APR-5000 User`s Manual
Contents
1. 3 Click on No Password button and enter the APR password 94025 6 Open Calibration Screen and Click on Calibration to set reflow to table co planarity See next page The APR head will be in the home up position 22 Metcal APR5000 LL zx Security Software Airflow Profile Camera Calibration TC Termo Calibrations Closed loop options m Calibration Procedures Click Head Pa Head Alignment Alignment MEE ES 7 Carefully remove the front cover of the reflow head and hold into place using a using a tie wrap or equivalent Note the location of the side to side and to fro adjustment screws on the left side of the vacuum tube Do not loosen yet 8 Reverse mount the Gun Sight Tool onto the board holder 23 m Reverse mounted Gun Sight Tool 9 Take vacuum pipette 12 remove rubber o ring and attach the vacuum pipette to the APR Removing the o ring allows you to optimize the vacuum pick up point accuracy 10 Follow prompts past the vision calibration to when the vacuum engages 11 Next mount the Calibration Mirror on vacuum pipette and using the down action keys lower the Calibration mirror approximately 25 over the reverse mounted Gun Sight Tool 12 Using your software options reduce the lowering speed to 001 294 13 Using the down action keys lower the mirror until the mirr2. OK INTERNATIONAL Precision Systems for the Electronics Bench APH 5000 User s Manual Specifications Introduction amp General Overview System Features and Accessories Set up Software Operation Calibration Nozzles and Vacuum Tubes Spare Parts and Accessories Site Preparation Warranty amp Service www okinternational com 1 7000 1370 D TABLE OF CONTENTS PREFACE Safety and Regulatory Information APR 5000 Series Main Unit Specifications SECTION Introduction and General Overview SECTION II System Features and Accessories SECTION III Set Up Procedures SECTION IV Software Operation SECTION V Hardware Trouble Shooting Optical and Head Calibration SECTION VI Nozzles Vacuum Pick up Nozzle and Accessories SECTION VII Calibration Kit and Spare Parts SECTION VIII Site Preparation SECTION IX Warranty and Service PREFACE SAFETY AND REGULATORY INFORMATION WARNING TO PREVENT FIRE OR SHOCK HAZARD DO NOT EXPOSE SYSTEM TO MOISTURE TO PREVENT FIRE OR SHOCK HAZARD DO NOT USE FLAMMABLE SOLVENTS NEAR OR ON THE SYSTEM WHILE CONNECTED TO POWER SOURCE TO PREVENT POSSIBILITY OF INJURY OR DAMAGE TO THE SYSTEM DO NOT OPERATE WITH ANY COVERS OR PANELS REMOVED CHANGES OR MODIFICATIONS MADE TO THIS PRODUCT WITHOUT EXPRESS APPROVAL FROM OK INTERNATIONAL COULD VOID THE USERS AUTHORITY TO OPERATE THE EQUIPMENT A caution e Read and understand the entire Operator s Manual before ins
3. Physically press the head X and Y axis switches on the APR 5000 heater head Check mark must turn on momentarily Physically pull camera out Check mark toggles from Camera Home switch to Camera EOT switch Notes Security Software Calibration Airflow Profile Camera TC Temperature Calibrations Closed loop options Test LI m Digital Input Rewlow Head UP Action Buttons A 0 00 B Down Action Buttons TH stem IV Next Button IV Head Home switch Head EOT switch IV Head Safety Switch Solenoid Lock switch Camera Home switch Camera EOT switch Overheat 110 220 Analog Input CJ 32 09 TCI 31194 02 TC2 31134 02 TC3 31194 02 PRTD 86 69 HRTD 148 26 SRTD 101 78 Vacc o0 N20ff Heater C N2L Bypass C N2M C N2H Temp 0 00 uu m Preheater Airflow 0 00 a Temp 0 00 eL m Pipe Cup Off Off C Up C Vac C Down C Blow C Free r Camera Power LUp LDn oc Cancel Apply Os 100s 200s 19 Metcal APR 5090 i 2x an Security Software Calibration Airflow Profile Camera check for vacuum TC Temperature Calibrations Closed loop options Test pressure at the pipette If Digital Input Rewlow Head h im i ei UP Action Buttons the vacu pressure 1s When off there is no ai
4. Option C Operator Engineer Password Enter Confirm Type in 94025 Station ID Cancel Apply 4 Click on the Test tab 5 This test window must be exited as shown below to avoid any process run issues 2175 Press Action Buttons M al APR5000 as noted Check mark a 2x identifies if buttons Security Software Calibration Airflow Profile Camera are working properly IE Temperature Calibrations Closed loop options Test Digital Input Inputs are not to UP Action Buttons Press Next Button as Down ction Buttons be altered or noted Check mark v Next Button 7 N2Df Heater tested i 30 V Head Home switch C identifies if button is Head EOT switch N2L Bypass v Head Safety Switch Solenoid Lock switch IV Camera Home switch Camera EOT switch Overheat 110 220 working properly Head Home switch check mark must be Analog Input C 32 09 checked yA 3119402 Cup Inputs are not to TE2 313402 Off Off Ee C Up C Vac be altered or TC3 31134 02 s Down Blow tested PRTD 8663 a Camera Power LE tt a i HRTD 148 26 SRTD 101 78 Yacc 0 10 Physically lift head up Head Switch must go off when head is lifted Cancel Apply Os 100s 200s Notes 18
