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APR-5000XL and APR-5000XLS Users Guide

1. Click Next to turn the vacuum on When the component is in position and the head is lifted up from the fixture remove the centering fixture and click Next Using the up and down keys on the APR 5000 XL system lower the head until the component has come into view and the over lay image of the component is directly above the solder pads Focus on the component Component Overlay Solder Pads Nea EEE LH LE ZI ZH ZH BGA 169 15AM If the image is not over laid correctly press one of the yellow buttons located on either side of the APR 5000 XL body and using the joystick orient the component into position Page 38 of 114 As prompted focus the PCBA and use the Up Down keys to focus the component Using the action buttons lower the head into position Use the Coarse button to lower the component to the PCB The head will lower to approximately 2 inches from the PCB At this point you will need to click Fine to continue Proceed until the component has touched the PCBA and the component is in position IMPORTANT While placing the component onto the PCB a fine adjustment of 10 mils or less Is recommended This avoids problems with crushed solder paste and minimizes solder bridging Adjust reflow nozzle height using the same up and down keys Wu Mekcal APRSOODKL 1 07 File Edit View Help ve Vision Camera Set reflow nozzle height eee Eee eee lv E C Fine Use Up Down Butt
2. 2 Ifthe vacuum nozzle image is not centered in the software window the in Y axis movement adjustment the image using the Y Adjustment screws using the appropriate Allen key Loosen and slid forward to alter y axis stop position Page 76 of 114 3 If the vacuum nozzle image is not centered in the software window in the X movement remove the camera heat shield plate and loosen the four camera lock down screws located underneath the front part of the camera Single camera version Camera Heat Shield Camera Lock Down Screws 4 When loosened adjust the X axis movement as needed to align the vacuum nozzle image to the center of the software image window X Axis Adjustment Screws Note When adjusting X axis make to adjust both screws on each side equally Page 77 of 114 5 When the image is centered tighten the camera lock down screws located underneath the front part of the camera screws identified in step 5 above 6 The final image should have the vacuum cup centered in the software window Now the vacuum head is central to the camera 7 Click the Next key and follow the prompts on the monitor Notes Page 78 of 114 13 APR 5000 XL Quick Nozzle Co planarity and Vacuum Nozzle Adjustment In the rare case that the vacuum nozzle is not central to the box nozzle after the unit has been calibrated the APR 5000 XL does allow for some adjustment Tools Required Any Vacuum Nozzle Vision Calibr
3. APR S000 XL Software U Page 48 of 114 Once the information has been entered proceed to Next button and click the Manual Mode Option This will take you to the active Manual Mode window amp Metcal APR5000 XL 1 05 05 File Edit Yiew Help Choose the action you woul like to perform C New Removal Process Process Setup geosnnnnnsssnsonnsnunsunn Taonssssnsnssssnunssnene New Placement Process C Modify Existing Process Profile Vision Manual Mode Window The Manual Mode Window allows the end user to use existing thermal plots while controlling all other mechanical features of the APR 5000 XL The following functions can be edited at any time during the a profile Direction of head movement Speed of head movement Vacuum tube movement Vacuum control Puff off control Metcal APRSOOOXL v1 05 05 Zu x File Edit View Help Initialize Process Info Manual Finish Process Setup Fast Tube Control Yac Control Down OFF Coarse Use Action Buttons C Fine Use Up Down Buttons 25 mils C Up C ON Eycle Advance Free Dop Profile Vision How can use Manual Mode to remove or place a component When you have reached this page you have option to use any saved thermal plots in the library To start Click of File as shown below Page 49 of 114 W Metcal APRSOOOKL 71 05 05 File Edit View Help Process Run Initialize Proc
4. Vision Control Panel r Lighting Control Once the component is immersed in flux use the Up keys to raise the head up and away from the flux transfer plate DTP Page 42 of 114 Using the action buttons lower the head into position Use the Coarse button to lower the component to the PCB The head will lower to approximately 2 inches from the PCB At this point you will need to click Fine to continue Proceed until the component has touched the PCBA and the component is in position Adjust reflow nozzle height using the same Up and Down keys WE Metcal APRSOOOXL 1 02 File Edit View Help ve Vision Camera Set reflow nozzle height VE 25 mils Process Setup Profile Vision Note OK International s patented reflow nozzle allows the nozzle to touch the PCBA with minimal clearance from the nozzle body 010 This increases thermal efficiency and reduces spacing issues that may exist The reflow nozzle can also reflow components when spaced up to 3mm from the PCBA This can be very helpful when reworking densely packed PCBAs Click Next to release the component Follow prompt on the screen to Create Profile W Metcal APRS5OOOXL v1 02 File Edit view Help Camera Nozzle Height Lift Profile is running Select Stop to abort Process Setup Profile Vision Profile Elapsed 4 seconds 400C Profiling during a process is allowed This on the fly profilin
5. i Profile Camera Calibration CHK Click Here for System Setup Security Software TC Hardware System Set Up Option Profile Vision m Mode No Password C Operator r Engineer Password Enter Type in 94025 Station ID Cancel 4 Click on the Test tab 5 This test window must be exited as shown below Page 53 of 114 Press Action Buttons as noted Check mark identifies if buttons are Press Next Button as noted Check mark identifies if button is working properly Head Home switch check mark must be checked Physically lift head up Head Switch must go off when head is lifted Notes working properly 2 x Temperature Calibrations Closed loop options Camera Security Software Calibration Test Airflow Profile Rewlow Head Airflow 0 00 eS w N2OR Heater NZL Bypass Digital Input UP Action Buttons l Down Action Buttons Next Button 7 Head Home switch ee ce a a N2H Solenoid Lack switch 0 00 v Camera Home switch F Camera EOT switch Overheat ManPreheater M 110 220 Airflow 0 00 Analog Input CJ 36 37 Temp zu TC 31194 02 mallPreheater 31194 02 Wee Airflow TCS 31194 02 TC4 31194 02 TCS 31194 02 HATO Arr SATD 39 27 PRATO 24 21 PATD 2 23 68 PATDS 24 20 PATD4 24 43 PATDS 24 35 FRTDE 23 74 Wace 0 02 WH 0 00 Inp
6. Page 32 of 114 The next option to appear in the window is Select component pickup method This option is required for the next step WE Metcal APR5O000KL 71 02 File Edit View Help Fickup Method Component Home Select component pickup method C Component pickup Process Setup C Pickup with paste f Profile Vision Vision Control Panel Component pick up Designed for use with the component pick up block Although not preferred this option also allows the end user to prepare the rework site with liquid flux instead of gel flux or solder paste Note Liquid flux does not evenly distribute the organic material necessary for a sound solder joint This method can create voids or opens Pickup with paste Designed for use with OK International component stenciling plate BST This method along with the correct stencil allows the end user to recreate OEM stand off height This process is preferred to both flux methods Pickup with flux dip Designed for use with OK International Dip Transfer Plates DTP this process allows end users to transfer gel flux onto the solder ball only increasing success rate and minimizing the amount of flux residue DTP Plate DTB Block Page 33 of 114 Component pickup Process Click on Component pickup Process and the Component window will appear Focus on the PCB pads When in this window follow the prompts place the centering fixture into position Me
7. Profile Camera Calibration WE Termo Calibrations Closed loop options Calibration Procedures C Off Click Head Head Alignment Alignment Optical 5 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 Page 60 of 114 E 7 u bd 6 Reverse mount the Optical Calibration Tool onto the board holder and use glass top on bottom surface of matching plate as shown Page 61 of 114 7 Take vacuum nozzle 12 remove rubber o ring and attach the vacuum nozzle to the APR Removing the o ring allows you to optimize the vacuum pick up point accuracy 8 Follow prompts past the vision calibration to when the vacuum engages 9 Next mount the Glass Calibration plate on vacuum nozzle and using the down action keys lower the Calibration Mirror approximately 25 over the reverse mounted calibration plate 10 Using your software options fine control reduce the lowering speed to 001 010 Reducing speed will increase you field of view 11 Using the down action keys lower the glass stencil plate until it nearly touches the reverse mount the Optical Calibration Tool and check distance to be parallel on all four edges Page 62 of 114 12 Must be parallel on all four edg
