Backup Profiles and part types must be writ-ten to an off-machine storage media(network server, memory stick, cd,etc.)

Off-machine databack-up is the mostcritical maintenancetask. Air-Vac is notresponsible for lostdata.

X

Nozzles Clean nozzles of flux and inspect o-rings and vacuum cups

X

Site Clean Tool(option)

Install the SC nozzle and activatethe SC vacuum to verify that astrong vacuum exists. Inspect tipcollector and blue vacuum cup forwear.

Vacuum cup shouldbe replaced after 8hrs. of use

X X

Machine Frame Clean the machine frame and themachine covers

Make sure there are no flux- or dis-pense media spoiled on the ma-chine

Dry lint-free cloth, incase of flux, use fluxremover

X

Vision Unit Clean the protective cover glass onthe lower and on the upper side ofthe vision unit

Kimwipes® DenaturedAlcohol

X

Pneumatic Unit Drain the air regulator filters of anywater or oil (verify the air pressure is0.55 mba)

X

Vacuum Filter Replace vacuum filter if vacuum isinsufficient to hold component.

See instructions inMaintenance Section

X

X-Y Axes Encoder Clean the linear glass or steel scaleencoder carefully

See instructions inMaintenance Section

X

X-Y-Z Axis Bearings Clean all the linear bearing railscarefully.

Lubricate the bearing rails after-wards slightly with oil

Benzine, dry lint-freecloth

3 in 1 oil

X

Z-axis Lead Screw Clean the lead screw

Lubricate the lead screw afterwardsslightly with oil

Benzine, soft brush

3 in 1 oil

X

Computer/Machine Hard Boot 8-10 hrs per shift

Nozzle Temperature Calibration See instructions inMaintenance Section

X

Site Clean Jar Filter Change Changing filter isdependent on usage

As required


0029.00.900 6-4

6.0.1 X-Y Axes Encoder Scale Cleaning Instructions

Supplies required: Denatured Alcohol and Kimwipes® cleaning wipes.

• When cleaning the encoder scale, wet the surface with the Denatured Alcohol and allowthe alcohol to loosen the dirt (or evaporated flux solutions) before wiping.

• Using the Kimwipes®, wipe carefully side to side, not end to end. Never try to remove thedust or dirt by rubbing very hard or using any abrasive material, this will damage the en-coder scale!

WARNING

USE DENATURED ALCOHOL AND KIMWIPES® TO CAREFULLY CLEAN THE ENCODER SCALE.USE OF ANY OTHER TYPE OF CLOTH OR CLEANING SOLUTION WILL DAMAGE SCALE.

Encoder Scale Y-Axis

Encoder Scale X-Axis

Cleaning direction

side to side

Cleaning direction

side to side


0029.00.900 6-5

6.1 Maintenance View

Note

FOR ACCURATE SOFTWARE DESCRIPTIONS AND SOFTWARE HELP USE THE ON LINE ROBOHELP WITHIN THE SOFTWARE VISUAL MACHINESTM.

This section can be skipped by all Operators. It is necessary to have the access level of Maintenance or higher to have access to the Maintenance View and its functions. The Maintenance View is opened by clicking the Maintenance button on the Views tab. The Maintenance View displays a partial machine configuration in a hierarchical tree structure. Bold marked items have an active maintain function that can be opened or executed. Omitted items do not have any maintenance functionality. Maintenance allows viewing and modifying the current state of the correspond-

ing item. Each peripheral may provide maintenance functions

6.1.1 Machine Maintenance

Select a bold marked item of the hierarchical Machine Mainte-nance tree: Clicking on this button will open the selected maintenance function. Clicking on this button will refresh the tree view. The OK button closes the main calibration page.

Note

THE MAINTENANCE TREE CAN APPEAR DIFFERENTLY DEPENDING ON THE SYSTEM CONFIGURATION.

THE FOLLOWING SECTIONS SHOW THE MOST IMPORTANT MAINTENANCE PERIPHERALS AND FUNCTIONS.


0029.00.900 6-6

6.1.2 Head Maintenance

The head maintenance page displays information of the current attached tool. Selecting another tool entry in the Current mounted Tool list and clicking OK changes the tool in Visual-Machines.

WARNING

CHANGING THE CURRENT MOUNTED TOOL DOES NOT CHANGE IT PHYSICALLY. PLEASE MAKE SURE THAT THE LINKED TOOL CORRE-SPONDS TO THE MOUNTED ONE.

The status bar shows the current mounted tool/nozzle combination on the head.

Signals: The actual state of the head signals are displayed in a graphical format. The digital signal to switch the Vacuum and Blow off air is available. Clicking on the button be-low the digital signal display toggles the current state. Also the Vacuum sensor can be monitored.

6.1.3 Force Sensor Maintenance

The force sensor maintenance page displays the current load on the force sensor table. Zero Force Sensor button resets the force sensor to 0 N. The Force Threshold field can be used to check the functionality of the system. Values set in this page have no effect during program execution. As soon as the force table has reached the set Threshold force, then the Trigger signal is activated.


0029.00.900 6-7

6.1.4 Machine Operator Panel Maintenance View

Through the Maintenance View, the Operator Panel buttons can be diagnosed: Panel Buttons: Start indicates the state of the Start-Button Stop indicates the state of the Stop-Button Enable indicates the state of the Enable-Button Manual indicates the state of the Release-Button Option1 indicates the state of the Option-Button Option2 indicates the state of the Light-Button Additional Panel Signals: Option1 Allows enabling/disabling the option Option2 Allows enabling/disabling the field illumination

6.1.5 Vision Unit

The Maintenance view of the Vision unit peripheral can display live streaming video. It allows changing light unit parameters and also camera features. All signals and motion axis can be operated in this menu page. Values set in this page have no effect during program execution Show Live Video activates the live video page. Laser Pointer sets the Laser Pointer output. If activated it displays a small red dot on a mounted board. It is lo-cated in the front section of the vision cube. Move Park Position button moves the vision cube to its defined park position. If the Multiple Filed of View option is installed it may move the Vision-X and the Vision-Y axes. Move Laser Position button moves the vision cube to its position, where the laser pointer is exactly in the cen-ter location of the nozzle. This position is used for teach processes with laser pointer guidance. Move CFoV Position button moves the vision cube to its position, where the vision center image is exactly in the center location of the nozzle. At the same time the Z-axis moves the nozzle into the correct focus level. This level can temporary be influenced by entering an Object Thickness value. The Zoom slider moves the motorized Vision-Zoom axis of the vision unit. The Vision-X Axis slider moves the motorized Vision-X axis of the vision unit. The Theta Axis slider moves the Theta axis. The Center Theta Axis moves the Theta-axis to its center position.


0029.00.900 6-8

Live Video Live video is being displayed. Clicking the Grid button shows a grid in front of the live video. The number of grid lines in x- and y-direction can be changed by editing the correspond-ing text fields. Clicking on the Parameters button opens the cam-era parameter adjustment page. It allows modifying camera features, such as contrast and brightness. The Light Intensities of the linked Light Unit peripheral can be adjusted. The brightness and the contrast of the image can be directly changed. The new values are immediately transmitted to the camera so that the effect can be checked on the screen. The Show all features button is only available for users with Administrator access level or higher. Clicking on the Show all features button expands the page and shows additional parameters that can be adjusted. The parameters are depending on the camera type and driver; only the supported features are shown. Selecting a feature allows changing its value by dragging the slider below the list. Enabling the check box of a one-push feature allows changing its state. The white balance one-push feature for example, does allow executing directly a white balance operation of the camera. The white balancing effect can be seen on the live video. The Apply Camera Default button sets all features back to the last saved state. Clicking on the Save Camera Default button does save the current feature setting as the default setting. These values will be used to initialize the camera at each start of Visual-Machines. The Video Parameters button opens the driver dialog to modify directly video parameters. This page is depending on the installed camera driver and is not part of this documenta-tion.

Note

SHOW ALL FEATURES SHOW CAMERA SUPPORTED FEATURES. THE AVAILABLE VALUES AND ONE-PUSH FEATURES ARE DEPENDING ON THE INSTALLED CAMERA TYPE AND DRIVER.


0029.00.900 6-9

6.1.6 Hot Gas Tool

The Maintenance of the Hot Gas Tool displays the actual state of the current mounted nozzle.

• Choose a nozzle from the drop-down list that is mounted on the tool.

• Click the OK button to save the current setting.

Note

BY CHANGING THE NOZZLE YOU HAVE TO MAKE SURE THAT THE RIGHT NOZZLE IS PHYSICALLY CORRECTLY MOUNTED

The status bar is showing the current mounted tool / nozzle combination on the heads.

Heating Control: Current Temperature shows the actual temperature of the Hot Gas Tool. If this is bigger than the max temperature in the configuration page, the hot gas tool is not connected. Monitor Opens a new window where the heating curve is being displayed. Enable button enables/disables the heater. Temperature Set Point Sets the target temperature for the heater. Temperature Speed: Sets the speed for the heater to reach the defined set point. Hot Air Flow Control: Current Flow shows the current hot air flow Hot Flow Set Point for the tool Heater by-pass (fast cool down) Switches the valve that the heater element is by passed for rapid cool down processes. Heating Graph: The Clear button clears the graph Click on Add TC button to select a thermocouple channel that gets displayed in the heating graph


0029.00.900 6-10

6.2 Software Backup It is important to make safety copies of all the software parameters of the system and of all the programs. VISUALMACHINESTM provides a backup utility, which allows backing up configuration- and program files automatically at the launch or exit of VISUALMACHINESTM. These files are stored within a ZIP-File. If the PC is connected to a network, then it is essential that the back-up directory is re-defined to a network location which is part of a regular system back-up.

WARNING

IT IS IMPORTANT TO ALWAYS HAVE UP TO DATE SOFTWARE BACKUPS. THE CONFIGURA-TION DATABASE, THE LIBRARY- AND USER DATABASE AND THE PROGRAMS MUST BE SAVED TO BACKUP DEVICES ON A REGULAR BASIS. USE OTHER BACKUP LOCATIONS THAN THE MACHINES PC HARD DISK.

AIR-VAC IS NOT RESPONSIBLE FOR ANY LOST DATA.

The Backup utility is setup per default, that at every launch and exit of VISUALMACHINESTM all rele-vant database files are saved into a ZIP file into the default backup directory: C:\Program\VisualMachines\Backup This backup has been made on November 17, 2006.

Note

IF A SYSTEM MUST BE RE-INSTALLED, IT IS POSSIBLE TO REUSE AN AUTOMATIC CREATED BACK-UP DURING THE INSTALLATION OF VISUALMACHINES. CONSULT AIR-VAC ON HOW TO RE-INSTALL THE SOFTWARE AND THE BACKUP.

The Backup utility can be found on the Utilities bar with the appropriate access level.


0029.00.900 6-11

Use Backup Now to start immediately a backup process. Click on Show Backup Folder to open an explorer win-dow showing the content of the actual backup folder. Click OK to close the window. Files to backup: Configuration Database - The Configuration Database of the machine is backed up. Global Library Database - The library containing the patterns from the line and dot dispenser is backed up. User database - The database containing user accounts for VisualMachines is backed up. Program Files - All VisualMachines programs are backed up. It is also possible to Include all subdirecto-ries of the program directory. Backup Schedule: At Launch of VisualMachines a backup is created at every startup of VISUALMACHINES. Backup Directory: This field shows the actual path, where the ZIP-compressed files are stored. Click on … to browse the folder using the Please select folder dialog Create new folder prompts to type in a name for the new folder that will be created in the ac-tual folder


0029.00.900 6-12

6.3 Create Software Archive

Note

EACH TIME A QUESTION REGARDING THE SOFTWARE, OR REPORTING A SOFTWARE- OR PROCESS PROBLEM, PLEASE HAVE THE APPROPRIATE SOFTWARE ARCHIVE READY. THE SOFTWARE ARCHIVE CAN BE CREATED VERY EASILY, IT MERGES MULTIPLE BACK-UP FILES INTO A ZIP FILE.