5. COMP F APR DK1 APR FM FL APR 2 FLL APR 2 FLS APR 2 FLSL APR 2 FLSS APR 2 FS APR 2 FSL APR 2 FSS APR 2 PF 1 PICK APR TF 1 APR Reflow Nozzle 6mm x 6mm APR Reflow Nozzle 8mm x 8mm APR Reflow Nozzle 8mm x 9 5mm APR Reflow Nozzle 10mm x 10mm APR Reflow Nozzle 13mm x 13mm APR Reflow Nozzle 15mm x 15mm APR Reflow Nozzle 18mm xm 18mm APR Reflow Nozzle 20mm x 20mm APR Reflow Nozzle 23mm x 23mm APR Reflow Nozzle 25mm x 29mm APR Reflow Nozzle 27mm x 27mm APR Reflow Nozzle 30mm x 30mm APR Reflow Nozzle 35mm x 35mm APR Reflow Nozzle 40mm x 40mm APR Reflow Nozzle 45mm x 45mm APR Reflow Nozzle 49mm x 49mm APR Vacuum pick up nozzle 1mm O D APR Vacuum pick up nozzle 3mm O D APR Vacuum pick up nozzle 5mm O D APR Vacuum pick up nozzle 8mm O D APR Vacuum pick up nozzle 12mm O D APR Vacuum pick up nozzle 19mm O D Nozzle Removal Pad APR 5000 Nozzle Kit APR 5000 CSP and Micro SMD Nozzle Kit Vacuum Nozzle Removal Tool Computer with 16 CRT Monitor Computer with 17 Flat Screen Monitor Demonstration PCB with BGA amp CSP Component Kit APR 5000 Flat Monitor PCB Finger Long Pack 2 Thick PCB Finger Long Pack 2 Thick PCB Finger Short Pack 2 Thick PCB Spring Finger Long Pack 2 Thick PCB Spring Finger Short Pack 2 PCB Finger Short Pack 2 PCB Spring Finger Long Pack 2 PCB Spring Finger Short Pack 2 KIT Solder Paste Flux Prep Plate Component Pick Up Plate Tape Feeder Micro SMD re UBS APR VNZ ORINGK APR 5AK AP
6. Tel 33 0 4 72 26 20 30 Fax 33 0 4 72 26 20 35 Italy Dover Italy S R I Strada Statale 11 No 28 20010 Vittuone Milano Italia Phone 39 02 9025161 Fax 39 02 90111147 4 China OK Electronics Beijing Co Ltd No 1 Building A 10 Long Qing Street Beijing Economic amp Technical Developing Zone Beijing 100176 P R China Tel 86 10 67878490 Fax 86 10 67878491 Japan OK International Japan Co 5 3 1 Heiwajima Ota ku Tokyo 143 0006 Japan Tel 81 3 5753 0085 Fax 81 3 3765 8855 India OK International D3 302 Lok Upavan Phase Il Glady s Alwaris Road Majiwade Thane West 400601 Maharashtra India Tel 91 22 25396047 Singapore OK International Sales Support Office 1 Temasek Avenue 4227 01 Millenia Tower Singapore 039192 Tel 65 67263914 Mobile 65 9798 4443 65 94874276 42 Mouser Electronics Authorized Distributor Click to View Pricing Inventory Delivery amp Lifecycle Information OK International APR TC3 APR CL APR 5AK VNZ ORINGK TF 1 APR VRT APR YAK APR VA APR CALKIT APR PHB APR
7. Tube 9 Raise head 10 Do not remove 11 Select airflow rate and make adjustments to the profile settings in the profile window Click Next 12 L M H 13 Hit action buttons to move reflow head to the home position Click Next 14 Start To verify your new process 15 When completed click Next Software prompts select Next 16 Select to release component Window opens to save profile A caution Please do not use your hand to catch the component Even after the cooling cycle the component can be extremely hot 16 V HARDWARE TROUBLE SHOOTING amp CALIBRATION The following trouble shoot guide details a step by step process software trouble shooting guide that will help identify APR 5000 hardware faults If needed Optical Calibration and Head Calibration is also detailed For more in depth calibration procedures and required parts refer to the APR 5000 Calibration Kit part number APR CALKIT APR 5000 Hardware Trouble Shooting Guide Set Up 1 Turn APR 5000 unit on and boot the APR 5000 Software 2 Open System Set Up by clicking System Set Up 3 Click on No Password button and enter the APR password 94025 Metcal APR5000 T File Edit View Help Process Run Process Setup Profile Camera Calibration CHK Click Here for System Setup Security Software TC Hardware System Set U p PET wen fa p Password
8. cartridge assembly Employing OK International Smart Heat Technology into your rework process will virtually eliminate the potential of accidentally removing any pads when removing residual solder This is because OK International patented Smart Heat technology ensures that tip temperature is constantly maintained regardless of the 238 thermal demand of the assembly that is being reworked For more information on OK International Smart Heat Technology please contact your local OK International representative or visit www okinternational com for more information The following blade style tips are available for the MX 500 Series Rework System SMTC x60 410 length SMTC x62 870 length SMTC x61 620 length SMTC x110 1 55 length Please note that x denotes tip temperature All cartridges are available in 500 600 and 700 series styles 5 500 F 0 600 F and 1 700 F As an option you can utilize a vacuum desoldering system such as the SP 440 Self Contained Desoldering System or MX 500DS Shop Air Desolder Solder Rework System to vacuum residual solder from the PCB NOTE ON CLEANING Although isopropyl rubbing alcohol and cotton swab work satisfactory for removing flux residue it is strongly recommended you contact your solder paste manufacturer for recommendations for cleaning the residue left by their products SOLDER PASTE DEPOSITION and FLUX APPLICATION Component Stenciling Templates The applicat