8. Heat Reflow Aurflow High Bottom Heat Preheat Large Bottom Heat Preheat Small Ato 78 Puff Puff Tine amp e pi 500 00 me APR Software Reading Air Flow Gauge Reading Small Bowl zen APR Software Reading Air Flow Gauge Reading Large Bowl 70 to 80 gt 500 Ft min Page 93 of 114 15 Apply and save settings follow the APR 5000 XL Software instructions prompts 16 Remove the Air Flow Gauge and Air Flow Gauge Fixture from the Air Flow Thermal Calibration Fixture Notes Page 94 of 114 17 APR 5000 XL Head Thermal Calibration Tools Required NZA 490 490 Thermocouple Probe Convection Thermal Calibration Fixture Procedure 1 Turn APR 5000 XL unit on and boot the APR 5000 XL Software 2 Ensure the heaters and thermocouples are at room temperature 3 Open System Set Up by clicking System Set Up 4 Click on No Password button and enter the engineer s APR password 1923523 and return W Metcal APR5000 File Edit View Help Process Run Cl ick a Profile Camera Calibration CHK H ere fo r System Setup Security Software TC Hardware Sy stem Profile Vision Br BEER Set U p RETTET SY L un Option M Engineer Password Enter Station ID Type in 1923523 Cancel 5 This will kick you out to the APR process page again To be
9. Help Camera Nozzle Height Lift Profile is running Select Stop to abort Process Setup Profile Vision Profile Elapsed 4 seconds 400C Profiling during a process is allowed This on the fly profiling allows the end user to quickly change the profile during the record mode and get the profile right the first time around To make changes during a process simply left click your mouse on one of the 10 temperature bars five for Top Heat and five for Preheater and drag the bar into the desired position This feature allows the end user to modify existing processes as well Page 36 of 114 Temperature Setting Bars Slated 2002 1 11043 When the profile has been determined proceed to Save the profile To save the profile the end user must press Finished Pickup with paste Process Click on Pickup with paste and the Component window will appear Focus on the PCB pads When in this window follow the prompts place the centering fixture into position Place the BGA Stenciling Template BST into position Page 37 of 114 Wu Metcal APRSOOOKL 1 07 File Edit View Help Cup Nozzle Camera Pickup Method Move forward centering fixture Insert plate or nest and set component pickup height Process Setup C Fine Use Up Down Buttons 25 mils I Down Pile oh Vie ug Bonn Vision Control Panel Lower the head into position and pick up the solder pasted component
10. again To begin calibration open System Set Up again by clicking System Set Up This will open Calibration Screen Page 98 of 114 6 Click Temp of Preheater to begin process Metcal APR5000 21 System Setup 21 Security Software Calibration Airflow Profile Camera ERG Temperature Calibrations Closed loop options Test Calibration Procedures Off Flow Preheater Flow Reflow Head Temp of Preheater Temp of Reflow Head Click this option to open Preheater Calibration Cancel Apply Os 100s 200s 300s 400s 500s Process File Grad amp Temp Process Type Placement Time oc 7 Select large heater for calibration and place Convection Thermal Calibration Fixture and thermocouple probe in place Connect thermocouple probe to input five TC5 Position of calibration hole must be left front See below Page 99 of 114 8 Follow the prompts and center the thermocouple as shown below This must be done to ensure accurate temperature reading Thermocouple must be in center as before 9 Follow the prompts on the monitor through the auto calibration process Graph should be similar to graph below Metcal APR5000 preheat yellow fixture apr5000 File Edit View Help Process Run Profile Vision Duration 1006 seconds Started 2002 07 12 06 07 57 500C 400C 300C 100C gt oc Os 100s 200s 300s 400s 500s 600s 700s 800s 900
11. cup onto the component Process Setup Page 40 of 114 When the component is in position and the head is lifted up from the fixture remove the centering fixture and click Next Using the up and down keys on the APR 5000 XL system lower the head until the component has come into view and the over lay image of the component is directly above the solder pads Focus on the component by using the fine up and down control keys and not by using the Focus function Component Overlay Solder Pads SGA 169 LAM If the image is not over laid correctly press one of the yellow buttons located on either side of the APR 5000 XL body and using the joystick orient the component into position Page 41 of 114 As prompted focus the PCBA and use the Up Down keys to place the component in focus After the component has been aligned and focused to the PCB pads click next Using the spatula provided with the flux transfer kit soread a controlled bead of gel flux onto the flux transfer plate DTP As prompted move the centering fixture forward and place the flux transfer plate DTP into the centering fixture Using the down keys lower the component into the flux transfer plate DTP Metcal APRS5OOOXL 1 02 File Edit view Help Component Home Remove Compone Process Setup Pa anna Enable operator control during process C Fine Use Up Down Buttons 25 mils Up Down C Profile Vision
12. free head calibration procedure Lack of vacuum Check 15 hg of vacuum is available at vacuum cup If not check for air leaks or vacuum pump failure Use test tab to check Unsuccessful component Pick up plate is not co See calibration procedure pick up on camera planar to vacuum cup for flatness calibration procedure Faulty o ring Replace o ring Page 103 of 114 pick up on camera vacuum cup Component pick up not Component slide in X Y is Check centralization pick up central to nozzle out of adjustment plate to vacuum cup See procedure in this manual vision window adjustment See manual Vision window is too small PC resolution is not Use 17 inch monitor check optimized or monitor is resolution as per manual wrong size specification Erratic top or bottom heater Possible RTD failure Use test tab in software plots not from window to view RTD is thermocouples approximately 100 ohms at 25 C Error Codes Message Corrective Action Critical System Error X Contact 1 Check administrator rights for PC OK International Technical Service 2 Reinstall software Contact OK International Technical Service for help in resolving your system malfunction Communications Failure X See 1 Ensure the serial cable is properly Troubleshooting Section of the connected to the communications port on your Operator s Manual computer 2 Ensure the serial cable is properly connected to the APR 5000 hardware 3 Ensure
13. gt OK INTERNATIONAL Precision Systems for the Electronics Bench 205 Westwood Ave Long Branch NJ 07740 equipment 1 877 742 TEST 8378 ET Fax 732 222 7088 u sale qui USA steam amp T APR 5000XL and APR 5000XLS Users Guide 7000 1590_E Page 1 of 114 Copyright 2004 OK International Inc 12151 Monarch Street Garden Grove CA 92841 Visit us on the web at www okinternational com PROPRIETARY NOTICE This document contains proprietary data of OK International Inc The receipt or possession of this document does not convey any rights to reproduce it disclose its contents or to manufacture the concepts and details disclosed by this document This document may not be copied or disclosed in whole or in part to anyone without written permission of an officer of OK International Inc All rights reserved Page 2 of 114 CONTENTS Fe EEE E TTT 4 1 Introduction and General Overview unsesseessessssesennnnnnsnnnnnnnenennnnnnennunnnsnnennennnennennn nennen 9 2 System Features and Accessories cccccccecccecceeeceecceeecscecueceuesauecaeecseesueeseesageseeeseeess 11 eae 1 a m 1 BL e ee ee 13 ME ein ee ei e a E EE T T A E E ETEN 20 IRE E i gt E E A antescaus en ooncemenengnet anuseacsuntonesaseuascnanteqnananteneaesasen 24 o NEW Facom FTOCOS S en EEEE EEE 31 E ie Ss eel T ee ee ee 44 SM cal eN e e E A E E E E EE ES 46 9 APR 5000 XL Test Tab Window ccccccceccsecsseceetee
14. heater Airflow Select either small heater or large heater to set flow calibration Simultaneous calibration of the small and large preheater is not allowed The APR 5000 XL software is now in calibration mode Page 88 of 114 Airflow Calibration Window System Setup Camera TE Temperature Calibrations Closed loop options Security Software Calibration Test Airflow Profile Top Heat Reflow Aurflouy High Medium ot 3a wo mm oe Ir Low Dt Bottom Heat Preheat Large Ae S 35 Bottom Heat Preheat Small Aiton i 78 x Puff Puff Tiri j 300 00 A 7 Remove top heater grill from machine 8 Setthe Turbo airflow meter to measure knots A reading of 5 knots should be obtained by sliding airflow slider until 5 0 is measured If multiply by 100 this measures feet per minute thus meeting the OK International APR 5000 XL specification of 500 feet per minute Depending on voltage country the meter should be set between 70 and 80 Page 89 of 114 Set meter to middle position for knots measurement of 5 0 9 Once Flow Preheater software Screen is open place Air Flow Calibration meter into position as shown Vary airflow speed until airflow setting reaches 5 0 knots 10 Vary the Bottom Heat Preheater Small airflow until the airflow setting on the Turbo meter reaches 5 0 knots See below When this is done save settings
15. nicht vertraut sind sollten Sie zun chst in die Funktionen eingewiesen worden sein Unit should be operated only from the type of power source indicated on the serial number label Schlie en Sie das Ger t nur an die Stromversorgung an die auf dem Typenschild angegeben ist 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 Page 4 of 114 Verwenden Sie nur die zum Lieferumfang geh renden Netzkabel und achten Sie darauf dass Sie diese nicht besch digen Ersetzen Sie besch digte Kabel durch Originalkabel des Lieferanten A This CAUTION symbol on the equipment refers the user to the User s Manual for additional information This symbol appears next to the relevant information in the manual Das Symbol Caution Vorsicht am Ger t verweist auf weitere Informationen im Handbuch Dieses Symbol erscheint neben den entsprechenden Hinweisen in der Bedienungsanleitung This HOT symbol on the equipment warns the user of a hot surface and potential injury if touched Please refer to the User s Manual for additional information This symbol appears next to the relevant information in the manual Das Symbol Hot Hei am Ger t warnt vor hei en Oberfl chen und m glichen Personenverletzungen Weitere Informationen finden Sie in der Bedienungsanleitung in der die Hinweise entsprechend gekennzeichnet sind