The Administrator application can be opened by double clicking onto the icon on the desk top or by CTL-ALT-A. The Create Archive function is useful to create a special compressed archive file.

Note

THE COMPRESSED FILES ARE ZIP COMPATIBLE AND CAN BE RE-USED AS THE RESTORE OPTION DURING VISUALMACHINES INSTALLATION (SEE INSTALLATION). FOR FURTHER IN-FORMATION PLEASE SEE THE ONLINE HELP WITHIN THE ADMINISTRATOR APPLICATION.


0029.00.900 6-13

6.3.1 BLOW-OFF AIR ADJUSTMENT

The ONYX 29 assembly head supports vacuum and blow-off air to pick-up and place objects. The blow-off air is used to insure disengagement of the part from the nozzle. This is especially impor-tant for small, lightweight parts.

The Blow off adjustment throttle valve is located below the Solder head cover. To get access to the throttle valve, remove the two screws of the head cover.

Switch off the assembly head vacuum using the Head peripheral in the Maintenance view. Switch on the blow-off air. Adjust the manual blow-off air adjustment valve, until the blow-off air can be felt at the nozzle.

After the proper adjustments, lock the throttle valve, switch off the blow off air and install the head cover again.

6.3.2 VACUUM FILTER

The ONYX 29 assembly head vacuum uses an inline filter. The filter is located under the back cover of the head. If the process includes heavy evaporating flux, then the filter must be replaced on a regular base.


0029.00.900 6-14

6.3.3 Upper Heating Element Replacement

1.Take of the white Cover 2.Take of the Top Cover by 3.Loosening the two set Screws and take off the Plate

Top Cover

Plate Set Screw

ScrewWhite Cover


0029.00.900 6-15

4.Loosen the three Screws and slide the top Cover through the Tube 5.Take of the three Screws and lift up the Cover

Screw Top Cover

Cover Screw


0029.00.900 6-16

6.Take of the three Screws and slide the Pipe through the Tube 7.Loosen the two screws, take off the Connector and slide the Connector Bracket to the rear side

Pipe

Screw

Screw Connector Connector Bracket


0029.00.900 6-17

8.Take off the black Wiring (two), remove the Tube, unscrew the GND Screw , disconnect the Connector. 9.Loosen the Screw, one from the Top Side, and one by using the Allen Key.

Tube Black Wiring GND Screw Connector

Screw Top Side

Screw Allen Key


0029.00.900 6-18

10. Remove the old Heating Element, mount the new Heating Element back until you get to the mechanical end Limit. Note: To remount all removed parts follow the same procedure backwards.

Heating Element


0029.00.900 6-19

Temperature Calibration: 11.Mount the Cal Nozzle ,connect the Hand Hold Meter Note the Temperature 12.Go to Calibration , double click Hot Gas Tool enter the readout Value in 1.Ambient Temperature Temp. then select Get Value the Software will calculate the Value in mV, verify that the Value in 2.SpecifyTargetTemperature Temp. is 300

Cal NozzleTemperature

Hand Hold Meter

Enter and SelectDouble Click


0029.00.900 6-20

13.Go to Maintenance, Double click Hot Gas Tool enter Temperature set Point 300 Temperature speed 65 Hot Flow Set Point 60 SLM click on Enable 14.Activate Temperature Adv. The Moitor start after 300 sec. Check the read out on the Hand Hold Meter note the Value sample 280 °C

Select


0029.00.900 6-21

15.Go back to Calibration double click Hot Gas Tool enter the difference Value you get from the Hand Hold Meter Sample 280°C enter the Value in calibration Calculator 3. 5Min.300°C@60SLM Temp. Then select Computer Calibration Note: The Calibration is done exit the screen and start the Visual Machine Software

Double Click Enter and Select


0029.00.900 6-22

6.4 Spare Part List Complete spare part lists are attached in the APPENDIX A.

Note

ALL PARTS DECLARED IN SPARE PART CLASS 1, THE WEAR AND TEAR COMPONENTS, ARE NOT COVERED BY THE WARRANTY, SEE THE GENERAL DELIVERY TERMS.

Spare Part Classes

1 SPARE PARTS WHICH NEED TO BE REPLACED ON A REGULAR BASE AND WHICH NEED TO BE STORED AT THE CUSTOMER, WEAR AND TEAR PARTS

2 SPARE PARTS WHICH NEED TO BE REPLACED SELDOM

3 SPARE PARTS WHICH SHOULD NOT NEED TO BE REPLACED

6.4.1 ONYX 29 Selective soldering system Amount Unit Spare part

class Article

number Article description

1 Stk. - 300.01.010 IP-500 Platform 1 Stk. - 200.01.292 Application base plate 1 Stk. - 300.01.024 X-Z-Axis 150mm ONYX 29 (OBC 30mm) 300.01.026 X-Z-Axis 230mm ONYX 29 (OBC 70mm) 1 Stk. 2 109.02.013 ONYX 29 Air-Vac operator panel cover 1 Stk. - 300.01.057 Supply 3Ph 3x208VAC 1 Stk. - 300.00.394 Manual Motion 1 Stk. - 300.01.040 Thermocouple module with 4 ports 300.01.058 Thermocouple module with 8 ports 1 Stk. - 300.00.397 Field illumination 1 Stk. - 300.01.007 Advanced solder head 1 Stk. - 300.01.050 Vision system with MFOV 1 Stk. - 300.00.483 Board holder 508 mm 1 Stk. - 700.00.007 HexSight Acquisition Software license 1 Stk. - 700.01.000 VisualMachines Software license 1 Stk. 800.01.057 ONYX 29 (3x208VAC) – Electrical documentation


0029.00.900 6-23

6.4.2 ONYX 29 Base IP-500 Platform 300.01.010

Pos. Article number Article description 602 300.01.011 X-Y system 603 300.01.015 Base

Pos. Amount Unit Spare part

class Article


305 1 Stk. 3 109.16.091 Network cable RJ45 Cat. 5e, Length 0.5m 308 1 Stk. 3 109.16.034 Cable FireWire 6pin/6pin, Length 2m 309 1 Stk. 3 109.16.101 Network cable RJ 45 Cat. 5e, Length 2m 310 2 Stk. 3 109.16.109 System cable 3x0.75mm2, Length 2m 601 1 Stk. 3 300.00.989 IT-MAS2 with Force- and Temp. sensor


0029.00.900 6-24

300.01.011 X-Y System

Pos. Article number Article description 602 300.01.012 Side part left 603 300.01.013 Side part right 604 300.01.014 Y-Beam

Pos. Amount Unit Spare part class

Article number

Article description

601 1 Stk. 3 300.00.431 Transport safety lock


0029.00.900 6-25

300.01.012 Side part left


Article number

Article description

307 6 Stk. 3 109.11.008 Disk magnet d10x5 NdFeB 308 1 Stk. 3 109.32.022 Linear encoder scale 309 2 Stk. 2 109.51.056 Warning label strong magnetic field


0029.00.900 6-26

300.01.013 Side part right


Article number

Article description

303 7 Stk. 3 109.11.008 Disk magnet d10x5 NdFeB


0029.00.900 6-27

300.01.014 Y-Beam


Article number

Article description

316 2 Stk. 3 101.04.002 Puffer d 11mm, SJ-5303 320 7 Stk. 3 102.00.012 Linear bearing MNN 9-G1 323 3 Stk. 3 109.11.004 Disk magnet d7x3 NdFeB 326 1 Stk. 3 109.32.022 Linear encoder scale 327 2 Stk. 2 109.51.056 Warning label strong magnetic field 602 1 Stk. 3 300.01.059 Linear motor coil 603 1 Stk. 3 300.01.063 Analog linear encoder MS20.04


0029.00.900 6-28

A ( 1 : 2 )300.01.015 Base


Article number

Article description

319 4 Stk. 3 100.00.223 Fitting screw d6 / M5x8 BN13 326 1 Stk. 2 109.02.009 Emergency switch 327 1 Stk. 3 109.02.010 Contact element with 2 opener 328 1 Stk. 3 109.02.014 Motor safety switch, lockable, 16A 329 1 Stk. 3 109.02.015 One phase switch on/off black 330 4 Stk. 2 109.04.025 Force sensor 130x30x22mm 331 1 Stk. 2 109.09.007 Power Supply SP100-24 (Ua=24VDC/4.2A) 332 1 Stk. 2 109.09.010 Open Frame Netzteil NFM-20-12 333 1 Stk. 2 109.09.016 Power Supply SP320-48 (Ua=48VDC/6.7A) 336 4 Stk. 3 109.14.002 Solid - State - Relays 75 -264VAC/ 10A 343 1 Stk. 3 109.24.009 LED green, flat, chrom, 24VDC 345 2 Stk. 3 109.55.007 Miniature switch 3+1 close pos. (24VDC) 601 1 Stk. 3 300.00.011 Distribution board Operator Panel 602 1 Stk. 3 300.00.026 Operator panel complete 611 1 Stk. 3 300.00.959 MAX2-48V Controller cpl. 614 1 Stk. 3 300.01.064 Encoder cable X-axis IP-500 615 1 Stk. 3 300.01.066 Motor cable X-axis IP-500 616 1 Stk. 3 300.01.071 Fibre optic cable single length =1.05m 617 1 Stk. 3 300.01.076 Cable harness Y-axis

Pos. Sub module Article description


0029.00.900 6-29

Pos. Sub module Article description 613 300.01.039 Connector module

300.01.039 Connector module


class Article


305 3 Stk. 1 109.05.025 Fine fuse 6.3A fast blow, type SP 5 x 20 306 1 Stk. 1 109.05.026 Fine Fuse 4A fast blow, type SP 5x20 307 10 Stk. 1 109.05.036 Fine fuse 8A slow blow, SPT 5x20mm 313 1 Stk. 2 109.51.005 Warning label 25 x 25mm lightning 602 1 Stk. 3 300.00.514 Cable foot switch


0029.00.900 6-30

6.4.3 X-Z Axis 150mm ONYX 29 300.01.024 (OBC 30mm)

Pos. Article number Article description 601 300.01.023 X-Z-Axis 150mm base module (OBC 30mm)


Article number

Article description

305 2 Stk. 3 101.04.003 Parabolic buffer type KP d=20mm 602 1 Stk. 3 300.01.059 Linear motor coil 603 1 Stk. 3 300.01.063 Analog linear encoder MS20.04


0029.00.900 6-31

300.01.023 X-Z Axis 150mm base module (OBC 30mm)


Article number

Article description

318 1 Stk. 3 101.18.002 Z-axis break 86621-03H00-24V 319 1 Stk. 3 101.22.007 Ball bearing 4/10/4 320 1 Stk. 3 101.22.033 Axial bearing ZKLR 0624.2Z 321 1 Stk. 2 101.28.006 Power grip belt GT 2MR-112, 6m 322 4 Stk. 3 102.00.012 Linear bearing MNN 9-G1 326 1 Stk. 2 109.51.005 Warning label 25 x 25mm lightning 601 1 Stk. 2 300.00.038 Z-Encoder complete 602 1 Stk. 3 300.00.907 Z-Motor complete