9. Down software buttons on screen or the action buttons Move head down to place position Click Next Adjust the nozzle height Click Next 13 Create Profile This screen allows the setup of the air flow and heating parameters of the reflow cycle Select the airflow rate High Med Low Grab and move the temperature and time bars to the desired positions to create the thermal characteristics of the profile Click to run profile or to continue without running the profile The display will prompt you to Hit action buttons to move reflow head to the home position the head will move at high speed to the top position A window automatically opens to allow for the profile to be saved 14 Save This allows you to run the new process in verify mode permitting you to change the settings while it runs and then save the profile Or you can just save the process Process setup New Process Hemoval 1 2 Process Info Software prompts Select Yes to attach vacuum cup and reflow nozzle during process Run and creates a custom user s prompt 3 Pull out camera to continue 4 Adjust camera settings focus height zoom lamp intensity and iris controls Click Next Return camera home to continue Adjust the reflow nozzle height Using action buttons move nozzle into position on PCB Click Set method of lifting Click Next gis 8 Retract Vacuum
10. Optical Calibration Gun sight Nozzle Removal Pad Kapton Tape PCB Spring Finger Long Pack 2 Under Board Support APR 5000 Adjustable V Block for CSP Components USB External Video Adaptor Vacuum Nozzle Removal Tool Power Cord Video Cable Monitor Cable Flathead Screwdriver Phillips Screwdriver 3 Specialty Hex Wrenches 1 Standard Hex Wrench Set s ie B Figure 1 Main Unit Components Figure 1 1 ONDOEN 11 12 Power on LED Reflow head X axis release button Camera amp Lighting assembly Reflow head up button Reflow head down button Type K thermocouple inputs 3 Y Axis micrometer Command Enter button X Axis micrometer Open Frame adjustable printed circuit board holder Reflow head Y axis release button Component theta control 9 2 0 E Ll a Figure 2 2 Version 2 Main Unit Components Rear View Figure 2 1 amp 2 2 So om moa Oo RS 232 connector Composite video output Main air connector for reflow head Nitrogen Shop air input connector Fuse Holder Version 1 Breaker Version 2 AC Power input Reflow head electrical connector Main power switch 10 4 T5 ES ES LA I L Le caution The main unit is very heavy Please uncrate it with 2 people DO NOT LIFT THE MAIN UNIT BY THE RAILS LIFTING BY THE RAILS WILL DAMAGE THEM lll SET UP PROCEDURES A A
11. PR 5000 Main System Prior to performing initial set up unpack all accessories from their shipping containers Ensure that your APR 5000 has arrived complete by verifying that all of the accessories listed in Section Il of this manual have been included After all components are located setup can then begin 1 Remove the APR 5000 Main Unit and all accessories from their shipping containers When setting up this equipment be sure to arrange it in a position that allows the user to operate this machine in a comfortable well spaced environment IMPORTANT Every APR 5000 Rework System has been factory assembled and calibrated Recalibration is not necessary after initial setup However verifying calibration and product functionality is strongly recommended prior to initial use This procedure is thoroughly discussed later in the manual in the section titled Calibration eT B Computer and Software Setup System Requirements To run the APR 5000 you will need the following PC with Pentium III processor 600 MHz or higher recommended 128 MB of RAM memory 3 5 floppy disk drive Hard disk drive with at least 20 Megabytes of free space CD ROM 32MB AGP video card or equivalent 17 Monitor 28dpi Windows 98 2000 or Windows NT operating system The APR 5000 is not Windows XP compatible Set up Unpack the computer and all its accessories 2 Using the documentation supplied by the PC Manufacturer ma