16. perfect one on one 14 Place picture frame into bottom cal fixture to space the top plate from the bottom plate This is used to stop mechanical alignment of top plate to bottom plate and acts as a spacer See below Page 73 of 114 15 Before placing bottom plate it is a good idea to now move the head with the joystick and then realign with joystick to exact overlay this will prove 100 placement accuracy 16 Return camera and follow instructions to place top plate on bottom calibration plate 17 To verify optical calibration and placement using the 90 bent light source provided in the kit light the under side of the numbers When the calibration is correct light will pass through the numbering and it will be visible Letter 2 represents 002 cut through letter 3 represents 003 and 4 represents 004 The X is a 002 and shows rotation inaccuracy if light is blocked If by moving the light underside you can see all the numbers and the x clearly placement and calibration are complete Notes Page 74 of 114 12 Centralization of Vacuum Nozzle in Software Window Tools Required VNZ 12 Glass Optical Calibration Tool Ball Allen Keys Procedure 1 Place the optical calibration plate into position as shown below The calibration fixture must be central to the pre heater grate a ee Bm is z Er nr al Be yi ee ey are to ie Ty sag oo APR 5000 XLS camera featured Page 75 of 114
17. picture is square lock top screw up again Locking screw Rotational Adjustment Page 69 of 114 11 APR 5000 XL Optical Calibration Procedure Tools Required VNZ 12 Vacuum Nozzle Vision Calibration Tool Allen Keys Procedure 1 Turn APR 5000 XL unit on and boot the APR 5000 XL Software 2 Open System Set Up by clicking System Set Up Metcal APR5000 ia File Edit View Help Process Run Process Setup Profile Camera Calibration CHK Click Here for System Setup Secuity Software TC Hardware System Set Up Option Profile Vision Mode No Password Operator r Engineer Password Enter Type in 94025 JJ awct Station ID 3 Click on No Password button and enter the APR password 94025 4 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 Page 70 of 114 Metcal APR Security Software Airflow Profile Camera Calibration TC Termo Calibrations Closed loop options Calibration Procedures C Off Head Alignment Click Optical option Optical Cancel Apply 5 Place the optical calibration plate into position as shown below The calibration fixture must be central to the pre heater grate Place top calibration plate in upward po
18. the APR 5000 hardware power is on 4 If you still experience problems please contact Technical Service APR Hardware Error X Please Ensure the serial cable is properly contact Technical Service connected to the communications port on your computer Ensure the serial cable is properly connected to the APR 5000 hardware Ensure the APR 5000 hardware power is on If you still experience problems please contact Technical Support Messages 7 12 Hardware problem Please contact Technical Service Message 13 15 Cool down the APR5000 Rerun process If Page 104 of 114 you still experience problems please contact Technical Support 9 Message 14 10 Check camera position Rerun process If you still experience problems please contact Technical Service Motor Malfunction X See Ensure there is nothing physically impeding Troubleshooting Section of the the movement of the reflow head Operator s Manual If the reflow head was completely lowered before starting the software try closing the software and starting the program again Ensure the serial cable is properly connected to the communications port on your computer Ensure the serial cable is properly connected to the APR 5000 hardware Ensure the APR 5000 hardware power is on If you still experience problems please contact Technical Service Camera Malfunction X See 1 Ensure there is nothing physically impeding T
19. way that impedes the disconnection of the main power cord in case of an emergency F r den Anwender ist die Benutzung eines Erdungsbandes w hrend der Bedienung der APR 5000 XL XLS zwingend erforderlich A Mandatory use of a grounding strap is required when operating the APR 5000 XL XLS F r den Anwender ist die Benutzung eines Erdungsbandes w hrend der Bedienung der APR 5000 XL XLS zwingend erforderlich Page 10 of 114 2 System Features and Accessories APR 5000 XL XLS ARRAY PACKAGE REOWRK SYSTEM INCLUDES 1 APR 5000 XL XLS Series Base Unit 2 Adjustable size board holder 3 APR 5000 XL XLS Accessory Kit APR 5XLAK APR 5XLAK ACCESSORY KIT INCLUDES Lid Storage Organizer 18 1 4 x 13 3 8 x 3 5 8 MPVB Adj V Block for BGA Components Optical Calibration Kit Tape Kapton Handle Squeegee CSP VB Adj V Block for CSP Components Fine gauge multi colored thermocouples Sincl Wrench hex key T handle 9 64 6 blade Wrench hex key T handle 7 64 6 blade screwdriver slotted 3 16 width 7 blade screwdriver Phillips 2 7 13 16 long Ball end hex key set Cable EGA CGA ser Monitor ext db9f db9m 6 ft Cable video w RCA 2 meter low loss Nozzle removal pad APR 5XLAK contents checklist O Ring Kit Vacuum nozzle removal pad PCB spring finger long pack 2 PCB spring finger short pack 2 Kit solder paste flux prep plate APR Vacuum pick up nozzle 1mm O D APR Vacuum pick up nozzle 3mm O D AP
20. will copy over Transferred Thermal Plot u Page 51 of 114 When the plot has been transferred to the Manual Mode Window proceed to Start the thermal cycle when ever you are ready to begin Use the functions available to help you manipulate the mechanical functions of the APR 5000 XL Note This is a temporary function that cannot be saved By clicking on Next the Manual Mode Window will close To start the thermal profile press the Start button Quick reference guide Direction of head movement Speed of head movement Vacuum tube movement Vacuum control Puff off control Start button Controls the Controls the begins thermal profile Controls the speed of head movement vacuum tube vacuum pump location iW Metcal APR5SOt OXL v1 05 05 x File Edit View Controls the puff off assist release of component Ay caution Please do not use your hand to catch the component Even after the cooling cycle the component can be extremely hot Nehmen Sie das Bauteil nicht mit der Hand auf da es auch nach der Abk hlphase noch sehr hei sein kann Page 52 of 114 9 APR 5000 XL Test Tab Window Set Up 1 Turn APR 5000 XL unit on and boot the APR 5000 XL 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 File Edit Yiew Help Process Run Process Setup
21. A This HEAVY LIFTING symbol on the packaging warns the user to team lift the APR 5000 XL XLS during removal from packaging and installation on the workbench Please refer to the User s Manual for additional information This symbol appears next to the relevant information in the manual Mit dem Symbol Heavy lifting schwer auf der Verpackung wird der Bediener darauf aufmerksam gemacht dass das Ger t nur von mehreren Personen aus der Verpackung genommen und an dem Arbeitsplatz installiert werden sollte Weitere Informationen finden Sie in der Bedienungsanleitung in der die Hinweise entsprechend gekennzeichnet sind Page 5 of 114 Other Safety Tips e Unplug the unit before cleaning Clean the exterior of the system with a damp cloth Do not use solvent based cleaners WARNING When there is no power to the APR the reflow head will slowly descend to the down position from its home position This may result in the head assembly coming in contact with the work piece To avoid potential damage to the workpiece it is highly recommended it be removed before removing power from the APR Users may also consider the use of an Uninterruptible Power Supply UPS in areas where unplanned power outages occur 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
22. New Removal Process is now complete IMPORTANT These features allow the end user to create the correct profile for the process movement and makes thermal profiles easier to modify or e mail To monitor your profile attached the five thermocouples to the PCB and component as needed Profile Window Options Options in the Profile Window allow the end user to add eight time lines and modify existing temperature lines while the program is in process This allows the end user to record eight key data points in the profile These options can be activated when the using the pointer on the screen Data within those crossing lines will be monitored as part of the graph data located on the lower middle part of the screen How to activate new time lines Left click your pointer on a far right of your screen where the dotted time line is When active simply hold and drag the new line to any point on the profile you wish to record How to modify existing temperature lines Left click your pointer to any one of the four available temperature lines and drag the line to vertical position desired Page 29 of 114 Temperature Left click mouse and Lines hold amp drag time line 5 Metcal APR5000 XL v1 02 File Edit view Help Create Pr amp le Camera Process Setup Profile is running Select Stop to abort Profile Vision Profile Elapsed 0 seconds 400c