0029.00.900 6-32

6.4.4 X-Z-Axis 230mm ONYX 29 300.01.026 (OBC 70mm)

Pos. Article number Article description 601 300.01.025 X-Z-Axis 230mm base module (OBC 70mm)


Article number

Article description

305 2 Stk. 3 101.04.003 Parabolic buffer type KP d=20mm 602 1 Stk. 3 300.01.059 Linear motor coil 603 1 Stk. 3 300.01.063 Analog linear encoder MS20.04


0029.00.900 6-33

300.01.025 X-Z-Axis 230mm base module (OBC 70mm)


Article number

Article description

318 1 Stk. 3 101.18.002 Z-axis break 86621-03H00-24V 319 1 Stk. 3 101.22.007 Ball bearing 4/10/4 320 1 Stk. 3 101.22.033 Axial bearing ZKLR 0624.2Z 321 1 Stk. 2 101.28.006 Power grip belt GT 2MR-112, 6m 322 4 Stk. 3 102.00.012 Linear bearing MNN 9-G1 326 1 Stk. 2 109.51.005 Warning label 25 x 25mm lightning 601 1 Stk. 2 300.00.038 Z-Encoder complete 602 1 Stk. 3 300.00.907 Z-Motor complete


0029.00.900 6-34

601

601

6.4.5 ManualMotion 300.00.394


Article number

Article description

301 2 Stk. 3 101.22.016 Ball bearing 6/13/5 686 2Z 601 1 Stk. 2 300.00.321 Encoder manual motion

Schrauben von Encoder verwenden

301 303 1 303 3

601

2302


0029.00.900 6-35

6.4.6 Thermo couple module with 4 ports 300.01.040

1

601

301

302

6.4.7 Thermo couple module with 8 ports 300.01.058

301

3021

601/ 602


0029.00.900 6-36

6.4.8 Field illumination 300.00.397

601 601


Article number

Article description

601 2 Stk. 3 300.00.438 Field illumination lamp

6.4.9 Field illumination lamp 300.00.438

2

303

601

1

303

301

302

304


Article number

Article description

601 1 Stk. 3 300.00.433 Illumination board field illumination


0029.00.900 6-37

6.4.10 Advanced solder head ONYX 29 300.01.007

Pos. Article number Article description 602 300.01.004 Pneumatic unit 603 300.01.018 Advanced solder head


Article number

Article description

302 1.1 m 3 106.17.001 Polyurethane - Tube d = 8mm, black 303 6 m 3 106.17.002 Polyurethane - Tube d = 6mm, black 304 1 Stk. 3 109.27.006 Amplifier 1-Q-EC DEC 24/1


0029.00.900 6-38

300.01.004 Pneumatic unit

Pos. Article number Article description 602 300.00.969 Pneumatic chassis 603 300.01.019 Pneumatikchassis Seitenteil 606 300.01.022 Site Clean System 607 300.01.029 Site clean system hose


class Article


303 1 Stk. 1 106.02.005 Air-filter nylon white 304 2 Stk. 3 106.06.001 3/2 Solenoid valve SYJ 314M-5LOU-Q 308 2 m 3 106.17.002 Polyurethane - Tube d = 6mm, black 309 0.1 m 3 106.17.006 Silicon-Tube di=6mm, da=9, transparent 604 1 Stk. 3 300.01.020 Maintenance unit air 605 1 Stk. 3 300.01.021 Maintenance unit nitrogen 608 1 Stk. 3 300.01.055 Site clean interface 610 1 Stk. 3 300.01.070 Fibre optic cable dual length= 2.85m


0029.00.900 6-39

300.00.969 Pneumatic chassis


class Article


308 1 Stk. 3 106.06.005 3/2 Solenoid valve VK 332 5 D0-M5 310 1 Stk. 3 106.12.002 Vacuum ejector 24l/min 311 1 Stk. 3 106.15.002 Pneumatic safety valve, AS1001F-04 315 1 Stk. 3 109.14.002 Solid - State - Relays 75 -264VAC/ 10A 319 2 Stk. 3 109.27.006 Amplifier 1-Q-EC DEC 24/1 602 1 Stk. 3 300.00.959 MAX2-48V Controller cpl.


0029.00.900 6-40

300.01.019 Pneumatic chassis side part


Article number

Article description

306 1 Stk. 3 106.01.003 Flow Through Muffler 307 3 Stk. 3 106.06.005 3/2 Solenoid valve VK 332 5 D0-M5 309 1 Stk. 3 106.12.006 Vacuum Pump (Venturi) 320 1 Stk. 3 106.20.009 Mass Flow Controller Vögtlin


0029.00.900 6-41

300.01.022 Site clean system


Article number

Article description

302 1 Stk. 2 106.02.003 Canister site clean system 305 1 Stk. 1 106.02.004 Filter element site clean canister

300.01.029 Site clean system hose


class Article


305 1 Stk. 1 106.17.010 High temperature tube 0.5OD x 0.25ID


0029.00.900 6-42

300.01.018 Advanced solder head ONYX 29

Pos. Article number Article description 602 300.00.464 Theta-axis drive ONYX 29 603 300.00.465 Theta-axis poti ONYX 29 604 300.01.006 Advanced solder head base


Article number

Article description

304 2 Stk. 2 101.28.007 Power grip belt GT 2MR-74 6M 307 1 Stk. 2 109.51.006 Warning label 25 x 25mm hot surface 602 1 Stk. 3 300.00.464 Theta-axis drive ONYX 29 603 1 Stk. 3 300.00.465 Theta-axis poti ONYX 29


0029.00.900 6-43

300.00.464 Theta-axis drive ONYX 29


Article number

Article description

601 1 Stk. 3 300.00.614 Gear motor Theta-axis 300.00.465 Theta-axis poti ONYX 29

301

304

1


Article number

Article description

1 1 Stk. 3 200.01.225 Pulley Z13 301 1 Stk. 3 109.12.026 Potentiometer (10-turns) PD2310 1kOhm/2W


0029.00.900 6-44

300.01.006 Advanced solder head base


Article number

Article description

310 1 Stk. 3 101.22.026 Rotational spacer 6x8x12x7 311 1 Stk. 3 101.22.027 Rotational spacer 8x10x15x7.5 312 1 Stk. 3 101.22.028 HEPCO bearing (excenter) 313 2 Stk. 3 101.22.029 HEPCO bearing 314 0.12 m 3 106.17.006 Silicon-Tube di=6mm, da=9, transparent 315 1.25 m 3 106.17.008 Silicon-Tube di=4, da=7, black 601 1 Stk. 1 300.00.140 Hot air heater complete 2000W 602 3 Stk. 3 300.00.473 Stick complete 606 1 Stk. 2 300.00.888 AC Power Supply 230/12VAC 0.5VA


0029.00.900 6-45

6.4.11 Vision system with MFOV 300.01.050

Pos. Article number Article description 601 300.00.454 Mechanical Stop X complete 603 300.00.564 Distance block vision system 605 300.01.047 Vision unit base module 606 300.01.048 Prism attachment fix 607 300.01.049 Y-carriage vision 608 300.01.072 Vision Y-guiding plate


0029.00.900 6-46


Article number

Article description

5 1 Stk. 3 200.02.490 Transport safety lock Vision Y 306 4 Stk. 3 102.00.012 Linear bearing MNN 9-G1 308 1 Stk. 3 109.04.028 Inductive sensor IWFM 18U7504/S35A 604 1 Stk. 3 300.00.819 Gear motor Vision X

300.00.454 Mechanical stop complete

301 (Kleber)

2

1

300.00.564 Distance block vision system


0029.00.900 6-47

300.01.047 Vision unit base module


class Article


3 2 Stk. 3 200.01.131 Protection glass 317 0.03 m 3 106.17.002 Polyurethane - Tube d = 6mm, black 318 1 Stk. 3 108.00.013 FireWire camera DFK 21F04 319 1 Stk. 3 108.01.004 Macro zoom objective Computar MLH-10X 320 1 Stk. 3 108.06.010 Tele converter 2x with C-mount 321 2 Stk. 3 109.08.003 Fan 40x40x10 mm, 24 VDC 322 1 Stk. 3 109.16.095 Firewire cable 6pin/6pin, Length 3m 323 1 Stk. 3 109.24.019 Laser Pointer FP-65 324 1 Stk. 2 109.51.058 Warning label 15 x 15mm laser beam 602 1 Stk. 3 300.00.457 Upper illumination board 603 1 Stk. 3 300.00.458 Lower illumination board 604 1 Stk. 3 300.00.459 Potentiometer Vision Zoom-axis 605 1 Stk. 3 300.00.460 Gear motor vision


0029.00.900 6-48

300.01.048 Prism attachment fix

3011

2

3

302


Article number

Article description

1 1 Stk. 3 200.01.123 Beam splitter prism 30mm


0029.00.900 6-49

300.01.049 Y-carriage vision


Article number

Article description

305 4 Stk. 3 102.00.012 Linear bearing MNN 9-G1


0029.00.900 6-50

300.01.072 Vision Y-Guiding plate


class Article


601 1 Stk. 3 300.00.568 Motor vision Y-axis 602 1 Stk. 3 300.00.636 Motor/Encoder Interface Card


0029.00.900 6-51

303

3056

3028

309

9

301

7

3

309

2

304

1 10

305304

307601

3075 4

306

3

301

303

2

1305 302 306

304

6.4.12 Board holder 500 mm 300.00.483

Pos. Article number Article description 601 300.00.373 Board holding clamp


class Article


15 4 Stk. 3 200.00.206 Bearing 301 4 Stk. 3 109.11.004 Disk magnet d7x3 NdFeB 302 4 Stk. 3 100.12.007 High hand screw M3x10 303 4 Stk. 3 101.27.003 Spring Nr. 9005.02.001 304 8 Stk. 3 102.02.001 Bearing Sferax 1017 B-BL GO 601 6 Stk. 3 300.00.373 Board holding clamp

300.00.373 Board holding clamp


Article number

Article description

301 1 Stk. 3 101.27.002 Spring VD-063N


0029.00.900 6-52

6.4.13 Preheater – 5600 watt, 19” square – 0029.06.041


0029.00.900 6-53


0029.00.900 6-54


0029.00.900 6-55

6.4.14 Board cooling 490 mm 300.00.409

(Board cooling to 300.00.761)


Article number

Article description

306 1 m 3 106.17.002 Polyurethane - Tube d = 6mm, black


0029.00.900 6-56

6.4.15 Direct view camera 300.01.045


Article number

Article description

302 1 Stk. 3 108.00.013 FireWire camera DFK 21F04 303 1 Stk. 3 108.01.004 Macro Zoom Objective Computar MLH-10X 304 1 Stk. 3 109.16.095 Firewire cable 6pin/6pin, Length 3m

* 1 Stk. 3 108.06.010 Tele converter 2x with C-mount 601 1 Stk. 3 300.01.384 Ring light direct view camera 602 1 Stk. 3 300.01.387 Cable illumination direct view camera

* Optional

ONYX29 User’s Guide Chapter 7: General Specifications & Options

0029.00.900 7-1

7: General Specifications & Options7: General Specifications & Options7: General Specifications & Options7: General Specifications & Options 7 ONYX 29 Specifications, Overview and Options ..................................................................................3 7.1 GENERAL SPECIFICATIONS.......................................................................................................................3 7.2 OPTIONS .................................................................................................................................................4 7.2.1 70MM (2.75”) TOP SIDE CLEARANCE........................................................................................................4 7.2.2 SITE CLEANING SYSTEM ..........................................................................................................................4 7.2.3 IR SENSOR..............................................................................................................................................5 7.2.4 BOARD COOLING SYSTEM ........................................................................................................................5 7.2.5 UNIVERSAL INSERTION TOOL....................................................................................................................5 7.2.6 AUTOMATIC COMPONENT SHUTTLE...........................................................................................................6 7.2.7 PASTE-ON-DEVICE MICRO STENCIL ADAPTER ..........................................................................................6 7.2.8 FLUX DIP PEDESTALS ..............................................................................................................................7 7.2.9 DIRECT VIEW CAMERA & MOUNT ASSEMBLY ............................................................................................7 7.2.10 DISPENSING SYSTEM...........................................................................................................................8 7.2.11 FOUR (4) ADDITIONAL THERMOCOUPLE PORTS.....................................................................................8 7.2.12 FUME EXTRACTION MANIFOLD..............................................................................................................9 7.2.13 ERGONOMIC WORKSTATION.................................................................................................................9