12. R VA Under Board Support APR 5000 VNZ Pipette O Ring Kit APR 5000 Accessory Kit External Video Adaptor USB VII CALIBRATION KIT amp SPARE PARTS Listed below are the calibration kit and spare parts that are available for your APR 5000 Rework System Parts APR CALKIT APR AH APR VF APR HHA APR HCA APR CL APR CA APR PCGC APR AS APR VPC APR LCPCB APR ACPCB APR MC APR PHK APR PHO APR PHB APR HHP APR ALRWH APR ABK APR PHRTD APR XAA APR VPUK APR XALSK APR CF APR YALSK APR THK APR YAK APR 5000 Calibration Kit APR 5000 Air Hose Kit APR Vacuum Filter APR Heater Head Assembly APR 5000 Head Cover Assembly APR Camera Lamp Top amp Bottom APR Camera Assembly APR Protective Camera Glass Cover APR Air Solenoid for solenoid 1 4 APR Vacuum Pump Compressor APR Logic Control PCB APR AC PCB APR Motor Control APR 5000 Pre Heater Kit 115 220 VAC APR 5000 Pre Heater O rings APR 5000 Pre Heater Blower APR 5000 Heater Head Pump APR 5000 Arm Lock Retractable Wire Harness APR 5000 Action Button Kit APR 5000 Pre Heater RTD APR 5000 X Axis Assembly APR 5000 Vacuum Pick Up Kit APR 5000 X Axis Lock Solenoid Kit APR 5000 Cooling Fan APR 5000 Y Axis Lock Solenoid Kit APR 5000 Table Hardware Kit APR 5000 Y Axis Kit Vill SITE PREPARATION Solder Removal Prepare the site to receive a new component by removing all of the residual solder This can be accomplished by using an MX 500 Series Rework System with blade
13. e flux can be accomplished with OK International Dip Transfer Plates These plates allow for a simple controlled application of paste flux to the solder balls of your BGA or CSP component They are available in many sizes and depths Please contact your local representative for information and availability Custom sizes and configurations are available OK International has pioneered the application of high viscosity paste flux using specialized fixtures to ensure consistent repeatable results 1 Select the Dip Transfer Plate that meets your components requirements for size and depth 2 Using the supplied spatula fill the cavity with paste flux Use the spatula to smooth the flux level with the sides of the transfer plate This ensures a repeatable deposit 3 Place your component into the component pick up plate and pick it up with the vacuum pipette 4 Using the micrometers align the component in the X Y and Theta axes 5 Remove the adjustable component fixture and replace it with the flux transfer plate 6 Slide the prism into the placement arm this unlocks the Z axis arm and allows you to rotate the knob to dip the component into the flux Slide the flux transfer plate towards the placement arm to the component pick up position 7T Follow the screen prompts to lower the component into the flux transfer plate so the solder balls contact the bottom plate of the flux transfer plate Depress the Z axis UP buttons to return t
14. em parameters security levels and enter the calibration modes Process Run Placement T mode og Select Process Run from File Menu Open the desired profile Attach vacuum cup Attach reflow nozzle Click Next Pull out camera to continue Insert centering fixture Click Next Use action buttons to pick up the component Camera view pops up on the screen Press action buttons to move head into focus Click Next Manually fine adjust component to vacuum tube this brings the component into focus using the Up Down buttons on the screen Align the component using the X Y and Theta axes adjusters Click Next and return camera home Display will now change to the profile view Hit action buttons to move the reflow head down into placement position Adjust component height using computer screen buttons Click Select Next to release the component onto its target pads ee 9 10 11 12 13 14 Hit action buttons to lower reflow head to set nozzle height Fine adjust nozzle height using computer screen buttons or APR 5000 manual keys Click Next Select Next and then click Start to begin the profile When profile is completed Click Next Hit action buttons to move head to home position Save Saves graphics as a DAT file Click Finish to complete process Process Set Up New P
15. he component to the focus position 8 Remove the component pick up plate and inspect the impression left in the flux to ensure all the solder balls have been coated 9 Check component alignment and adjust as required 10 Follow the screen prompts push in the camera and click next 11 Place the component as directed by the screen prompts and continue with the placement process that you have selected IX WARRANTY AND SERVICE WARRANTY POLICY amp SHIPPING PROCEDURES The APR 5000 Array Package Rework System is under warranty for a period of 12 months from the purchase date for all parts and labor excluding misuse Heating elements and lamps are under warranty for a period of 90 days 5000 Array Package Rework Sys APR 5000 C Array Package Rework Sys w PC APR 5000 CF Array Package Rework Sys w PC amp Flat Screen 40 TECHNICAL SUPPORT Hot Line service Please contact your nearest office for technical support OK International Inc 12151 Monarch Street Garden Grove CA 92841 USA Phone 1 714 799 9910 Fax 1 714 799 9533 European Headquarters OK International Ltd Eagle Close Chandlers Ford Hampshire SO53 4NF U K Phone 444 0 23 8048 9100 Fax 44 0 23 8048 9109 Germany OK International GmbH Frankfurter Strasse 74 D 64521 Gross Gerau Germany Phone 449 0 61 52 71 12 0 Fax 49 0 61 52 71 12 22 France OK International SA Rue de la Sa ne ZAC de Folliouses les Ech ts 01706 Miribel Cedex France