23. OG 23 74 Yace 0 02 rfl 0 00 Using your mouse grab the bar and slide it back and forth This tests the component upper lamp Aa Hino Using your mouse grab the bar and slide it back and forth This tests the PCBA lower lamp Page 57 of 114 System Setup 2x Temperature Calibrations Closed loop options Camera TC Security Software Calibration Test Airton Profile Rewlow Head Airflow 0 00 Digital Input UP Action Buttons T Down Action Buttons Next Button IY Head Home switch Head EOT switch IY Head Safety Switch IY Solenoid Lock switch IY Camera Home switch Camera EOT switch I Overheat Ih 110 220 Using your mouse grab the bar and run the bar left to right to test airflow and heat accordingly N2OF Heater i NZL C Bupass Manfreheater Airflow 0 00 Analog Input Cl 3637 Temp EL e EEE SmallPreheater tca 1194 02 aito IT J Using your mouse TC3 31194 02 A grab the bar and Ta 3119 02 u run the bar left to Tes 3119 02 unt ar right to test airflow sATD 3337 and heat PATO 2421 accordingly PATO 2368 PATO 24 20 PATO 24 43 PATDS 2435 PATDE 2374 Yacc 0 02 vf 0 00 ann u 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 XL and may caus
24. PR ZAM APR XLRP APR TCP APR JS APR XAM APR YAM APR DCPS APR XLPHK APR XLPHB APR XLPHRTD APR XLMC APR SSR APR EMIPCB APR SVCA APR XLABK APR EBK APR CALKITXL APR 5000 XL Vacuum Pick Up Kit APR 5000 XL Theta Rotation Motor APR 5000 XL Pneumatic Cylinder Head APR 5000 XL Z Axis Motor APR 5000 XL Reflow Pump APR 5000 XL Thermocouple Panel APR 5000 XL Joy Stick APR 5000 XL X Axis Motor APR 5000 XL Y Axis Motor APR 5000 XL Dc Power Supply APR 5000 XL Preheater Kit APR 5000 XL Preheater Blower Set Of 2 APR 5000 XL Preheater Rtd Set Of 2 APR 5000 XL Motor Control APR 5000 XL Solid State Relay Set Of 2 APR 5000 XL Emi Circuit Board APR 5000 XL Split View Camera APR 5000 XL Action Button Kit APR 5000 XL Enable Button Kit APR 5000 XL Calibration Kit Page 109 of 114 23 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 OK International MX 500 Series Rework System with blade 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 s patented Smart Heat Technology ensures that tip temperature is constantly maintained regardless of the thermal demand of the assembly that is being reworked For more information on OK International Smart Heat Tec
25. R 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 E ee ee ee ee ee el eae ee a re ec ee en a ee a a er ee a Ve Page 11 of 114 13 10 APR 5000XL and APR 5000XLS Users Guide 7000 1590_D Page 12 of 114 Main Unit Components Figure 1 and Figure 2 LED Power Indicator Reflow Head Composite video output Computer RS232 cable input Open Frame adjustable printed circuit board holder Next Button Enter Reflow Head Up Action Button 2 button operation 1 on each side of casting Reflow Head Down Action Button 2 button operation 1 on each side of casting 9 X amp Y Axis Enable Button 2 button operation 1 on each side of casting 10 Type K thermocouple inputs 5 11 X Y amp Theta Adjustment Control 12 Main Power Switch 13 Camera amp Lighting assembly 14 Nitrogen input 15 Circuit breaker 16 Main power cord 17 Flow meter head 18 Cooling fan Se Ae eS 3 Set Up Procedures The main unit is very heavy Please uncrate the unit with 2 people DO NOT LIFT THE MAIN UNIT BY THE PCBA BOARD HOLDER RAILS LIFTING BY THE RAILS WILL DAMAGE THEM Das Basisgerat ist sehr schwer Bitte nur mit 2 Personen auspacken HEBEN SIE DAS HA UPTGERAT NICHT AN DEN SCHIENEN AN UB ESCHADIGUNGEN ZU VERMEIDEN Page 13 of 114 APR 5000 XL XLS Main System Prior to performing initial set up unpack all accessories from their shi
26. This completes small heater flow rate calibration Page 90 of 114 Camera TE Temperature Calibrations Closed loop options Security Software Calibration Test Airflow Profile Top Heat Reflow Aurflow High Medium Low Bottom Heat Preheat Large To achieve 5 knots speed on Airflow Flow Meter the slide bar must be greater than 80 Bottom Heat Preheat Small Airflow 11 Now to set large bowl heater flow rate cover center cone for small heater to stop airflow going into this chamber with small metal disc supplied Cover Disc Page 91 of 114 12 Now use calibration fixture with flow meter to the left of the machine as shown Do not forget to close the center hole and open the hole under the flow meter as shown 13 Adjust the large heater flow rate to read five knots the same as small heater Five knots is 500 feet per minute 14 Vary the Bottom Heat Preheater Small airflow until the airflow setting on the Turbo meter reaches 5 0 knots See below When this is done save settings This completes small heater flow rate calibration Page 92 of 114 Vary airflow speed Medium until airflow setting Low reaches 5 0 knots This will be between 70 80 Airflow 85 x System Setup is Camera TE Temperature Calibrations Closed loop options Security Software Calibration Test Airflow Profile Top
27. ange the profile during the record mode and get the profile right the first time around To make changes during a process simply right click your mouse on one of the 10 temperature bars five for Top Heat and five for Preheater and drag the bar into the desired position This feature allows the end user to modify existing processes as well Duare SUG secur Slated ANETTE Temperature Setting Bars When the profile has been determined proceed to Save the profile To save the profile the end user must press Finished To Save T C plots you must EXPORT the profile Page 45 of 114 Notes 8 Manual Mode Setup mode that allows the end user to import existing thermal plots not Processes and operate the APR 5000 XL manually Click on No Password button and enter the APR password 1923523 Click Software tab and then enable in the Manual Mode option Page 46 of 114 Metcal APR5000 05 0 Fi oystem Setup xl Security Software Process File amp Operator Selects Last Used p 2 Default Browse Serial Port m Measurement Units Inch xi En gt Temperature Units COM3 Centigrade Fahrenheit COM4 Manual Mode Enable Disable Action Prompt _ Nitrogen Tee C Enable Disable Cancel Go to APR 5000 XL Main page and click on Process Setup Metcal APR5000 L 1 02 File Edit View Help Process Run Process Setup J System S
28. arge preheater PCB Desc C Small preheater Process Setup f Profile Vision Page 25 of 114 In this window an option to enter information is prompted It is highly recommended that the Yes button be clicked and data be entered in each of the three fields This information will be viewed in Process Run when this particular file is opened WW Metcal APR5000 L 1 02 Process Info Cup Nozzle Camera Vision Initialize cup and reflow nozzle during Process Run and create a custom user prom User Prompt Attach vacuum cup and reflow no Select Next continue Cup Part Number Nozzle Part Number Select Yes to attach vac geeveneaneneey Process Setup ee lt Back Next gt Cancel Ms By selecting Yes information keyed in re Me User Prompt Cup Part Number and Nozzle Part Number will display below Os NY 300s 400s 500s 600s Grad amp Temp Process File Process Type Removal J Component Ref Preheater Large a Mstart 4 S KI MMetcal aprsoooxL M APR 5000 xL Software U RR 10 58 am After entering the required data click Next and proceed to Camera The APR 5000 XL software will automatically switch to the Vision screen The following information is now available to modify e Head Speed Coarse and Fine Adjustment e Lighting Controls Top amp Bottom e Camera Focus e Camera Zoom Page 26 of 114 Thi
29. atable measurements 3 Open System Set Up by clicking System Set Up 4 Click on No Password button and enter the engineer s APR password 1923523 and return File Edit View Help Process Run Process Setup CI i ck Profile Camera Calibration CHK System Setup Security Software TE Hardware Here for Profile Vision ie NoP d System 2 gt asswor perator SetUp OO ULC O pt O n r Engineer Password Enter Confirm Station ID Type in 1923523 5 This will kick you out to the APR process page again To begin calibration open System Set Up again by clicking System Set Up This will open Calibration Screen 6 Click TC tab to begin process Page 81 of 114 W Mekcal SPR SOO u Msystemsetup ie TC Temperature Calibrations Closed loop options Test Security Software Calibration Airflow Profile Camera Calibration Procedures de Off Click this option to Head Alignment open thermocouple calibration Optical 7 The APR 5000 XL software is now in calibration mode DO NOT ADJUST AT THIS POINT 8 Connect the Omega Thermal Injection Meter to TC1 thermocouple input on the top right and turn the meter on and set the meter at 200 C Set in the ON position Page 82 of 114 9 Using the slide bars slide the bars in the or to set the monitor and meter to the same temp
30. ation Tool Allen Keys Procedure 1 Turn APR 5000 XL unit on and boot the APR 5000 XL Software 2 Open any standard placement or removal process per the instructions in this manual 3 Once a process has been opened click on Vision Metcal APR5SOOOXL 1 02 File Edit View Help Vision Camera Nozzle He Select method of lifting component C Retract vacuum tube C Raise head ve ow Do not remove Process Setup 4 View the image on the monitor If the image of vacuum cup is not central to the nozzle proceed to the next step Centering of VAC Cup is set to one side 5 If the nozzle is not centra r heater screws located on the bottom of the heater head and slightly move the heater head into position Page 79 of 114 Bottom View Screw Holes 6 Ifthe nozzle is not complainer to the PCB insert the small Allen key into one of the three holes located on the inner ring and adjust This provides the end user with an angular adjustment of nozzle to PCB Bottom View Adjustment Screws N i ET VE GERT GET OE E EE Sg x Notes 14 APR 5000 XL Thermocouple Calibration Page 80 of 114 Tools Required Thermal Injection Meter Convection Thermal Calibration Thermocouple Thermal Calibration Fixture for XL Procedure 1 Turn APR 5000 XL unit on and boot the APR 5000 XL Software 2 Run a default profile without taking to warm up the machine inside to get repe