0029.00.900 7-2


0029.00.900 7-3

7 ONYX 29 Specifications, Overview and Options

7.1 General Specifications Dimensions and Weight Width 32” (823 mm) Depth 32” (821 mm) Height 38” (951 mm) Weight 120 kg (264lbs) Electrical 3-phase power U (Voltage) (3 x 240 VAC) I (Current) (16 A) S (Power) (5800 VA) F (Frequency) (60 Hz) Air source Air pressure 4 - 6 bar 100 l/min Axes acceleration X 1,5 ms-2 Limited to guarantee Y 1,5 ms-2 operator safety Z 1,5 ms-2 Axes speed X 0,15 ms-1 Limited to guarantee Y 0,15 ms-1 operator safety Z 0,15 ms-1 Working area X 15.7” (400 mm) Y 15.7” (400 mm) Z 150 mm (30 OBC mm) Optional 70 OBC mm Theta +/- 12 degree Vision-X 60 mm Vision-Y 220 mm Vision-Zoom 3 – 30 mm FOV (Field Of View) Axes resolution X 0,001 mm Y 0,001 mm Z 0,001 mm * Process Accuracy X +/– 0,009 mm +/– 3 Sigma Y +/– 0,009 mm Z +/– 0,020 mm Theta +/– 0,02 o Board dimensions Maximum size 20” x 20” (508 x 508 mm) Maximum thickness 6 mm Clearness above 30 mm optional 75 mm Clearness below 20 mm optional 30 mm Pre-heater area 19” x 19” (490 x 490 mm) Vision system Object size 0,2 x 0,2 to 70 x 70 mm Illumination Component illumination with adjustable light intensity Board illumination with adjustable light intensity Vision X/Y/Zoom Closed loop motorized Focus manual adjustable

Values based on glass flip chip placements on glass substrate, further variation of accuracies available upon machine configuration.


0029.00.900 7-4

7.2 Options

7.2.1 70mm (2.75”) Top Side Clearance

Objective • Provide increased top side clearance for assem-

blies with vertical daughter cards or tall devices that exceed the standard 30mm (1.2”) top side clearance.

Includes: • Machine frame modifications for additional

clearance. • Longer z-axis stroke to access the board.

Photo • 1.9” tall through hole device fits easily under the

Vision System. • Extended z-axis stroke enables nozzle to reach

the board to rework the BGA.

7.2.2 Site Cleaning System

Objective • Fully automated removal of residual site solder

without damaging the pads or solder mask. Eliminates the need for traditional solder iron/solder wick process and associated issues (ie. manual intervention, mechanical contact of pads).

How It Works: • The site cleaning tool pattern is automatically

generated based on the part dimension. • Hot gas reflows the residual solder on the pads. • A vacuum sensor continuously adjusts the height

of the composite vacuum tip to provide non-contact site cleaning.

Notes Of Interest: • Non-contact site cleaning will become critical for lead-free rework due to the significantly

higher temperature required to reflow the residual site solder. • Small, medium and large composite vacuum tips provided. • Micro tips and collectors also available.

Photos: • Various size composite tips. • (Inset) Site cleaning system in process.

Heat Vacuum


0029.00.900 7-5

7.2.3 IR Sensor

Objective • Provides process repeatability by insuring that

the board is at the exact same target tempera-tures each time before localized reflow begins.

How It Works: • Operator is instructed to position the sensor

head at the beginning of the process. • The non-contact temperature sensor monitors

topside board temperature and automatically triggers the localized reflow process once the target temperature is reached.

Photo • Non-contact IR Sensor with pivoting head and laser pointer.

7.2.4 Board Cooling System

Objective • Provides controlled cool down of both the device

and assembly to effectively manage time-over-reflow and to facilitate handling of the assembly after rework.

How It Works: • High laminar flow of cool air is directed between

the bottom heater and the assembly, providing rapid cooling.

• Programmable control allows the cooling air to be turned on/off whenever desired.

Notes Of Interest: • The cooling rate of the solder joint after reflow is critical. The faster the cooling rate, the

smaller the solder grain size and the higher the fatigue resistance. Photos:

• Illustration of laminar flow of cool air passing between the bottom of the board and top of preheater.

• Software controlled cool down.

7.2.5 Universal Insertion Tool

Mechanically self-centers any square device for accurate pick up. Used in conjunction with component shuttle. Photo:

• Mechanically centered 35mm SBGA. • (Inset) 6mm Flip Chip.

Cool Air Flow


0029.00.900 7-6

7.2.6 Automatic Component Shuttle

Objectives: • Provides a safe, repeatable location for compo-

nent pick up, flux dipping and drop off away from the heated work area.

• Eliminates manual component loading and re-moval in the heated work area.

How It Works: • Software-controlled pneumatic shuttle enters the

work area for pick up, flux dipping or drop off then exits the work area.

• Shuttle-based component pick up and flux dip-ping is force controlled.

Notes Of Interest: • Multi-location pick and flux dipping capability for

multi-processing of small devices (custom tool-ing required).

Photos: • Home position away from work area. • Work position for force-controlled component

pick-up.

7.2.7 Paste-On-Device Micro Stencil Adapter

Component-specific micro stencil applies solder paste di-rectly to the component spheres. Pasted device in stencil is placed in micro stencil adapter, which is used in conjunction with the component shuttle to pick the pasted device. Notes Of Interest:

• Air-Vac does not supply the component-specific micro stencils. Recommended supplier is Mini Micro Stencil (760-591-3804).

Photos: • MLF68 with center ground pad in micro stencil (solder paste applied to device). • Micro stencil installed into adapter for direct pick from shuttle.


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7.2.8 Flux Dip Pedestals

Stainless steel fluxing pedestals with precision-machined depth provides controlled application of tacky flux directly to the solder spheres on the device. Used in conjunction with the component shuttle. Notes Of Interest:

• Various sizes and depths available. Recom-mended depth is 50% of ball height.

Photo • PBGA196 imprint on flux pedestal in component

shuttle.

7.2.9 Direct View Camera & Mount Assembly

Objective • Provides high magnification

site viewing including the abil-ity to verify component reflow has occurred.

How It Works: • Operator is instructed to posi-

tion the DV camera on the site. Focus, zoom and lighting adjustments are made to op-timize clarity.

• The site image is integrated with the software and dis-played on the PC monitor.

Notes Of Interest: • The DV camera is a valuable

process development aid especially for difficult to see tiny devices. • The DV camera is also recommended for use in conjunction with the dispensing option

to provide dispense inspection capability. Photos:

• Camera/mount assembly. • Close-up view of BGA spheres.


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7.2.10 Dispensing System

• Provides on-machine dispensing of flux, solder paste, adhesive, epoxy or underfill.

• Proprietary time/pressure dispenser features automatic pressure compensation and pro-grammable vacuum adjustment for accurate and repeatable results.

• Uses precision DL Technology dispense nee-dles.

• Automatic pattern generation software makes creating dispensing patterns a snap.

Notes Of Interest: • Dispensing requires ambient machine/assembly

temperature. Nozzle cool air injection and the board cooling system can be simultaneously ac-tivated to prepare the machine and assembly for dispensing, however this is not practical from a time standpoint for each individual rework proc-ess.

• The on-machine dispense option is typically used in either a batch mode or for low volume, specialty applications.

7.2.11 Four (4) Additional Thermocouple Ports

Objective • Four (4) additional TC channels (total of 8) provides ad-

ditional monitoring capability for advanced process de-velopment applications. The ONYX29 includes four (4) TC channels.


0029.00.900

7.2.12 Fume Extraction Manifold

Objective • Removes flux vapors from the work environment

for operator health and safety. Includes:

• Fume extraction manifold and hose assembly. Notes Of Interest:

• Requires connection to a central exhaust or self-contained filtering system.

7.2.13 Ergonomic Workstation

Objective • Provides a self-contained work cell environment for the machine and operat

Features: • 60”W x 36”D ultra-sturdy construction with anti-static laminate surface and C• Available accessories include lockable storage drawer, nozzle rack, monit

keyboard tray. All are designed for ergonomic operation.

ExhaustManifold

7-9

or.

PU holder. or stand and


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ONYX29 User’s Guide Chapter 8: Program Execution

0029.00.900 8-1

8888: Program Execution: Program Execution: Program Execution: Program Execution 8 Program Execution ..................................................................................................................................3 8.0 EXECUTION VIEW, MAIN EXECUTION.........................................................................................................3 8.0.1 PROGRAM HEADER ..................................................................................................................................3 8.0.2 PROGRAM ERROR CONTROL: ...................................................................................................................5 8.1 EXECUTION MONITOR ..............................................................................................................................5 8.2 PROGRAM STATUS...................................................................................................................................6 8.3 DIRECT SIGNAL MANIPULATION .................................................................................................................6 8.4 MACHINE OPERATOR PANEL ....................................................................................................................6


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0029.00.900 8-3

8 Program Execution

Note

FOR ACCURATE SOFTWARE DESCRIPTIONS AND SOFTWARE HELP USE THE ON LINE ROBOHELP WITHIN THE SOFTWARE VISUAL MACHINESTM.

8.0 Execution View, Main Execution After starting VISUAL MACHINESTM, the Execution View is opened automatically. Otherwise the Execution View is opened by clicking the Execution button on the Views tab. The Execution View allows opening and executing existing programs.

All access levels allow the access to the Execution View and its functions. A program must be loaded and selected for execution. There can only 1 program be selected for execution. The exception is when executing calibration sequences, then the selected program is temporarily removed. At the end of the calibration it is automatically selected again. The Main Execution provides the functionalities to load, to start and to stop programs. When there are program er-rors during the program execution an error message is displayed in the Program Error Control section, so that the user can interact with the program execution.

8.0.1 Program Header

The header shows the name and the description of the selected program. If no program is selected, it will display "No Program…"

Clicking on this Quick Select button will open a sub-menu with all loaded programs. Selecting a program from the pull-down list will directly assign it to the execution so that it can be started.

Clicking on this Select or open program button will open the "Select and Open Program" window. It is possible to browse for finding the correct programs in various direc-tories and then to select programs.


0029.00.900 8-4

Clicking on this Close the current program for Execution button will unload the current se-lected program.

Clicking on this Copy the current selected program button will copy the selected program. It will let the user give a new internal name and description. The program does get directly selected in the execution. The Options button opens a pull-down menu where you can enable/disable some display options like the Monitor or the Program Status window (see below). Cycle field defines the number of repetitions of the program before the program execution is fin-ished. The left field shows the current execution status. Dry Run Enable/Disable mode allows operating the system without using any heat. Training Enable/Disable mode allows training pre-defined process parameters.