16. ion of new solder paste or flux directly to the component s solder balls can be accomplished with OK International Component Stenciling Templates The templates allow the precise application of solder paste without concern for surrounding parts on your PCB Since the component is pasted rather than the board operators find this to be a much faster and simpler solution Please contact your local representative for information and availability Custom sizes and styles are available Solder Paste Application using the Component Stenciling Templates 1 Select the correct solder paste plate for your component and application 2 Position the component onto the component side of the plate the side with the smaller cut out or etched component corners 3 Secure the component with the supplied clamp assembly Please be careful not to over tighten the clamp as this can cause the plate to bend which will affect print quality 4 Apply solder paste to the solder balls using the supplied spatula When printing make sure the stencil face remains clean after your print this ensures correct solder paste volume 5 Carefully remove the component clamp assembly and position the solder paste plate onto the component pick up plate aligning it with the two tooling pins 6 Using the vacuum pipette lift the component from the solder paste plate and continue with your alignment process 39 Dip Transfer Plates The application of high viscosity past
17. k the Next key and follow the prompts on the monitor 15 Pick up the component gun sight from the calibration fixture The gun sight top plate must be picked up from the board holder The pins on the gun sight keep both the top and bottom gun sights aligned prior to pick up 16 Using the Head Action Keys align the focused vacuum cup image to the PCBA gun sight image and to the component gun sight DO NOT adjust the micrometers d X 34 17 Adjust the gun sight adjustment screws located on the side of the camera until the component gun sight overlays the PCBA gun sight Adjustment screws Note The prism adjustment screws are adjusted as needed to overlay the top and bottom gun sight images Each of the four screws can be adjusted as needed to achieve this 18 Follow the directions on the screen 19 To verify optical calibration using the down action keys lower the component gun sight to the PCBA gun sight Notes 36 VI NOZZLES VACUUM PICKUP NOZZLE AND ACCESORIES Nozzles NZA 060 060 NZA 080 080 NZA 080 095 NZA 100 100 NZA 130 130 NZA 150 150 NZA 180 180 NZA 200 200 NZA 230 230 NZA 250 290 NZA 270 270 NZA 300 300 NZA 350 350 NZA 400 400 NZA 450 450 NZA 490 490 Vacuum Pick Up Nozzle VNZ 01 VNZ 03 VNZ 05 VNZ 08 VNZ 12 VNZ 19 Accessories AC RP APR NK APR NK CSP APR VRT APR COMP APR
18. ke all the necessary connections and power the computer ON 3 Using the supplied disks install the APR 5000 software The software will automatically start the Installshield Wizard Follow all the prompts and the software will self install 4 Connect the PC to the APR 5000 utilizing the supplied RS 232 cable 5 Connect the video output Figure 2 2 to the video input on the PC utilizing the supplied RCA video cable C Final Power up Sequence 1 Plug in the power cord on the APR 5000 Main Unit 2 Set the APR 5000 Main power switch to the on position 3 On the desktop Double click E the icon Your APR 5000 Series Rework System is now ready for operation IV Software Operation Once your system has been setup and your software has been installed you must follow this sequence for everyday operation of your APR 5000 system 12 1 Set the APR 5000 Main power switch to the on position 2 On the desktop Double click E the icon Allow system to initialize Your startup screen will appear as follows woe From this startup screen you have 3 options 1 2 3 Process Run This selection allows you to open and run a previously created and stored profile for either placement or removal Process Setup This selection allows the modification of a previously stored profile or the creation of either a placement or removal profile System Setup This selection allows you to set the syst
19. mp 350 C 662 F 400 C 752 F Closed loop RTD 250 X 230mm 10 X 9 0 5 2 0mm 55 gm 92 oz BGA CSP LGA Micro SMD MLF Bumped Chip 8 24 l min L 8lpm M 16lpm H 22lpm 350 W top 1 5kW bottom 15 Hg 381mm Hg 50 X 76 X 71 cm w X d X h 64 Kg 140Lbs One year parts amp labor 90 days heaters amp lamps Item Description 115 230 VAC Array Package Rework System Array Package Rework System with Computer Array Package Rework System with Computer and Flat Screen Monitor Environmental Conditions all models e Suitable for indoor use only at altitudes not exceeding 6500 ft 2km e All systems must be grounded e Maximum relative humidity of 80 at 88 F 31 C decreasing linearly to 50 at 104 F 40 C Temperature range of 41 F 5 C to 104 F 40 C Mains supply voltage fluctuations not to exceed 10 of the nominal voltage Pollution degree 2 per IEC 644 Insulation category II Vision System The APR 5000 systems provide a maximum four sided view of 46mm x 46mm 1 77 x 1 77 The camera magnification has a range of 10X to 27X Shipping Data 28 W x 36 D x 32 H Size Weight 180 Ibs 82 KG Il INTRODUCTION AND GENERAL OVERVIEW Thank you for your purchase of an APR 5000 Array Package Rework System Each unit has been inspected thoroughly by OK International prior to shipment and with proper maintenance will give you years of reliable performance This Operator s Instruc