31. ault Reason Solution No video picture Hauppauge Disconnected Connected Video Cable into back of computer integrated Hauppauge card No monitor picture VGA cable connected to Connect to horizontal video incorrect out put card See computer connection procedures in this manual Page 102 of 114 incorrect procedure in this manual noisy yellow plug thermocouple Damaged thermocouple Replace thermocouple a Thermocouple is not Attach to PCBA using attached to the PCBA or Kapton tape component Reflow Head is shorting Raise head off wires thermocouple wires Preheater plot not reaching Fan or heating element Check all four heaters and set point large preheater failed blowers for large bowl See the software test tab window Blower speed is set too low Using airflow calibration procedure check blower speed See the software test tab window Preheater plot not reaching Fan or heating element Check both heaters and set point small preheater failed blowers for large bowl See the software test tab window Blower speed is set too low Using airflow calibration procedure check blower speed See the software test tab window Component moves on Excessive air set point in Adjust Puff Off in Process placement Puff Off Setup to achieve placement without removing component Range is from 1 MS to 1 thousand MS Unsuccessful component Check solder reflow Check Reflow at removal removal temperature Eutectic or point PD
32. can result in a risk of fire or electric shock Safety and EMC Information Declaration of Conformity TUV Certified 89 336 EEC EN61326 1 1997 EN 55011 CISPR 11 1998 FCC CFR Part 15 Subpart B EMC Standards Europe North America 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 interference 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 Page 6 of 114 e Consult the dealer or an experienced radio TV technician for help Specifications Input Voltage Power Consumption System Total Pre Heater Large Configuration Pr
33. controller in the direction you need the reflow head vacuum tube to turn Controller Top View OP Page 19 of 114 4 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 XL system 1 Set the APR 5000 XL Main power switch to the on position Turn on the controller 2 On the desktop Double click the Oki icon To begin operation first turn the APR 5000 XL on and then launch the software After the system has initialized and the head has homed three options will appear on the primary software page Process Run Allows end user to open and use a current or saved profile Process Setup Allows the end user to design Place and Remove profiles System Setup Allows for verification and calibration of APR 5000 XL Primary Software Page A A 8 SI meter arson v Page 20 of 114 Window Options and Features The following Window Options and Features are available in all Process Setup windows File Options in File are limited and are self explanatory with the exception of Export and Import The Export and Import functions allow the user to export or import thermal profiles from a saved file This function is the only way thermal plots can be saved and e mailed from machine to machine WE Metcal SPR50002L 71 02 File Edit View Help Process Run d System Setup Frocess Setu
34. d Stencil Plate Page 111 of 114 Dip Transfer Plates The application of high viscosity paste flux can be accomplished with OK International s 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 OK International 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 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 Place your component into the component pick up plate and pick it up with the vacuum pipette Using the joystick align the component in the X Y and Theta axes 5 Remove the adjustable component fixture and replace it with the flux transfer plate 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 zZ axis UP buttons to return the component to the focus position Remove the component pick up plate and inspect the impression left in the f
35. e Heater Small Configuration Reflow Head Circuit Breaker Pre Heater Base Temperature Control Type Maximum Source Temperature Reflow Head Large Pre Heater source temp Small Preheater source temp Airflow Control Supply Optional Nitrogen Input Nitrogen Operating Spec Component Handling Maximum Size Minimum Size Maximum Weight PCB Handling Capability Maximum Size Maximum Thickness Vision Maximum Field of View Maximum Magnification system Dimensions Estimate WxDxH Weight 200 240 VAC 50 60 Hz 20 AMP single phase 3700 W 2800 W 1400 W 550 W 15 AMP 15 AMP Closed Loop Control RTD Sensors 400 C 842 F 350 c 662 F 350 c 662 F Preset to 8 16 amp 24 l min Self contained pump Standard Feature Not to exceed 65 PSI 4 7 BAR 55mm x 55mm 2 2 x 2 2 1 0mm x 1 0 mm 0 040 x 0 040 55 g 0 92 oz 622mm x 622mm 24 5 x 24 5 6 0mm 0 240 55mm x 55mm 2 2 x 2 2 10 55X 914mm x 914mm x 711mm 36 x 36 x 36 100Kg 220lbs Page 7 of 114 Warranty One year parts amp labor 90 days heaters amp lamps System Part Numbers Part Number Item Description APR 5000 XL XL Array Package Rework Sys with Standard Vision APR 5000 XLS XL Array Package Rework Sys with Split Vision APR M17 APR Monitor 17 Flat Panel APR CNTRL EN APR Controller English Version APR CNTRL SP APR Controller Spanish Version APR CNTRL JP APR Controller Japa
36. e a Process Run failure When any tests or adjustments are done and the test window is closed a grey reset window will appear This is normal when resting the APR 5000 XL software Notes Page 58 of 114 10 APR 5000 XL Head Alignment Procedure The Head Alignment procedure details the correct process necessary to center the image and vacuum tube in the center of the monitor This process consists of two process must be finished before the Optical Calibration procedure These steps are Vacuum Coplanar Calibration and Head X Y Calibration Vacuum Coplanar Calibration Tools Required VNZ 12 Vacuum Nozzle Glass Optical Calibration Tool Allen Keys Procedure 1 Turn APR 5000 XL unit on and boot the APR 5000 XL Software 2 Open System Set Up by clicking System Set Up W Metcal APR5000 File Edit View Help Process Run Process Setup Profle Camera Calibration CHK Click Here for System Setup Security Software TC Hardware System Set Up Profile Vision Paii O ptio n No Password Operator Engineer Password Enter Confirm Station ID Type in 94025 3 Click on No Password button and enter the APR password 94025 4 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 Page 59 of 114 P Metcal APR5000 Security Software Airflow
37. entative for information and availability Custom sizes and styles are available Page 110 of 114 Solder Paste Application using the Component Stenciling Templates 1 2 Select the correct solder paste plate for your component and application Position the component onto the component side of the plate the side with the smaller cut out or etched component corners 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 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 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 Using the vacuum pipette lift the component from the solder paste plate and continue with your alignment process Two types of paste deposition plates exist 1 2 To print on balled devices these are called BST plates Balled stencil template To print on flat components such as LLP or LGA Land Grid Array this is the only recommended way to rework these type of parts as different volumes of solder paste need to be applied to the component pads this is done with this plate called BRP Plates Body recognition plate Type 2 Body Recognition Plate Type 1 Balle
38. erature 200 C When this done channel 5 is calibrated Mi a1 APR SULLA I i Temperature Calibrations Closed loop options Security Software Calibration Test Airflow Profile Camera TC Shifts Shit TCI 1 0 Oo oe Using your mouse lt tl _____ _ oT aie Ne Shit TC3 40 slide bar and move in the O or to set TC1 to E Ve 200 C L O Shift CJ so m Cancel 10 Repeat steps 7 9 to calibrate TC2 through TC5 Note Offset only updated when Apply and ok buttons have been pressed Notes Page 83 of 114 15 APR 5000 XL Reflow Head Airflow Calibration Tools Required NZA 490 490 Nozzle In Line Air Flow Meter Procedure 1 Turn APR 5000 XL unit on and boot the APR 5000 XL Software 2 Open System Set Up by clicking System Set Up 3 Click on No Password button and enter the engineer s APR password 1923523 and return Metcal APR5000 File Edit View Help Process Run Process Setup Profile Camera Calibration CHK Click System Setup Security Software TC Hardware Profile Vision Mode Here for No Password System rn ____ un Set U p Engineer Password O pt ion Enter Confirm Station ID Type in 1923523 4 This will kick you out to the APR process page again To begin calibration Open System Set Up aga
39. es If the calibration mirror is not parallel to the reverse mounted metal plate loosen the adjustment screws as necessary and adjust the head manually until the mirror is parallel to the reverse mounted calibration tool Top two screws adjust front to back motion for front and rear They act as lock down screws so the bottom screws must be loosened first Loosen bottom two screws and adjust the side to side movement Grasp the head and manually moving it into position Refer to the picture below Page 63 of 114 Top two screws adjust front to back motion for front and rear They act as lock down screws so the bottom screws must be loosened first Loosen bottom two screws and adjust the side to side movement Grasp the head and manually moving it into position Note For a final test lower the glass stencil plate to the reverse mounted tool release the glass stencil and attempt to pick up the plate If aligned correctly the steel vacuum pipette will pick up the component Adjust as needed 13 When the glass stencil plate is parallel to the reverse mounted Optical Calibration tool tighten the lock screws and reassemble font cover to APR heater head Notes Page 64 of 114 APR 5000 XL Pickup Nest Coplanar Adjustment The Pickup Nest Coplanar Adjustment is critical for accurate placement of the component as it determines where the component will be picked and where the rotation of the component w