Note

TRAINING MODE ALLOWS SETTING PROCESS PARAMETERS IN REAL ENVIRONMENT DUR-ING THE PROGRAM EXECUTION, FOR EXAMPLE TEACHING POSITIONS, SETTING DIMEN-SIONS OR SETTING LIGHT PARAMETERS. TRAINING MODE FUNCTIONALITY DEPENDS ON EACH PROCESS AND MAY APPEAR DIFFERENT DEPENDING ON THE SYSTEM CONFIGURA-TION.

ONLY QUALIFIED PERSONNEL WITH THE LABEL “TECHNICAL OPERATOR” OR HIGHER HAS ACCESS TO THE TRAINING MODE THROUGH THE “DIRECT ACCESS FEATURE”.

Inspection Enable/Disable mode allows executing View processes in the program. If this option is disabled, the View processes are not executed. When using interactive soldering processes, the executed profile will be shown at the end of the process sequence when enabled. Speed sets the velocity in percent for the robot axes. Click the Start button to run the currently selected program Click the Pause button to pause the currently running program


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8.0.2 Program Error Control:

The Program Error Control gets always enabled when there is an error occurring during the program execution. The user can make decisions how to continue by clicking the following buttons: Resume button will go on with the next process in the loaded program Retry button will retry a procedure within the process Skip button will skip a procedure within the process or even the whole process by continuing with the next one Stop button immediately aborts the current running program Process Properties button is active when process proper-ties are available

Note

THE MEANING OF THE ERROR CONTROL BUT-TONS IS DIFFERENT FROM ERROR TO ERROR. THE TEXT BESIDES EACH BUTTON WILL DE-SCRIBE ITS EFFECT ON THE PROGRAM/PROCESS EXECUTION

8.1 Execution Monitor The Monitor window can be enabled under the pull down Options, see section above. Tempera-ture curves of peripherals are being displayed during program execution:

Using the Menu button opens a new submenu: Clear Monitor will clear all curves on the monitor. Hide Monitor will hide the monitor. Click on the Monitor button in Program Control strip to show it again. Display Legend will show a legend below the graph. Display Last Values will show the last values of the monitor lines below the graph. Zoom all option allows zooming the whole history of the captured values. Export… will open an export dialog that allows saving the graph to a file or to clipboard in different image formats. Export to File… will open a dialog to save the graph by values to a *.csv file that can be imported in Microsoft Excel. Below the standard entries you can see a list of all peripherals that are supporting the monitoring function. By clicking on a peripheral name, you can select an entry to add its curve to the graph.


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8.2 Program Status The Program Status window is open automatically as soon as the execution of a program is started. It shows the position of the execution in the currently running program. Icons in the tree have the following meaning:

Process has still to be done

Currently running process

Process has done successfully

Process was having an error

8.3 Direct signal manipulation Below the program error control menu, depending on the system configuration, digital output signals are listed which may be selectable during a paused execution.

8.4 Machine Operator Panel

START Starting a program for execution. This button has the same function as the START

BUTTON in the EXECUTION VIEW and of the foot switch (optional). A program can be executed only when it is loaded and selected. The program name must appear in the header of the EXECUTION VIEW, when it is properly selected. For program exe-cution the Emergency-stop button must be released and the power to the axes must be enabled.

If a program is paused it is possible to re-start the program by selecting the START BUTTON.

STOP Stops, pauses the program at the next program step. This button has the same

function as the PAUSE BUTTON in the EXECUTION VIEW. If the program is already paused, activating the STOP BUTTON again, stops the pro-

gram from execution, the program can not be continued it needs to be restarted.


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ENABLE The ENABLE BUTTON is used to enable the axes power after the E-stop has been released. When the axes power is enabled, the axes can not be moved manually. Once the power is enabled, the power can be disabled using this button again.

MANUAL Once the power is enabled, the MANUAL BUTTON switches the control of an axis to

the Manual Motion Mode (ManualMotion)…. Turning the ManualMotion wheels on the operator panel moves the selected axis. This can be used especially to teach points on an axis. The selected axis can be moved manually this way.

ManualMotion start level All axes are enabled

ManualMotion first level Left wheel = X-axis (coarse or fine) Right wheel = Y-axis (coarse or fine) ManualMotion second level Left wheel = Z-axis (coarse or fine) Right wheel = No axis assigned

ManualMotion third level Left wheel = X-axis (fine or coarse) Right wheel = Y-axis (fine or coarse) ManualMotion fourth level Left wheel = Z-axis (fine or coarse) Right wheel = No axis assigned ManualMotion fifth level Starts again at first level… To disable the ManualMotion mode, select the Enable button which enables all

axes and deactivates the manual motion mode. During the vision alignment process, these wheels are used to match the compo-nent to the board.

OPTION The option button has no factory defined function. It can be used for any function

within the process sequences. LIGHT The light button is used to switch on and off the Field Illumination. THETA Using these buttons allows rotating the Theta axis for alignment of

the part on the nozzle.


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ONYX29 User’s Guide Chapter 9: Electrical Modules and Schematics

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9999: Electrical Modules/Schematics: Electrical Modules/Schematics: Electrical Modules/Schematics: Electrical Modules/Schematics 9 Electrical Modules & Schematics...........................................................................................................3 9.0 ELECTRICAL MODULES AND LOCATIONS.....................................................................................................3 9.0.1 IT-MAS MODULE OF THE ONYX 29 LEFT COLUMN .....................................................................................4 9.0.2 ELECTRICAL MODULES OF THE ONYX 29 ADVANCED SOLDER HEAD...........................................................5 9.1 DISTRIBUTED CONTROL SYSTEM ...............................................................................................................5 9.1.1 MAX2 CONTROLLER ................................................................................................................................6 9.1.2 IT-MAS2 MASTER CONTROLLER ..............................................................................................................7 9.2 CONTROL SYSTEM INTERFACE TABLE (I/O LIST).........................................................................................7 9.2.1 I/O TABLE ONYX 29 BASE MODULE .........................................................................................................8 9.2.2 I/O TABLE ONYX 29 HEAD MODULE .........................................................................................................9 9.2.3 GENERAL PURPOSE CONTROLLERS.........................................................................................................10 9.3 FUSES OF THE ONYX 29 .......................................................................................................................11 9.3.1 FUSES ON THE BACK PANEL....................................................................................................................11 9.4 ELECTRICAL SCHEMATICS ......................................................................................................................12


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0029.00.900

9 Electrical Modules & Schematics All the machine peripherals in general are operated at low voltages (below 60VDC). All motors in the system are powered with 48 VDC. All digital signals are operated at 24VDC, and all analog signals are operated at 0-10 VDC. To remove the base plate, disconnect the pre-heater and the board cooling hose, remove the cover screws in each corner and remove the screws located be-low. Then the base plate can be removed carefully.

9.0 Electrical modules and locations The power input, fuses and DC-power generation is located below the base plate. All fuses are accessible from the back, without removing the base plate.

Ident Description Page Column

A Q41 Main Power on/off 4 1 B G43 Power supply 24 VDC 4 3 C G44 Power supply 48 VDC 4 4 D G45 Power supply 12 VDC 4 5 E N146 Motor controller for Theta 14 6 F B84 4 force sensors 8 4-8 G X101 MAX-2 Base module 10 1

BC

E

A

F F

G

9-3

Description Main 3-phase power switch Generates 24VDC power for all I/O’s Generates 48VDC power for all motors Generates 12VDC direct view camera General Purpose controller Theta axis Force sensors of force sensor table X/Y, Manual Motion and general I/O

F

D

F


0029.00.900 9-4

9.0.1 IT-Mas module of the ONYX 29 left column

The IT-MAS2 Master module is responsible as the computing bridge between the “Ethernet world” PC and the distributed system controllers. On the IT-MAS2 Master module all the system synchro-nization tasks are being performed, such as coordinated motion of two axes. The IT-MAS2 Master can be connected over RS232, or as in this application using Ethernet. The IT-MAS2 Master then communicates over fiber optic with the other distributed MAX2 control modules. When replacing the IT-MAS2 Master module, make sure the corresponding IP-address is being downloaded (de-fault IP-Address = 192.168.1.100)

Ident Description Page Column Description A V317 Power LED 31 7 Indicates the power state of the system B N81 IT-Mas2 8 1 Communication bridge IT-MAS2 B1 Four thermocouple inputs 8 1-4 Thermo couples from front panel B2 Four force sensor inputs 8 4 Force sensor amplifier B3 Ethernet connection to PC 8 2 Communication to PC B4 RS232 connection to PC 8 3 Only for programming (not connected) B5 Fiber optic ring input /output 8 4 Info-link bus to distributed controllers

B

B1

B2

B3 B4

B5

A


0029.00.900 9-5

9.0.2 Electrical modules of the ONYX 29 advanced solder head

Inside the Advanced- or Economy solder head, there is another MAX2 controller module with the corresponding distribution card located. All head motors and all head I/O signals are supported up in the head:

Ident Description Page Column Description N101 Head module controller 10 1 Head motion and head I/O controller X101 Head module distribution 10 1 Head motion and head I/O distribution

9.1 Distributed control system The ONYX 29 uses a distributed control system. A single module contains amplifiers to drive two servo motors and includes all the needed analog and digital I/O channels. Because of the high density of its electronics, one control module replaces a conventional VME or industrial computer chassis. Also because of their small size and mass, they can be placed on moving axes, for ex-ample inside the Solder head, and in small spaces near the actual sensor and motors that are used throughout the system.


0029.00.900 9-6

Ethernet

MAX2 Head

PC

IT-MAS2

External Network

Info-Link

FireWire

CameraVision unit

FireWire

Optional Direct view

camera

MAX2 Base

Function Location Controller Address IP-Address Master Controller Left column IT-MAS2 0x00 192.168.1.251 Slave Controller #1 Head INFO-MAX2 0x10 - Slave Controller #2 Base INFO-MAX2 0x20 - PC 192.168.1.100

Subnet Mask: 255.255.255.0

9.1.1 MAX2 controller

The MAX2 controllers are used to control the motion axes, the digital- and analog signals used in the system.

MAX2 Module 2 DC- or 3-phase motors (200 Watt) 2 PWM signals (2.5A) 2 Encoder input signals 16 Digital output signals (24V, 2A) 16 Digital input signals (24V) 4 Analog output signals (16 Bit) 14 Analog input signals (16 Bit)


0029.00.900 9-7

When replacing a MAX2 controller module, make sure the address switch in the front of the new MAX2 is set identically as on the

replaced module and all jumper positions must be set the same. Additionally the configuration soft-ware of that particular controller must be down loaded to the controller. The MAX2 controller can communicate with a PC directly over RS 232. Within the ONYX 29, the MAX2 controllers communicate over the fiber op-tic cable Info Link with the IT-MAS2 (Master con-troller).

9.1.2 IT-MAS2 Master controller

The IT-MAS2 Master module is responsible as the computing bridge between the “Ethernet world” PC and the distributed system controllers. On the IT-MAS2 Master module all the system synchro-nisation tasks are being performed, such as coordinated motion of two axes. The IT-MAS2 Master can be connected over RS232, or as in this application using Ethernet. The IT-MAS2 Master then communicates over optic fibre with the other distributed MAX2 control modules. When replacing the IT-MAS2 Master module, make sure the corresponding IP-address is being down loaded cor-rectly (default IP-Address = 192.168.1.100)

IT-MAS2 Master controller module Master computer for the entire system with communication bridge PC machine (Ethernet) to distributed controllers Info-link (fibre optic ring). Included is the force sensor amplifier which is link directly with the motion hardware. 4 Thermocouple channels 4 Force sensor input channels

9.2 Control system interface table (I/O list)

Note

FOR A SYSTEM SPECIFIC I/O LIST, USE THE DOCUMENTS BELONGING TO THE EQUIPMENT

ALL LABELS ARE DEFINED WITH PAGE AND COLUMN NUMBER OF THE SCHEMATICS. FOR EXAMPLE M168 REPRESENTS A MOTOR WHICH CAN BE FOUND ON PAGE 16, COLUMN 8.