20. mp cloth Do not use solvent based cleaners e Slots and openings in the system provided for ventilation and to ensure reliable operation and protection from overheating The openings should never be blocked or covered e Do not overload power outlets and extension cords This can result in a risk of fire or electric shock SAFETY AND EMC INFORMATION Declaration of Conformity We declare our sole responsibility that the product APR 5000 to which this declaration relates is in conformity with the following standards and bears therefore a CE mark e EN 61010 1 e EN 61010 2 010 Safety Standards The APR 5000 is in conformity with international safety requirements and bears the following safety marks e ETLu e ETLc EMC Standards Europe e EN 61000 3 2 3 e EN 61326 1 North America e 47 CFR part 15 FCC Class A meets Class A limits Federal Communications Commission This equipment has been tested and found to comply with the limits for Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in an industrial installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful i
21. nterference to radio or television reception which can be determined by turning the system off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult the dealer or an experienced radio TV technician for help Minimum Computer Operation Specification APR 5000 Rework System Base Unit Input Voltage 115VAC 230VAC 50 60Hz Base Unit Power 2000 watts Consumption Circuit Breaker Subzone 15 amp Heaters Circuit Breaker Main Unit 15 amp Max Source Temperature Bottom side heater Soe 0a Max Source Temperature s o from Micro Oven S EUST 4 Basic Specifications of the APR 5000 APR 5000 Base Unit Input Voltage Base Unit Power Consumption Circuit Breaker Subzone Heaters Circuit Breaker Main Unit Max Source Temperature Bottom side heater Max Source Temperature from Micro Oven Temperature Control Range Maximum PCB Dimensions PCB Thickness Component Maximum Weight Component Types Airflow Heater Element Vacuum Pump Base Unit Dimensions Base Unit Weight Warranty System Part Numbers Part Number APR 5000 APR 5000 COMP APR 5000 COMP F Rework System 115VAC 230VAC 50 60Hz 2000 watts 15 amp 15 a
22. onvection reflow profile specifically tailored to the requirements of that particular PCB device and solder paste Accurate duplication of original oven reflow parameters is achieved During the course of the reflow profile source temperatures and time intervals can be modified On the Fly eliminating the need to wait for the current profile to terminate before modifications can be made Precise solder joint temperatures are measured and displayed on a real time graphical display thus providing the necessary data to accurately and easily establish the optimum reflow profile for each particular application within minutes A caution When operating this equipment please exercise caution If this unit is used in a manner which it is not intended for serious personal injury may occur Please read this operators manual thoroughly prior to use ll SYSTEM FEATURES AND ACCESSORIES APR 5000 SYSTEM INCLUDES 1 APR 5000 Series Base Unit 2 Adjustable size board holder 3 APR 5000 Accessory Kit APR 5AK ACCESSORY KIT INCLUDES VNZ 01 VNZ 03 VNZ 05 VNZ 08 VNZ 12 SOFT APR 5000 FS APR 2 21104 20534 20066 AC RP 20207 FSL APR 2 UBS APR 20987 APR VA APR VRT APR Vacuum pick up nozzle 1mm O D APR Vacuum pick up nozzle 3mm O D APR Vacuum pick up nozzle 5mm O D APR Vacuum pick up nozzle 8mm O D APR Vacuum pick up nozzle 12mm O D APR 5000 Installation Software PCB Finger Short Pack 2 Thermocouple fine gauge Squeege Handle
23. oop options m Calibration Procedures C Off Click d Head Alignment Optical The calibration fixture must be central to the pre heater arate 6 Follow prompts on screen to the Focus Vacuum Cup prompt This approximately two steps into the software procedure 7T Press the down keys to focus the vacuum nozzle and using the head actions keys align the image of the focused vacuum cup to the software window 31 8 If the vacuum nozzle image is not centered in the Y axis movement adjustment the image using the Y Adjustment screws using the appropriate Allen key 9 If the vacuum pipette image is not centered in the X movement remove the camera shield and loosen the four camera lock down screws located underneath the front part of the camera Screws located underneath the camera 10 When loosened adjust the X axis movement as needed to align the vacuum nozzle image to the center of the software image window Nom X axis adjustment screws Note When adjusting X axis make to adjust booth screws per side equally 11 Replace camera shield 12 When the image is centered tighten the camera lock down screws located underneath the front part of the camera screws identified in step 10 above 13 The final image should have the vacuum cup centered in the software window Now the vacuum head is central to the camera eee 14 Clic