40. ess Info System setup Process Setup Use Action Buttons Print Instructions Ctrl F se Up Down Buttons 25 mils Print Profile window Eeri pi Print Vision Window r start Bee Advance Export Exit Pick the desired thermal plot from your thermal plot library that you have developed ie Metcal APRSOOOZL 71 05 05 File Edit wiew Help m m good profile profile goodploks profile qgoodplots profile goodplots profile nogoodyviking profile secondtry viking profile small bow teste profile thermalsmallbou1 profile u profile C z a amp al m My i em FS My Network P Files of type Profiles profile Cancel soge Once the thermal profile has been chosen the profile will automatically appear in front of the Manual Mode Window Page 50 of 114 Hirita APA SEMMOG FOSOS Pie Cae Ves iiae thermalimalll ural pirihi ETTUBEFETTUEEFTTSELELTU CERES EEE SR ESRC EE ELLI EE EER SR CE SE EE SRR ECE ER PR ee i Click and Grab on the actual plot line AA AR Tmel Te Tmed Tme5 Timet TmerT Tem When the thermal plot is on the screen as shown above use your left mouse key and grab the thermal plot and slide it into the Manual Mode Window When the plot is properly grabbed from an actual plot bar a small Profile glyph will appear At this point slide the Profile glyph onto the Manual Mode Window and the profile
41. eteeteeeeueceeseeessesaeeeeeceseeeaetaeeeeeeas 53 10 APR 5000 XL Head Alignment Procedure 2220240220020000000nnno non nn nnn nenne nnn een 59 11 APR 5000 XL Optical Calibration Procedure 22u222022002002000n0 nn nnnnnnenne nennen 70 12 Centralization of Vacuum Nozzle in Software WINdOW cccccsecceeceeeeeeteeeeeeseeeeeenaes 76 13 APR 5000 XL Quick Nozzle Co planarity and Vacuum Nozzle Adjustment 80 14 APR 5000 XL Thermocouple Calibration cccccecceccceeceeeeeeteeteeeeeeteeeeseceeeeeeeeeteeees 82 15 APR 5000 XL Reflow Head Airflow Calibration cccccccsseceeeseeseeteeeseeteeeeeseeeteesees 85 16 APR 5000 XL Preheater Airflow Calibration Small and Large 022 02 20 88 17 APR 5000 XL Head Thermal Calibration 22u22202202200220200 Rn nnn nenne nennen 96 18 APR 5000 XL Large Preheater Thermal Calibration cccccccceccseeceeeteeeeeeeeeeeeeeeeees 99 19 APR 5000 XL Thermal Calibration of Small Preheater 2202200220220 22220 102 20 Trouble Shooting Grid amp Error MESS GEG ccccccceeccececeecceecaeecaseceeeceeeceeseuesaeeseeens 103 21 Nozzles Vacuum Pickup Nozzle And Accessories ccccceeceeeeeeceeseeseeeeeeeeseeseeeees 108 22 Calibration Kit amp Spare FS on een 110 EFT A een OR a 111 A ee Pla SERVER E EE 114 25 Technical Suppo
42. etup Profile Vision Type in the necessary information such as Chip Package Component Ref location of component on PCB and PCB Desc PCB description and choose the amount of heating your PCB needs by either picking Large preheater or Small preheater Page 47 of 114 Wu Metcal APRSOOOKL 1 02 File Edit View Help Initialize Process Info Cup Please enter the following information for this process Process Setup Chip Package Component Ref Large preheater PCB Desc C Small preheater Profile Vision In this window an option to enter information is prompted It is highly recommended that the Yes button be clicked and data be entered each of the three fields This information will be viewed in Manual Window ONLY ne See Process Info Vision Camera acuum cup and reflow nozzle during Process Run and create a custom 6 User Prompt Attach vacuum cup and reflow no Sel Cup Part Number Nozzle Part Number gensenenseneen u 5 By selecting Yes information keyed in Pe NSS Ne re User Prompt Cup Part Number and Nozzle Part Number will display below 100C mn 400s 500s 600s Os 20g 300s Grad amp Temp Time 3 Time 4 Time 6 i 0 Process File Process Type Removal Yacuum Cup PN Nozzle PN Chip Package Component Ref EEE 10 58 am Preheater Large start 4 S SI MMetcal aprsoooxt v1 iw
43. g Qing Street Beijing Economic amp Technical Developing Zone Beijing 100176 P R China Tel 86 10 67878490 Fax 86 10 67878491 OK International Japan Co 5 3 1 Heiwajima Ota ku Tokyo 143 0006 Japan Tel 81 3 5753 0085 Fax 81 3 3765 8855 OK International D3 302 Lok Upavan Phase II Glady s Alwaris Road Majiwade Thane West 400601 Maharashtra India Tel 91 22 25396047 Singapore OK International Sales Support Office 1 Temasek Avenue 27 01 Millenia Tower Singapore 039192 Tel 65 67263914 Mobile 65 9798 4443 65 94874276 Page 114 of 114
44. g allows the end user to quickly change the profile during the record mode and get the profile right the first time around To make changes during a process simply right click your mouse on one of the 10 temperature bars five for Top Heat and five for Preheater and drag the bar into the desired position This feature allows the end user to modify existing processes as well Page 43 of 114 Temperature Setting Bars When the profile has been determined proceed to Save the profile To save the profile the end user must press Finished When this has been accomplished proceed to Save the profile To save the profile the end user must press Finished The New Placement Process is now complete 7 Modify Existing Process Modify Existing Process allows the end user to modify any Removal or Placement process This simplifies the process and allows multiple component types to be removed from the same PCB Follow the prompts on the screen and modify the data as needed Click Next to release the component Page 44 of 114 Follow prompt on the screen to Create Profile W Metcal APRSOOOXL 1 02 File Edit View Help Camera Nozzle Height Lift Profile is running Select Stop to abort Process Setup Peosssnuunsenussnssunsnunsnsnense Cycle Advanc Profile Vision Profile Elapsed 4 seconds 400C Profiling during a process is allowed This on the fly profiling allows the end user to quickly ch
45. gin calibration open System Set Up again by clicking System Set Up This will open Calibration Screen 6 Click Temp of Reflow Head to begin process Page 95 of 114 Metcal APR5000 mi oystem Setup 21 Security Software Calibration Airflow Profile Camera Aue Temperature Calibrations Closed loop options Test Calibration Procedures Off Flow Preheater Flow Reflow Head Temp of Preheater Temp of Reflow Head Click this option to open Reflow Heater Head Cancel Apply oc Os 100s 200s 300s 400s 500s Process File Grad amp Temp Process Type Placement eee Y T T T T 7 Attach NZA 490 490 nozzle to APR Reflow Head 8 Place Convection Thermal Calibration Fixture and thermocouple probe in place connect thermocouple probe to input three as shown below When located central to window close the box window slide Connect Thermocoupl 0385019 035019 e probe to LS Page 96 of 114 9 Follow the prompts and center the thermocouple as shown below This must be done to ensure accurate temperature reading Make sure t c is in the center of the calibration window as shown this should be marked for repeatability with the mechanical stop Locate thermocouple in exactly the center Also vertically open as in photo 10 Follow the prompts on the monitor through the auto calibration process 11 Thermal graph should look sim
46. he base action buttons and control stick Proper understanding of the Reflow Head movement is necessary It is recommended that the end user become familiar with the X Y and Theta controller to optimize use and avoid any movement errors that may occur during a standard process run Page 17 of 114 A caution The X Y amp Theta controller is not dependant on the software and is operational when the APR 500 XL base is powered up Die X Y amp Theta Steuereinheit ist nicht von der Software abh ngig und ist betriebsbereit sobald das APR 5000 XL Basisger t eingeschaltet ist X Y and Theta Control Xand Y Controller Action Button Xand Y Controller Action Button X or Y Axis Head Movement Depress the yellow Enable button on either side and point the controller in the direction you want the reflow head to go You need only press one of the two controller Enable buttons These are located on either side of the APR 5000 XL casting and allow for ambidextrous use The movement of the head is proportional in direction and pressure This allows for diagonal movement at any grade and speed NOTE Theta movement is disabled when the yellow enable button is depressed Page 18 of 114 Y Axis Movement Controller Top View Fine Theta Adjustment Fine Theta adjustment is done when the yellow Enable button on either side are NOT depressed This allows for fine movement with minimal touch Simply turn the top of the
47. hnology please contact your local OK International representative or visit www OK International com for more information The following blade style tips are available for the OK International 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 OK International 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 application of new solder paste or flux directly to the component s solder balls can be accomplished with OK International s 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 OK International repres
48. ilar to this for reflow nozzle Metcal APR5000 File Edit View Help Align Camera Nozzle Height Calibration RH Create Profile Temp of heater Select Start to begin the profile lt Back Next gt Cancel Started 2002 08 26 13 41 52 Profile Vision Duration 1754 seconds Process File Temp Process Type l 1752 347 696 1049 1393 Yacuum Cup PN 101 0 2 152 0 1 203 01 254 0 1 305 Nozzle PN Chip Package TC1 Component Ref PCB Desc TES 72 0 2 150 0 1 201 01 251 01 301 Page 97 of 114 18 APR 5000 XL Large Preheater Thermal Calibration Tools Required NZA 490 490 Thermocouple Probe Convection Thermal Calibration Fixture Procedure 1 Turn APR 5000 XL unit on and boot the APR 5000 XL Software 2 Ensure the heaters and thermocouples are at room temperature 3 Open System Set Up by clicking System Set Up 4 Click on No Password button and enter the engineer s APR password 1923523 and return Metcal APR5000 Process Run Process Setup Profile Camera Calibration CHK Click System Setup Security Software TC Hardware Here for Profile Vision m Mode No Password System ang Operator Seabee ed NE LE ai pans es ais pis Baie Be Set Up r Engineer Password Option Enter Confirm Station ID Type in 1923523 5 This will kick you out to the APR process page