0029.00.900 9-8

9.2.1 I/O table ONYX 29 Base module Signal Motor Pin RemarksMotor 1 X-Axis motor X25Motor 2 Y-Axis motor X26

PWM (High Current)PWM 1 X27PWM 2 X28

Analog InputsAI 01 Site clean vacuum sensor internalAI 02 Mass flow air valve input X19/1AI 03 Pyrometer temperature sensor (Option) X19/3AI 04 Theta-axis potentiometer X20/9AI 05 Thermoresistor Pre-heater 1 (PT100) X20/11AI 06 Thermoresistor Pre-heater 3 (PT100) X21/19AI 07 Thermoresistor Pre-heater 4 (PT100) X21/25AI 08 Thermoresistor Pre-heater 2 (PT100) X22/17AI 09 X11AI 10 Thermocouple Channel 5 X12AI 11 Thermocouple Channel 6 X13AI 12 Thermocouple Channel 7 X14AI 13 Thermocouple Channel 8 X15AI 14 Thermocouple offset measurement internal

Analog OutputsAO 01 Mass flow air valve output X17/1AO 02 Theta-Axis speed X17/6AO 03 X18/11AO 04 X18/16

Encoder InputsX-Axis encoder X7Y-Axis encoder X8Handw heel lef t X5Handw heel right X6Digital Inputs

DI 01 Start push button & Foot sw itch X34/1 Base_DI_FootSwitchDI 02 Stop/Abort push button X34/2 Base_DI_StopButtonDI 03 Enable/Release axes push button X34/5 Base_DI_ReleaseButtonDI 04 Manual push button X34/6 Base_DI_ManualButtonDI 05 Option push button X35/9 Base_DI_OptionButtonDI 06 Light/Field illumination push button X35/10DI 07 Theta-Axis movement cw push button X35/13DI 08 Theta-Axis movement ccw push button X35/14DI 09 Manual loader base position X36/17DI 10 Manual loader w ork position X36/18DI 11 X36/21DI 12 X36/22DI 13 X37/25DI 14 X37/26DI 15 AC pow er synchronization (heaters) X37/29DI 16 Internal enable signal (E-Stop) X37/30 Internal (from X1/5)

Digital OutputsDO 01 Site clean vacuum valve X30/1 PNPDO 02 Nitrogen sw itch valve X30/3 PNPDO 03 Board cooling valve X30/5 PNPDO 04 Out light, external camera X30/7 PNPDO 05 Out dispenser, external dispenser contr. X31/9 PNPDO 06 Pre-heater 1 (SSR relay) X31/11 PNPDO 07 Pre-heater 2 (SSR relay) X31/13 PNPDO 08 Pre-heater 3 (SSR relay) X31/15 PNPDO 09 Pre-heater 4 (SSR relay) X32/17 PNPDO 10 Manual loader valve X32/19 PNPDO 11 X32/21 PNPDO 12 X32/23 PNPDO 13 X23/4,5 NPN

DO 14 Theta-axis disable/brake X24/4,5 NPN

DO 15 X23/3 NPN

DO 16 Theta-axis direction X24/3 NPN

XY

Base_AO_04

Base_AI_PreHeater1TempBase_AI_Preheater3Temp

Head_AI_PT100_onBoard

Base_AI_SiteCleanVacuumBase_AI_MassFlowBase_AI_PyrometerBase_AI_ThetaPos

Base_DI_FieldIllumination

Base_DI_ThetaJogCCWBase_DI_MLBasePosBase_DI_MLWorkPos

Base_DI_ThetaJog CW

Base_DI_14Base_DI_PowerSyncBase_DI_EStop

Base_DI_11Base_DI_12

Base_DO_SiteCleanVacuumSwitch

Base_AI_PreHeater4TempBase_AI_Preheater2TempBase_AI_9Base_AI_THC_5Base_AI_THC_6Base_AI_THC_7Base_AI_THC_8

Base_DI_13

Base_DO_PreHeater1Base_DO_PreHeater2

Base_DO_Dispenser

Base_DO_NitrogenSwitchBase_DO_BoardCoolingBase_DO_Light

Base_DO_ThetaDir

Base_PWM1Base_PWM2

Base_DO_11Base_DO_12Base_DO_13Base_DO_ThetaON

SW Sig Name

Base_DO_15

Base_DO_PreHeater3Base_DO_PreHeater4Base_DO_MLSwitch

Base_AO_MassFlowBase_AO_ThetaSpeedBase_AO_03


0029.00.900 9-9

9.2.2 I/O table ONYX 29 Head module Signal Motor Pin RemarksMotor 1 Z-Axis motor X25Motor 2 Vision Y-Axis motor X26

PWM (High Current)PWM 1 Object illumination X27PWM 2 Board illumination X28

Analog InputsAI 01 Nozzle vacuum sensor internalAI 02 X19/1AI 03 X19/3AI 04 Vision Zoom-Axis potentiometer X20/9AI 05 Vision X-Axis analog sensor X20/11AI 06 X21/17AI 07 X21/19AI 08 X22/25AI 09 Nozzle hot gas heater (type K) X11AI 10 X12AI 11 X13AI 12 X14AI 13 X15AI 14 Thermocouple offset measurement internal

Analog OutputsAO 01 Vision X-Axis speed X17/1AO 02 Vision Zoom-Axis speed X17/6AO 03 X18/11AO 04 X18/16

Encoder InputsZ-Axis encoder X5Vision Y-Axis encoder X10

Digital InputsDI 01 X34/1DI 02 X34/2DI 03 X34/5DI 04 X34/6DI 05 X35/9DI 06 X35/10DI 07 X35/13DI 08 X35/14DI 09 X36/17DI 10 X36/18DI 11 X36/21DI 12 X36/22DI 13 X37/25DI 14 X37/26DI 15 X37/29DI 16 Internal enable signal (E-Stop) X37/30 Internal (from X1/5)

Digital OutputsDO 01 Nozzle hot gas heater (SSR relay) X30/1 PNPDO 02 Nozzle vacuum X30/3 PNPDO 03 Nozzle blow off air X30/5 PNPDO 04 Heater element by-pass X30/7 PNPDO 05 Field illumination X31/9 PNPDO 06 Laser pointer X31/11 PNPDO 07 Z-Brake X31/13 PNPDO 08 X31/15 PNPDO 09 X32/17 PNPDO 10 X32/19 PNPDO 11 X32/21 PNPDO 12 X32/23 PNPDO 13 Vision X-Axis disable/brake X23/4,5 NPN

DO 14 Vision Zoom-Axis disable/brake X24/4,5 NPN

DO 15 Vision X-Axis direction X23/3 NPN

DO 16 Vision Zoom-Axis direction X24/3 NPN

SW Sig Name

Head_DO_VisionXDir

Head_DO_8Head_DO_9Head_DO_10

Head_AO_VisionXSpeedHead_AO_VisionZoomSpeedHead_AO_02

Head_DO_VisionZoomDir

Head_PWM_ObjectIlluminationHead_PWM_BoardIllumination

Head_DO_11Head_DO_12Head_DO_VisionXONHead_DO_VisionZoomON

Head_DO_LaserPointerHead_DO_ZBrake

Head_DO_FieldIllumination

Head_DO_NozzleVacuumHead_DO_NozzleBlowOffHead_DO_HeaterByPass

Head_DO_HotGasHeater

Head_AI_07Head_AI_08Head_HotGasTempHead_AI_10Head_AI_11Head_AI_12Head_AI_13

Head_DI_13Head_DI_14Head_DI_15Head_DI_EStop

Head_DI_12

Head_DI_10Head_DI_11

Head_DI_03Head_DI_04Head_DI_05Head_DI_06Head_DI_07Head_DI_08

Head_AI_VisionZoomPos

Head_DI_09

Head_AI_VisionXPos

Head_DI_01Head_DI_02

ZVY

Head_AO_03

Head_AI_06

AI_PT100_onBoard

Head_AI_NozzleVacuumHead_AI_02Head_AI_03


0029.00.900 9-10

9.2.3 General purpose controllers

The general purpose controllers are used for the Vision-X axis and for the Vision-Zoom axis. The Vision-X and Vision Zoom axes are located under the head cover: On both controllers, the potentiometer has to be adjusted fully open (completely to the clockwise side). The 3 jumpers on the controller boards have to be open, not set.

Jumper Pins Description SelectedJ1 1-2

2-3 When closed, then the shield is connected to chassis ground When closed, then the shield is connected to 24VRET

Yes No

J2 1-2 Analog Input AGND and 24VRET No J3

1-2 2-3

Reference voltage for the connected potentiometer: DC/DC Converter (GND) and DGND DC/DC Converter (GND) and 24VRET

Yes No

Do not move modules around system. The modules are configured for its perpendicular use and cannot be moved from the base to the x/y or to the head.


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9.3 Fuses of the ONYX 29 The 3-phase main power switch has included a 16A internal fuse per phase. If the fuse is acti-vated, the main switch is automatically switched off. After the problem has been fixed the switch can be switched on again. No fuses need to be replaced.

9.3.1 Fuses on the back panel

The fuses on the back panel are shown to the left, addi-tionally every installed pre-heater channel includes a fuse per phase.

Ident Description Fuse type Voltage Remarks F51 Power Outlet connector, phase F 6.3A 100-240VAC (50/60Hz) PC & Monitor F52 Power Outlet connector, neutral F 6.3 A 100-240VAC (50/60Hz) Phase in the US F43 Power Logic voltage F 4A +24VDC I/O logic power F45 Power Motor voltage F 6.3A +48VDC (+43VDC) Adjusted to 43 VDC F71 Hot Gas system, phase T 8A 240 VAC F72 Hot Gas system, neutral T 8A 240 VAC F62 Pre-heater 1 phase T 8A 240 VAC F62.1 Pre-heater 1 phase T 8A 240 VAC F64 Pre-heater 2 phase T 8A 240 VAC F64.1 Pre-heater 2 phase T 8A 240 VAC F65 Pre-heater 3 phase T 8A 240 VAC F65.1 Pre-heater 3 phase T 8A 240 VAC F67 Pre-heater 1 phase T 8A 240 VAC F67.1 Pre-heater 1 phase T 8A 240 VAC

Please note that the Fuse identification matches the location of the electrical schematics. For ex-ample Fuse F42 is listed on page 4 in column 2 in the electrical schematics (except F1 and F2).


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9.4 Electrical Schematics

Note:

THE ELECTRICAL SCHEMATICS ARE SUBJECT TO CHANGE AND MAY BE DIFFERENT COM-PARED WITH YOUR SYSTEM CONFIGURATION. THEREFORE MAKE SURE TO CHECK THE DETAILED ELECTRICAL SCHEMATICS PROVIDED WITH THE EQUIPMENT.