24. or nearly touches the reverse mount the Gun Sight Tool and check distance to be parallel on all four edges Must be parallel on all four edges 14 If the calibration mirror is not parallel to the reverse mounted the gun sight tool loosen the adjustment screws as necessary and adjust the head manually until the mirror is parallel to the reverse mounted calibration tool Loosen lock down screws These must be loosened for adjustment Manually move head to adjust as needed Top two screws adjust front to rear motion for front and rear Motion is pendulum like 25 15 For a final test lower the mirror to the reverse mounted gun sight tool release the mirror and attempt to pick up the component If aligned correctly the steel vacuum pipette will pick up the component Adjust as needed 16 When the calibration mirror is parallel to the reverse mounted gun sight tool tighten the lock screws Reassemble the front cover and proceed to the APR Head to Pick Up Point Alignment Procedure Head Notes 26 APR Head to Pick Up Point Alignment Procedure Tools Required Large Vacuum Gun Sight Tool Calibration Mirror Allen Keys 1 Drive the motor head down to the PCB pick up point and pick up the centered mirror 27 3 Pull out slide and loosen pick up point lock down screws Lock Down Screws are located opposite each
25. other on the camera for optimum adjustment Lock Down Screw 4 Adjust side to side as needed and front to rear as needed with mirror near the pick up point as a gauge Side to Side Adjustment 3 i if This side does not adjust 28 Front to Rear Adjustment 5 Adjust until mirror is parallel to the pick up fixture When parallel see below tighten the lock down screws Must be parallel on all four edges Notes 29 APR 5000 Optical Calibration Procedure This procedure must be done after the Camera to head Alignment procedure has been finalized Tools Required Large Vacuum Gun Sight Tool Allen Keys Procedure 1 Turn APR 5000 unit on and boot the APR 5000 Software 2 Open System Set Up by clicking System Set Up Metcal APR5000 File Edit View Help Process Run Process Setup Profile Camera Calibration CHK Click Here for System Setup Secuily Software TC Hardware e System Set U p Pla E avion E a Password Option 1 Engineer Password 4 p Confirm L SaionlD Type in 94025 3 Click on No Password button and enter the APR password 94025 4 Open Calibration Screen and Click on Calibration Tab and then click the Optical option 30 Metcal APR5000 i 2x Security Software Airflow Profile Camera Calibration TC Temo Calibrations Closed l
26. r to the cylinder i 0 00 B Down Action Buttons ien low or cannot lift a lo M NetButon N208 Hester component check the IV Head Home switch C N2L C B Head EDT switch PARS H Sese vacuum hoses and cee ee eae Ne sl vacuum pump olenoid Lock switc 0 00 Click The vacuum tube A nt Temp will retract Camera EOT switch f r Preheater Airflow 0 00 F LL Temp Pipe Off Up Vac Down Click When the button is depressed the vacuum tube is extended and locked PRTD 86 69 HRTD 14826 Click this button to EM check for component Vacc A release air pressure This has no minimum or maximum specification ai E but must be able to release a component instantly from the vacuum Pipette Click this button to check the pipette s component pick up capability When depressed the vacuum tube will be free floating Notes 20 Metcal APRS000 Fi System Setup a2 xl Security Software Calibration Airflow Profile Camera TC Temperature Calibrations Closed loop options Test m Digital Input r Rewlow Head UP Action Buttons 0 00 B Down Action Buttons Baton Ee IV Next Button IV Head Home switch Head EDT switch C N20ff Heater Click to turn on C N2L Bypass C ower