49. ill occur If the pickup point is not established before proceeding the calibration routine may not yield the desired results Tools Required Large Vacuum Nozzle Calibration Fixture Allen Keys 1 Drive the motor head down to the PCB pick up point and pick up the centered mirror 2 Follow the prompts on the screen 3 Drive motor up until the head is above the centering fixture Pull out the camera Page 65 of 114 Pull out slide and loosen pick up point lock down screws Lock Down Screws are located opposite each other on the camera for optimum adjustment Lock Down Screw Page 66 of 114 5 Adjust side to side as needed and front to rear as needed with mirror near the pick up point as a gauge This side does not adjust Front to Rear Adjustment Page 67 of 114 6 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 Page 68 of 114 Rotational Error of Picture in Monitor Adjustments Image rotated in screen Q kd a 2 s e 2 PREEZ TPES 4 Yu nu u m ZZ eeeeae ww m m m SED gt EAE SLEDE TZ ESZES 6 oo 6 eeeaetsoan doe ese eeoeoeooeose ees eeeeosveetd eos oe 0 9 9 oe oe 4 oe s ep 8 pP 2 2 2 PB 2 ne This can be adjusted by loosening top locking screw Then making very small adjustments to the leveling screw on the underside of camera box When
50. in by clicking System Set Up This will open Calibration Screen 5 Click Temperature Calibration Page 84 of 114 Metcal APR 5000 ad Click iL 2x Here for Security Software Calibration Airflow Profile Camera Temperature Calibrations Closed loop options Test System Set U O tion ss p Flow Preheater C Flow Reflow Head Calibration Procedures Temp of Preheater Temp of Reflow Head Click this option to open Flow Reflow Head calibration Cancel 6 Open Calibration Screen and Click on Flow Reflow Head to set reflow head airflow The APR head will be in the home up position Click OK to begin calibration 7 Attach the NZA 490 490 without vacuum cup to the head assembly 8 The vacuum calibration gauge is permanently mounted on the rear to APR 5000 XL Locate this meter before proceeding See next page for details Notes Page 85 of 114 Rear View 9 Toggle through the instructions and calibrate air flow meter and the APR 5000 XL software to the following specifications APR 5000 XL Factory Setting Software LOW 8 liters Medium 16 liters High 24 liters 10 Follow the APR 5000 XL Software instructions prompts 11 Flow Reflow Head Airflow Calibration is now complete Continue to the Pre heater Calibration Procedure Notes Page 86 of 114 16 APR 5000 XL Preheater Airflow Calibration Small and Large Tools Required Air Flow Gauge Fixture C
51. ke to perform C Manual Type in the necessary information such as Chip Package Component Ref location of component on PCB and PCB Desc PCB description and choose the amount of heating your PCB needs by either picking Large preheater or Small preheater Page 31 of 114 Wu Metcal APRSOOOKL 1 02 File Edit View Help Initialize Process Info Cup Please enter the following information for this process Chip Package Component Ref Large preheater PCB Desc C Small preheater Process Setup Profile Vision In this window an option to enter information is prompted It is highly recommended that the Yes button be clicked and data be entered each of the three fields This information will be viewed in Process Run when this particular file is opened Camera Vision User Prompt Cup Part Number Ba Nozzle Part Number e By selecting Yes information keyed a ee ee E EE ai in User Prompt Cup Part Number and Nozzle Part Number will display below Related info such as Flux or solder paste type can be entered fos se he under User Prompt D Os Time1 Time2 Time3 W APR 5000 XL Software U Ez agag 10 58 am Process File Process Type Removal Yacuum Cup PN Nozzle PN Chip Package Component Ref Desc Preheater Large Mstart A e I Metcal APR 5000 X After entering the required data click Next and proceed to Camera
52. l z ALL NM 398 1 300C Se ae a ee i ee oo EE me oc en ee E a E 200 0 ue ee Or Oe x i Ct 100 0 Data from temperature and time lines er ee N 200s 300s rad amp Temp PT TTT Tp Component Ref BGA 169 DEMO Timell Time 0 p Heat oo TEI PCB Desc DEMO PCB a Preheater Large Cut Copy Curve 100s Process File Process Type Removal Vacuum Cup PN YNZ 12 Nozzle PN NZA 270 270 Chip Package BGA 169 The Cut Copy Curve option allows the end use to copy a given profile line and superimpose it on another profile This option allows can be used to verify an existing profile and test the APR 5000 XL performance over time To activate this copy option right click your mouse pointer on the target line you wish to copy When activated an option window will appear in the middle of the monitor screen and prompt the end user to pick from one of the seven curves They are as follows Page 30 of 114 Panom Tiea e TC1 Specihy the curve to cub copy e TC2 TC3 Bottom Heat e TC4 ne e Top Heat 6 New Placement Process Go to Main Process Setup Window and click New Placement Process W Metcal APRSOODO L 71 05 05 File Edit View Help Process Setup Choose the action you would li
53. layed on the graph WE Metcal APRSOOOKL 71 02 File Edit ie Help Profile Time Display f w Profile Elapsed Froces Fata Table Display Profile Remaining fone Elapsed Process Setu P Zone Remaining System Setup Profile Vision Data Table Display Allows for end user to change the data collected Metcal APRSOO0O amp L 1 02 File Edit View Help Profile Time Display gt Ee ya u Data Table Display f Gradient and Temperature Gradient Only Proces Process Setu 5 Temperature Only System Setup f Profile Vision Where are these changes displayed on the graph These change data format This data is always present during a thermal profile plot and is located on the bottom right side of the screen Profile Live i 400s 500s Time i Displa Time y res III a nw 4 D ii Data Table TCA b Pr Data from Temperature Display and Time lines Page 23 of 114 5 Getting Started To begin using your APR 5000 XL system click Process Setup to begin designing your Removal or Placement process In this part of the software information is recorded and saved as a file for use in Process Run Note A saved profile can be opened and used in this mode however the added steps required to drive part ofthe program will make your common removal or placement tedious Remember this mode is primarily for profile design and not repea
54. lux to ensure all the solder balls have been coated 8 Check component alignment and adjust as required 10 Follow the screen prompts push in the camera and click next Place the component as directed by the screen prompts and continue with the placement process that you have selected Flux Dip plates BGA and CSP Page 112 of 114 24 Warranty And Service Contact your local authorized Ok International Representative or Distributor for details 25 Technical Support Contact OK International offers Hot Line service Please contact your nearest OK International office for technical support EHER 205 Westwood Ave Long Branch NJ 07740 equipment 1 877 742 TEST 8378 Fax 732 222 7088 N ET salesteam Tequipment NET European Headquarters OK International Ltd Eagle Close Chandlers Ford Hampshire SO53 4NF U K Phone 44 0 23 8048 9100 Fax 44 0 23 8048 9109 Germany OK International GmbH Frankfurter Strasse 74 D 64521 Gross Gerau Germany Phone 49 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 Tel 33 0 4 72 26 20 30 Fax 33 0 4 72 26 20 35 Page 113 of 114 Italy China Japan India Dover Italy S R l Strada Statale 11 No 28 20010 Vittuone Milano Italia Phone 39 02 9025161 Fax 39 02 90111147 OK Electronics Beijing Co Ltd No 1 Building A 10 Lon
55. m pump Ve ELIE SmallPreheater ae Airflow Click The vacuum 31194 02 tube will retract Da are Tene Pipe Cy Te Off Off oe Me 2368 ibe zi F DWI D Free N Camera T Power LUp _ LOn j Eig Small Click When the button is depressed the vacuum tube is extended and locked Click this button to check for component release air pressure This has no minimum or maximum specification 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 me u Notes Page 56 of 114 Notes Temperature Calibrations Closed loop options Camera TC Security Software Calibration Test Airflow Profile Digital Input Rewlow Head UP Action Buttons T Down Action Buttons Next Button IM Head Home switch T Head EOT switch IW Head Safety Switch IY Solenoid Lock switch IY Camera Home switch Camera EOT switch I Overheat hw 110 220 Airflow 0 00 el f N20f Heater C NZL Bupass NEM M2H Temp Click to turn on power to TT camera MainPreheater Airflow Analog Input C 36 37 Tel 31194 02 TC2 31194 02 TC 31194 02 TC4 31194 02 TES 31194 02 HATO efi SATE 39 27 PATO 24 21 FRO 23 68 PATOS 24 20 FRTO4 24 49 FATOS 24 35 FRAT
56. n When done with adjustments press Next and proceed to Lift In Lift the option to lift the component during the removal process is provided This option was designed to allow for a three distinct processes that are used in rework Retract vacuum tube Designed to minimize adjacent component heating that may occur after removal Raise head Designed for use with high I O removable such as large BGA components or CBGA Do not remove Designed to self center components that have slightly skewed but not bridged or reflow cold solder joints WE Metcal APRSOOOSL 71 02 File Edit View Help Vision Camera Nozzle He Frocess Setup Select method of lifting component C Retract vacuum tube C Raise head f Do not remove nn Fr Follow prompt on the screen to Create Profile During the Create Profile run two key buttons are visible One is Stop and the other is Cycle Advance Stop allows the process to be aborted before a profile has been created Cycle Advance allows the end user to cycle to the next zone Page 28 of 114 WE Metcal APRS5OOOXL 1 02 File Edit view Help Camera Nozzle Height Lift Process Setup Profile is running Select Stop to abort PPPPLLPLTPPPPLFLLPLLEPFPPFLPFFLRFER Cycle Advanc Profile Vision Profile Elapsed 4 seconds 400C When this has been accomplished proceed to Save the profile To save the profile the end user must press Finished The