800.01.067 ONYX29 (208VAC)

ONYX29 User’s Guide Chapter 10: Pneumatic Schematics

0029.00.900 10-1

10101010: Pneumatic Schematics: Pneumatic Schematics: Pneumatic Schematics: Pneumatic Schematics

ONYX29 User’s Guide Chapter 10: Pneumatic Schematics

0029.00.900 10-2

ONYX29 User’s Guide Chapter 11: Troubleshooting

0029.00.900 11-1

11111111: Troubleshooting: Troubleshooting: Troubleshooting: Troubleshooting 11 Troubleshooting.......................................................................................................................................3 11.0 NO POWER..............................................................................................................................................3 11.1 THE EMERGENCY STOP CAN NOT BE RELEASED ........................................................................................3 11.2 NO AIR PRESSURE...................................................................................................................................3 11.3 HOT GAS HEATER CAN NOT BE ENABLED, NO HEAT IS BEING GENERATED ...................................................3 11.4 NOT ENOUGH VACUUM AT THE NOZZLE......................................................................................................3 11.5 HEIGHT DURING SITE CLEAN PROCESS IS NOT CONSTANT...........................................................................3 11.6 SITE CLEANING TOOL DOES NOT REMOVE RESIDUAL SOLDER.....................................................................4 11.7 ROBOT FAILS TO CALIBRATE/SENSOR ERROR MESSAGE .............................................................................4 11.8 NOZZLE HITS VISION CUBE........................................................................................................................4 11.9 NOZZLE DOES NOT PICK UP DEVICE IN COMPONENT SHUTTLE .....................................................................4 11.10 NOZZLE DROPS PART PRIOR TO FORCE PLACEMENT ..............................................................................5 11.11 NOZZLE DOES NOT REMOVE DEVICE AFTER REFLOW..............................................................................5


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11 Troubleshooting

11.0 No Power • Check if the main 3-phase power is switched on (on the back side of the system). • Check if the system I/O switch of the ONYX 29 is switched on. • Check all the fuses according to the Chapter 9 Fuses of the ONYX 29 • Make sure the green LED on the right side of the operator panel is turned on.

11.1 The Emergency Stop can not be released • Check if the system has power. If there is no power on the system see the previous section. • Make sure the emergency switch button on the front panel is released. • Check that none of the axes are at its mechanical limit. Move all axes slightly in the direction

center of the traveling range.

11.2 No Air Pressure • Check the facility pressure, the input pressure into the machine and into the machine sup-

port. • Check the power of the system. The system must be powered on, the machine support main

switch and the machine main switch.

11.3 Hot Gas Heater can not be enabled, no heat is being generated • Check that the E-stop is released and enough air pressure into the system

is provided (see previous sections). The safety system status should be at the state Safety system: READY.

• Check the hot gas system fuse F71 of the ONYX 29 (see Chapter 9 Fuses) • Check that a nozzle with the type HOT GAS NOZZLE is mounted. This can be seen in the

maintenance screen of the Hot gas system. • Make sure that the temperature reading makes sense otherwise the analog sensor is not

properly connected.

11.4 Not enough vacuum at the nozzle • Check the facility pressure and the input pressure into the machine, the input pressure must

be above 5.5 bar (80 PSI). • Check if the nozzle flange has a perfect seal. If this cannot be tested, mount the camera

calibration nozzle and check the vacuum with the calibration nozzle mounted.

11.5 Height during site clean process is not constant • If the site clean moves away from the board during the site clean process, check the blue

vacuum cup to be sure a proper vacuum connection has been made. • Also, check to see if the tool is clogged with solder.


0029.00.900 11-4

11.6 Site Cleaning Tool does not remove residual solder • Check to see if the site clean tool is clogged with solder or if a good vacuum connection has

been made. There should be strong vacuum at the composite tip. Lead-free solder requires higher process temperature (top and bottom heater settings) to reflow it.

11.7 Robot fails to calibrate/sensor error message • The sensor in the pneumatic shuttle (option) needs to be adjusted.

11.8 Nozzle hits vision cube • Each nozzle has a specific overall length. Check the status bar at the bottom of the screen

to see what nozzle should be in the machine. Most likely, the wrong nozzle has been in-stalled.

11.9 Nozzle does not pick up device in component shuttle • Nozzle not installed in machine properly – vacuum leak. • Insufficient vacuum – vacuum tube in nozzle damaged or blocked, new o-ring/cup required. • Component pick is force controlled. Do not touch the machine during this step.


0029.00.900 11-5

11.10 Nozzle drops part prior to force placement • Keep hands off machine during this event. • If problem continues, see force verification procedure.

11.11 Nozzle does not remove device after reflow. • Device not fully reflowed. • No or low vacuum. • Programming issue.


0029.00.900 11-6

ONYX29 User’s Guide Appendix

0029.00.900 A-1

AppendixAppendixAppendixAppendix Appendix A: Complete List of Spare Parts.....................................................................................................3 RECOMMENDED SPARE PARTS PACKAGE................................................................................................................5

Appendix B: Standard Hot Gas Flow Tables .................................................................................................7

Appendix C: Picture Guides for Re-Packaging..............................................................................................9 TRANSPORT SAFETY LOCKS FOR THE MACHINE.......................................................................................................9

Appendix D: Exporting and Importing Programs........................................................................................13

Appendix E: ONYX29 Dispenser ...................................................................................................................17 1.1 SETUP...................................................................................................................................................17 1.2 INITIAL DISPENSER TOOL CONFIGURATION..............................................................................................19 1.3 OTHER SETUP .......................................................................................................................................20 1.4 RUNNING DEMO: TARRAY 144 10MM DISPENSE PROCESS....................................................................22 1.5 CREATING A NEW PROGRAM .................................................................................................................24 1.6 NEEDLE SIZE & PASTE MESH.................................................................................................................33


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Appendix A: Complete List of Spare Parts Unit Class Article # Description Remarks Stk. 1 106.02.005 Air-filter nylon white

m 1 106.17.008 Silicon – Tube d = 7mm, black

Stk. 1 109.05.022 SMD - Fuse OMF 125, 4A fast blow

Stk. 1 109.05.025 Fine Fuse 6.3A fast blow, type SP 5 x 20

Stk. 1 109.05.026 Fine Fuse 4A fast blow, type SP 5x20

Stk. 1 109.05.036 Fine Fuse 8A slow blow, SPT 5x20mm

Stk. 1 300.00.140 Hot air heater complete 2000W

Stk. 2 106.02.004 Filter Element Canister

Stk. 2 109.02.009 Emergency switch

Stk. 2 109.02.013 ONYX 29 Air-Vac operator panel cover

Stk. 2 109.04.025 Force sensor 130x30x22mm

Stk. 2 109.04.026 DMS Force sensor amplifier

Stk. 2 109.09.003 DC/DC - Wandler 24V/5V 400mA

Stk. 2 109.09.004 DC/DC - Wandler 24V/5V, 400mA

Stk. 2 109.09.005 DC/DC - Wandler 24V/12V, 80mA

Stk. 2 109.09.006 Power Supply SP300-48 (Ua=48VDC/6.25A)

Stk. 2 109.09.007 Power Supply SP100-24 (Ua=24VDC/4.2A)

Stk. 2 109.32.001 Rotational encoder, ERN 1020, 500 Steps

Stk. 2 109.32.002 RSF Reader head linear encoder

Stk. 2 109.51.005 Warning label 25 x 25mm lightning

Stk. 2 109.51.056 Warning label 25 x 25 mm magnetic field

Stk. 2 300.00.038 Z-Encoder complete

Stk. 2 300.00.105 Board holding clamp

Stk. 2 300.00.321 Encoder manual motion

Stk. 3 100.00.223 Fitting screw d6 / M5x8 BN13

Stk. 3 100.12.007 High hand screw M3x10

Stk. 3 101.04.002 Puffer d 11mm, SJ-5303

Stk. 3 101.04.003 Parabolic buffer type KP d=20mm

Stk. 3 101.22.002 Axial Bearing

Stk. 3 101.22.007 Bearing 4/10/4

Stk. 3 101.22.016 Ball Bearing 6/13x5 686 2Z

Stk. 3 101.27.002 Spring VD-063N

Stk. 3 101.27.003 Spring Nr. 9005.02.001

Stk. 3 101.28.006 Power grip belt GT 2MR-112, 6m

Stk. 3 102.00.012 Linear bearing MNN 9-G1

Stk. 3 102.02.001 Bearing Sferax 1017 B-BL GO

Stk. 3 103.01.010 EC-Motor EC16 with transmission

Stk. 3 103.01.011 Motor EC22 with transmission and encoder

Stk. 3 103.01.013 DC-Motor RE 26 18 Watt


0029.00.900 A-4

Unit Class Article # Description Remarks Stk. 3 103.03.004 Linearmotor coil LMD 05-030

Stk. 3 106.00.001 Maintenance unit (filter/controller)

Stk. 3 106.02.003 Canister, Site Cleaning

Stk. 3 106.06.001 3/2 Way magnetic valve

Stk. 3 106.06.005 3/2 pneumatic valve

Stk. 3 106.12.002 Vacuum ejector 24l/min

Stk. 3 106.15.002 Pneumatic safety valve, AS1001F-04

m 3 106.17.001 Polyurethane - Tube d = 8mm, black



m 3 106.17.006 Silicon-Tube di=6mm, da=9, transparent

m 3 106.17.008 Silicon-Tube di=4, da=7

Stk. 3 106.20.001 Manometer, d=50mm / G 1/8 / P= 0 - 10ba

Stk. 3 106.20.009 Mass Flow Controller Vögtlin

Stk. 3 108.00.003 Camera FireView-1C IEEE-1394

Stk. 3 108.01.004 Macro Zoom Objektiv Computar MLH-10X

Stk. 3 109.02.010 Contact element with 2 opener

Stk. 3 109.02.015 One phase switch on/off black

Stk. 3 109.04.028 Inductiv sensor IWFM 18U7504/S35A

Stk. 3 109.11.004 Disk magnet d7x3 NdFeB

Stk. 3 109.14.002 Solid - State - Relays 75 -264VAC/ 10A

Stk. 3 109.14.004 PhotoMos Relais AZQ202D / 2.7A

Stk. 3 109.16.034 Cable Firewire 6pin/6pin, Length 2m

m 3 109.16.040 Encoder cable RSF

Stk. 3 109.16.064 Cable Firewire 6pin/6pin, Length 0.5m

Stk. 3 109.16.065 Cable Firewire 6pin/6pin, Length 1m

Stk. 3 109.17.003 Spring loaded contact pin (400 °C)

Stk. 3 109.20.039 Ceramic terminal block

Stk. 3 109.24.009 LED green, flat, chrom, 24VDC

Stk. 3 109.24.015 Opto coupler DEK-0E 5VDC/48VDC/100

Stk. 3 109.24.019 Laser Pointer FP-65

Stk. 3 109.24.020 Opto coupler DEK-0E 24VDC/48VDC/100

Stk. 3 109.27.006 Verstaerker 1-Q-EC DEC 24/1

Stk. 3 109.32.012 520 mm Glass scale for MS6X

Stk. 3 109.55.007 Mini switch 3+1 Closing (24VDC)

Stk. 3 109.55.008 Mini switch 3+1 Closing (230VAC)

Stk. 3 200.00.206 Bearing

Stk. 3 200.01.131 Protection glass

Stk. 3 200.01.312 Interface pipe

Stk. 3 300.00.011 Distribution board Operator Panel

Stk. 3 300.00.026 Operator panel complete


0029.00.900 A-5

Unit Class Article # Description Remarks Stk. 3 300.00.147 FireBlox-1 interface card

Stk. 3 300.00.149 Firewire interface card

Stk. 3 300.00.236 FireBlox-1 digital controller/amplifier

Stk. 3 300.00.291 Digital I/O-cable X/Y-module

Stk. 3 300.00.292 Analog I/O-cable X/Y-module

Stk. 3 300.00.303 Motor cable Y-axis IP-500

Stk. 3 300.00.304 Encoder cable Y-axis IP-500

Stk. 3 300.00.390 Encoder cable X-axis

Stk. 3 300.00.415 FireBlox-1 head interface card

Stk. 3 300.00.429 Vaccum Sensor Card

Stk. 3 300.00.432 Single 3 Phase Amplifier Card

Stk. 3 300.00.433 Illumination board filed illumination

Stk. 3 300.00.438 Field illumination lamp

Stk. 3 300.00.450 Z-Motor complete

Stk. 3 300.00.457 Upper illumination board

Stk. 3 300.00.458 Lower illumination board

Stk. 3 300.00.471 Fan vision complete

Stk. 3 300.00.473 Stick complete

Stk. 3 300.00.476 RS232 Interface cable

Stk. 3 300.00.487 Thermocouple Card (0-5V/0-10V)