27. rocess Placement 1 Dee QU AD Click on process set up Click on Placement only Click on new process and enter chip package information Attach Vacuum Cup and Reflow Nozzle Yes Enter the vacuum cup part number No Click Next Attach Reflow Nozzle during process e Yes Enter the Nozzle part number e No Click Next Camera Pull out camera to continue Click Next Select Component Pick up Method Click Next 7 Component Set the height and the method for picking up the component Component Pick Up This mode picks up the part for a placement onto a previously prepared board Component Pick Up with Paste This mode picks up a component that has been stenciled with solder paste for placement onto the PCB Component Pick Up with Flux Dip This mode picks up of a component and allows the additional steps required to dip the part into a dip transfer plate Click Next Screen Prompt hit action buttons to return head to home position Click Next Screen Prompt remove the centering fixture from the camera housing Select Next to continue 14 Click Next 10 Vision Adjust camera parameters lamp intensity focus zoom and iris controls Click Next 11 Camera Return camera to home position to continue 12 Component Set the height for placing the component Coarse action buttons Fine Up
28. tallation or operation of the APR 5000 Heed all warnings on the system and in the operating instructions Use of the APR 5000 is intended only for the removal and placement of electronic components on to printed circuit boards by properly trained personnel If you are not familiar with the proper and safe operation of the APR 5000 do not operate until proper training has been obtained 23 e Theunit should be operated only from the type of power source indicated on the serial number label e Use only the supplied power cords Avoid damage to the power cord If damage should occur replace it with the approved OK International replacement power cord A This CAUTION symbol on the equipment refers the user to the Operator s Manual for additional information This symbol appears next to the relevant information in the manual This HOT symbol on the equipment warns the user of a hot surface and potential injury if touched Please refer to the Operator s Manual for additional information This symbol appears next to the relevant information in the manual A This HEAVY LIFTING symbol on the packaging warns the user to team lift the APR 5000 during removal from packaging and installation on the workbench Please refer to the Operators Manual for additional information This symbol appears next to the relevant information in the manual Other Safety Tips e Unplug the unit before cleaning Clean the exterior of the system with a da
29. tion Manual is a valuable resource It explains the systems options features specifications and the correct operation of your APR 5000 Array Package Rework System If any problems should occur during setup or operation of your system contact OK International s Technical Service or you may also contact your local Representative www okinternational com APR 5000 Array Package Rework System provides both accurate component placement and specifically tailored reflow profiles through OK International patented single component Micro Oven in one user friendly single platform rework system The challenges of Array Package Rework and the inability to easily inspect placement accuracy with BGAs in particular call for a solution that allows for simultaneous viewing of PC board pads and component pads or balls for accurate placement The APR 5000 fills this need with quick accurate placement through the use of an optical system employing dual image overlay technology The image of the BGA solder balls is overlaid with that of the PC board pattern The image is viewed on the computer monitor then the micrometers permit fine X Y and theta adjustment at up to 27X magnification Finally the part is placed and the vacuum is released automatically 6 After accurate component placement is achieved the vacuum pickup tube is automatically retracted and the reflow nozzle is lowered into place At this point the component is subjected to a 5 zone full c
30. to camera IV Head Safety Switch C ka P Solenoid Lock switch Tem 0 00 IV Camera Home switch P Camera EOT switch d Overheat m Preheater 110 220 Airflow 0 00 ML eA ESL ET Using your mouse c 3209 BEL grab the bar and Ter 3119402 ping slide it back and c2 319402 3 n forth This tests the Tea 31194 02 C Down component upper PRTD 96 69 C Free lamp HATD 148 26 r Canar sRTD 10178 Povia LUp Vacc 0 10 LDn Using your mouse Cancel Apply grab the bar and slide it back and forth This tests the oc Os 100s 200s PCBA lower lamp Before exiting the troubleshooting window you must ensure all check marks are in their original position Failure to do so will hinder the performance of your APR 5000 and may cause a Process Run failure Notes 221 APR Camera to Head Alignment Procedure Tools Required Large Vacuum Gun Sight Tool Calibration Mirror Allen Keys Procedure 1 Turn APR 5000 unit on and boot the APR 5000 Software 2 Open System Set Up by clicking System Set Up Metcal APR5000 File Edi View Help Process Run Process Setup Profile Camera Calibration CHK Click Here for System Setup Security Software TC Hardware System Set Up Profile C Vision oo m Option o O Enter Confirm Engineer Password Type in 94025 ae SaionlD O
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