Stk. 3 300.00.518 Site clean hose complete ONYX 29 Stk. = pieces / m = meter / Fl. = bottle

Recommended spare parts package Amount Unit Class Article # Description Remarks

5 Stk. 1 106.02.005 Air-filter nylon white

1 m 1 106.17.008 Silicon – Tube d = 7mm, black

5 Stk. 1 109.05.022 SMD - Fuse OMF 125, 4A fast blow

5 Stk. 1 109.05.025 Fine Fuse 6.3A fast blow, type SP 5 x 20

5 Stk. 1 109.05.026 Fine Fuse 4A fast blow, type SP 5x20

5 Stk. 1 109.05.036 Fine Fuse 8A slow blow, SPT 5x20mm

1 Stk. 1 300.00.140 Hot air heater complete 2000W


0029.00.900 A-6


0029.00.900 A-7

Appendix B: Standard Hot Gas Flow Tables

Nozzle Conversion Table – Standard DRS Nozzle Flow% LPM

Flow Rate Conversion DRS Flow % ONYX LPM

15 12 20 16 25 20 30 23 35 27 40 31 45 35 50 40 55 44 60 48 65 50 70 53 75 57 80 60 85 64 90 69 95 72 100 82 105 86

to previous Air-Vac equipment LPM – Liter per minute


0029.00.900 A-8


0029.00.900 A-9

Appendix C: Picture Guides for Re-Packaging The package material for the ONYX 29 machine and for the machine support has been designed es-pecially. The machine shall not be shipped without this proper package material.

WARNING

NEVER MOVE THE MACHINE WITHOUT PROPER PACKAGING. ALSO WHEN MOVING THE SYSTEM IN HOUSE, USE A PROPER SUPPORT WITH DAMPING. NEVER MOVE THE MACHINE DIRECTLY ON A TROLLEY.

STRONG VIBRATION, WITHOUT THE PROPER DAMPING MATERIAL BELOW THE MACHINE WILL DAMAGE THE LINEAR BEARINGS.

NEVER TRANSPORT THE SYSTEM WITH THE PRE-HEATER IN PLACE. THE PRE-HATER MUST BE REMOVED, PACKED SEPERATELY AND TRANSPORTED IN VERTICAL POSITION.

Transport safety locks for the machine 1 (Lock Vision X-axis)

2 (Lock Vision Y-axis)

3

4

WARNING

NEVER USE THE SHORT SCREWS REMOVED WITH THE Y-AXIS END PIECE, USE THE EXTRA LONG SCREWS PROVIDED WITH THE BRACKET. ATTACH THE BRACKET AS SHOWN ON THE LEFT PICTURE FIRST, AND THEN MOVE THE AXES WITH THE BRACKET CAREFULLY INTO FINAL PLACE, (THE Y-AXIS GLASS ENCODER CAN GET DAMAGED EASY)!


0029.00.900 A-10

5 (pre-heater packed separately)

6 (Machine on the pallet without pre-heater)

7 (Machine from the top) 8 (X/Y-axes bracket in place, use long screws!)

9 (Right side cushion) 10 (Machine on pallet with wooden crate)


0029.00.900 A-11

11 (With cushions in place)

12 (With left side compartment)

13 (Ship all extra material in left compartment) 14 (With left side compartment)

15 (Use plastic cover with wooden crates) 16 (Cardboard packaging)

WARNING

NEVER TRANSPORT THE SYSTEM WITH THE PRE-HEATER IN PLACE. THE PRE-HATER MUST BE REMOVED, PACKED SEPERATELY AND TRANSPORTED IN VERTICAL POSITION.


0029.00.900 A-12


0029.00.900 A-13

Appendix D: Exporting and Importing Programs Programs and part types can be transferred from one machine to another using the Export/Import func-tion.

Open a program

Click on Import and Export Program Icon.

Go To Programming

Click on Open (or double click on pro-gram.

Highlight program to copy

Click on Export selected Program.


0029.00.900 A-14

Click on Yes to “Do you want to open the export folder?”.

Highlight program(s) to copy.

Right click mouse and select copy.

Use arrow of Address bar to locate and select drive to be used to transfer program(s).

For thumb drive, right click and select paste. For CD drive, right click and select paste. Click on “Write these files to CD.” Follow directions for CD writer. Close screen.

For thumb drive, Go to “Safely Remove Hardware” at bottom right side of screen. Click on Stop. Remove thumb drive or disk when finished. Click on Close. Then Ok.


0029.00.900 A-15

Select Import Program.

Click on Import and Export Pro-gram Icon.

Go to Programming View.

Highlight program to transfer. Double click on program or click on Save.

Select folder to copy into.


0029.00.900 A-16

Select part type to copy into. Preferred Path.

Select if you wish to write over part type with same name.

Select if you wish to save with a different part type name.

Program will be imported.

Click Ok.

The program will be loaded to the Program Editor of the Program-ming View.


0029.00.900 A-17

Appendix E: ONYX29 Dispenser

1.1 Setup

Accura Dispenser –front and rear connections Accura Dispenser Pressure – Set to 100 Kpa Time Set – 000 Mode Button – In (steady state) Shot Button – Out (Off)

IMPORTANT:

BEFORE PROCEEDING WITH THE INSTALLATION OF THE DISPENSE HEAD, BE SURE THAT THE PREHEATER, BOARD, AND THE Z-AXIS HEAD HAVE BEEN COOLED DOWN TO NEAR AMBIENT TEMPERATURE.

Dispenser Front

Dispense Head


0029.00.900

Dispenser Rear:

ONYX29 Rear Pneumatic Connection: ONYX29 Rear:

To air filter To right rear of machine

To 110V

Connection from control cable (rear of Accura dispenser) to rear of ONYX29.

A-18


0029.00.900 A-19

1.2 Initial Dispenser Tool Configuration

• This will be done at AV unless the customer orders a Dispenser at a later date (call technician group to configure dispenser if this is the case).

• If you see the dispenser tool listed in the machine configuration page, the dispenser is config-ured.

Dispense Tool and 25g Needle are Configured:


0029.00.900

1.3 Other Setup Configure Force Table 1. Go to Configuration/Force Table/Table Configuration. 2. Verify that the Z motion step value has been changed from -0.001 to -0.010. This will make force

placement happen much faster.

2
1
A-20


0029.00.900

Configure Vision Image Also confirm that the Vision Unit image has been “flipped”, otherwise you will be at the opposite corner from where you need to be when you teach the four corner pads for dispensing. 3. Go to Configuration/Vision Unit 4. Go to Camera Driver/Show Video Parameters. 5. Confirm Image/Flip is checked. 6. Select OK.

Flip Vision Image

7. To confirm vision image configuration: Maintenance/Vision/Show Live Video/Parameter

Features/Video Parameters/Image Flip Box should be checked. 8. Save Camera Default

2

3

A-21

s/Show All


0029.00.9

1.4 Running Demo: TARRAY 144 10mm Dispense Process Parameters developed for 144 I/O, .8mm pitch, .45mm pad, Heraeus F365SN63-86D4 (type 4) solder paste. Purging 1. Go to Maintenance/Tools/Dispense Tools. 2. If hot gas tool is not highlighted, click on Robot Head. 3. Change current mounted tool to Dispense Tool.

2

1

00

3

A-22


0029.00.900

4. Dispense Tool and Tools will now be highlighted. Click on Dispense Tool under Tools.

Mounted Needle must be for 25 gauge. 5. Activate the pressure switch to create a paste “rope” prior to dispensing. If you cannot ge

tinuous straight rope, remove the needle and clean it. The “rope” should break only uown weight. If it does not, there could be air in the system and you must purge matuntil this condition is satisfied.

6. Open and run program for TARRAY 144 (10mm) Dispense only.

4

e

5

A-23

Current

t a con-nder its rial out


0029.00

1.5 Creating A New Program To Add Needle Sizes 1. Go to Maintenance/Robot/Head. 2. Change Current Mounted Head from Hot Gas to Dispense

Configure New Needle 1. Go to Configuration/Dispenser Tool. 2. Click on “Add New Item” to add a new needle. 3. Double click on “needle”. 4. Change the name and description to the needle size.

2

.900

2

1

1

3

4

A-24


0029.00.900

Machine Identification of New Needle 1. Go to Maintenance/Dispenser Tool. 2. Change current mounted needle to the new needle. 3. Select OK.

Calibrate New Needle. 4. Go to Calibration. 5. Under Tools, double-click on the new needle. Change the Z offset to 5.0mm. 6. Select apply, then OK.

m

2

A

(Z Oust b

(refe
2
1

ffset

rence)

4
e 5.0)
5

5

-25


0029

Add Dispense Process List to Part Type 1. Select the part type that you want to dispense (or create a new part type). 2. Add a new process list. 3. Name the new process list name “Dispense”. 4. Double click on the dispense Process List to go to Process List Editor.

2

1

4

.00.900 A-26


0029.00.900

Change to Proper Needle and Dispense Tool 1. Change tool to “Dispense” tool. 2. Change nozzle to desired needle.

Program Blocks: 3. Create the following three blocks:

• Stop Heating (Preheater) with all active sections checked. • Dot (Dispenser Tool) • View (Vision Unit)

Dot Dispenser Tool Position:

c

2
1
3
Place hecked
d

Teachchecke

A-27


0029.00.

Go to Pattern: 1. Uncheck “Automatically Optimize Pattern”. Dispense Pattern 2. Click on Dot Pattern Editor. 3. Click on Add. 4. Define Name. 5. Enter number of dots for X and Y. 6. Enter pitch for X and Y. 7. Click on Generate. 8. Click on OK.

2

1

900

1

3

4

5
6
A-28


0029.00.900

Z-Height Parameters 1. Make the following changes:

• Check “Measure Z-Height” • Select “Force Table”. • Check “First Dot”. • “Approach Height” should be 1.00mm. • “Table Force” should be .25N.

1

A-29


0029.00.900

Dispense Dot Parameters 2. Check “Use current mounted needle”. Dispense Motion Parameters

1

.

.1

1

c
.20 se
.2 mm

.

5.

.3 sec

A-30

0 mm 40% 2 sec 10% mm

5 mm


0029.0

Dispense Purging Parameters No data input required.

Programming 1. Go to Programming/Assemblies. 2. Under available Process Lists check “Dispense” and “AT”.

2

0.900 A-31


0029.00.900 A-32

NOTE

BE SURE THE MACHINE AND THE HOT GAS HEAD ARE AT AMBIENT TEMPERATURE PRIOR TO DISPENSING. USE THE BOARD COOLING SYSTEM AND COOL AIR BYPASS.

Maintenance You can put the entire Dispense Head including paste and needle in the refrigerator for storage. Attached are photos to disassemble Dispense Head for cleaning.

• Dispense Head – Disassembled for Cleaning

• Needles – Use Corresponding Gauge Cleaning Tools to Clean


0029.00.900 A-33

1.6 Needle Size & Paste Mesh The pad diameter determines the needle size. Use the largest possible needle. Must use a proper mesh paste based on needle size. Too large a mesh will not dispense through small needles.


0029.00.900 A-34

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