57. nd the basic operation of your APR 5000 XL XLS Array Package Rework System This manual is intended as a guide to the operation of the software The software itself provides users prompts and along with training will guide the operator in use If any problems should occur during setup or operation of your system contact OK International s Technical Support Department at experts okinternational com or refer to section XVII of this manual for the nearest local OK International Representative This OK Internatioal APR 5000 XL XLS Array Package Rework System provides both accurate component placement and specifically tailored reflow profiles through OK International s 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 XL XLS 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 motorized fine adjustment permits fine X Y Z and theta adjustment at up to 50X magnification Finally the part is placed and the vacuum is released automatically After acc
58. nese Version APR CNTRL TC APR Controller Traditional Chinese Version APR CNTRL SC APR Controller Simplified Chinese Version APR CNTRL KR APR Controller Korean Version APR CNTRL FR APR Controller French Version APR CNTRL GR APR Controller German Version Required for APR 5000 XL and APR 5000 XLS system Environmental Conditions all models Suitable for indoor use only at altitudes not exceeding 6500 ft 2km All systems must be grounded 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 210 VAC Pollution degree 2 per IEC 644 Insulation category II Vision System The APR 5000 XLS system provide split field image system to allow corner crossover on large components a maximum four sided view of 55mm x 55mm 2 2 x 2 2 The camera magnification has a range of 10X to 55X optical zoom Page 8 of 114 Shipping Data 48 W x 48 D x 48 H Size Weight 340 Ibs 154 KG 1 Introduction and General Overview Thank you for your purchase of a OK International APR 5000 XL XLS 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 Instruction Manual is a valuable resource It explains the systems options features specifications a
59. ntation supplied by the Controller Manufacturer make all the necessary 9 connections Connect the controller to the APR 5000 XL utilizing the supplied RS 232 cable Connect the video output from the APR to the video input on the controller utilizing the supplied RCA video cable and S Video adaptor When powering the system please use the following startup sequence Power on APR ii Power on the Controller iii Initialize the APR Software When powering down the system i Close the APR Software ll Power down the APR iii Power down the Controller This controller is for APR operation ONLY and is not meant to be a network computer Even though it will operate on a network it is not recommended This controller MUST NOT be locked while APR software is in use as this will shut down the I O and causes the controller to lose connection with the APR which may cause damage to your product and or the APR machine NEVER turn on the screen saver or power management options as this may cause a loss in connection between the controller and the APR machine NOTE If you receive a communication error at anytime reboot the computer and the APR and reinitialize the startup sequence Mouse and Keyboard Machine RS232 cable ne se NOLL NAL ns OA oz ale no Internal Hauppauge video card Video In video output card i a SS Controller Connections Page 15 of 114 Final Power up Sequence Attach an a
60. ons FH 25 mils i Bown E wi po oe Process Setup Page 39 of 114 Note OK International s patented reflow nozzle allows the nozzle to touch the PCBA with minimal clearance from the nozzle body 010 This increases thermal efficiency and reduces spacing issues that may exist The reflow nozzle can also reflow components when spaced up to 3mm from the PCBA This can be very helpful when reworking densely packed PCBAs Click Next to release the component Follow prompt on the screen to Create Profile Metcal APR5OOOXL v1 02 File Edit view Help Nozzle Height Lift Camera Process Setup Profile is running Select Stop to abort Profile Vision Profile Elapsed 4 seconds 400C When this has been accomplished proceed to Save the profile To save the profile the end user must press Finished Pickup with flux dip Process Click on Pickup with flux dip and the Component window will appear Focus on the PCB pads When in this window follow the prompts place the centering fixture into position Wu Metcal APRSOOOKL v1 07 File Edit View Help Cup Nozzle Camera Pickup Method Move forward centering fixture Insert plate or nest and set component pickup height 25 mils Profile Vision Ele Down Vision Control Panel When the fixture is in position and component oriented follow the prompts on the screen Use both coarse and fine adjustments to place the vacuum
61. onvection Thermal Calibration Fixture Turbo Airflow Meter Procedure 1 Turn APR 5000 XL unit on and boot the APR 5000 XL Software 2 Open System Set Up by clicking System Set Up 3 Click on No Password button and enter the engineer s APR password 1923523 and return Metcal APR5000 E Fe File Edit View Help Process Run Process Setup Profile Camera Calibration CHK System Setup Security Software TC Hardware Click Here for Profile Vision m Mode System Set Up No Password Option Een _ F Engineer Password Enter Confirm Type in 1923523 Station ID Cancel 4 This will open Calibration Screen and Click on Temperature Calibration to set pre heater airflow Page 87 of 114 Metcal APR 500 Security Software Calibration Airflow Profile Camera Ente Temperature Calibrations Closed loop options Test r Calibration Procedures Off Flow Preheater Flow Reflow Head Temp of Preheater C Temp of Reflow Head Click this option to open Flow Preheater Calibration Cancel 5 Select large or small heater for airflow calibration ik Metcal APR5000 L 1 05 06 File Edt View Help Flow of Preheater To start calibration procedure press Next C Small preheater Profle Vision 6 Open Calibration Screen and Click on Flow Pre heater to set pre
62. p Print Instructions Ctrl F Print Profile Window Erl E Export Import T Edit Options in Edit allow the end user to copy the actual screen as a screen print or as a profile image only Also the end user can modify the type of curves and Temp Time lines Metcal APRSOOOXL 71 02 Copy Window File Edit View Help screen prints the Cut Ctrl x F entire Image on Copy Ctrl C screen Copy Window Tkr Save Window Image CErl 5 Paste Cr Curve Options Tempi Time Line Options Save Window Image allows the end user to copy the profile image only Page 21 of 114 Curve Options Select Curve to be modified Curve Options Curve engl Display Hame Select Curve name style Dash dot dot oe Iv Visible width and color width FRE 1 idthsf 1 are always solid Color Select Cancel Apply Temp Line Options a Temp Time Line Options Select Line to be Line ene modified Select line style width and color Cancel Apply View Options in View allow the end user to change data viewed during recording or during use The two modifiable items are Profile Time Display and Data Table Display DE Metcal APRS5000XL v1 02 File Edit view Help Profile Time Display Proces Data Table Displaw Process Setup System Setup Profile Vision Page 22 of 114 Profile Time Display Allows the end user to change the time as disp
63. pping containers Ensure that your APR 5000 XL has arrived complete by verifying that all of the accessories listed in Section II of this manual have been included After all components are located setup can then begin e Remove the APR 5000 XL 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 XL Rework System has been factory assembled and calibrated Recalibration is not necessary after initial setup However verifying Airflow 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 Controller and Software Setup System Requirements To run the APR 5000 XL XLS you will need the following PC with Pentium Ill 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 4X AGP video card or equivalent 17 Monitor 28dpi 1280 x 1024 optimal resolution Windows 98 2000 or Windows NT operating system Internal Hauppauge Note To optimize screen use and vision resolution must be set at 1280 x 1024 Page 14 of 114 Computer Set up 1 Unpack the controller and all its accessories 2 Using the docume
64. ppropriate power plug to the stripped end of the power cord Use recommended power plugs e Nema 6 20 e Nema L6 20 IEC 60309 Use the following diagrams together with the manufacturer s recommended procedure for hooking up wires to a power plug MPORTANT Before connecting the machine to power you will need to determine the voltage at the wall socket Use a basic AC voltmeter to do this task Below are three different diagrams showing some basic wire configurations for the US These are not necessarily showing what configuration you will see Please have a qualified electrician wire in the machine Configuration 1 Measure from X to Y This measurement should always be 208VAC to 240VAC 2 Measure from G to X This measurement will be 110VAC 125VAC 3 Measure from G to Y This measurement will be 110VAC 125VAC 115VAC 240VAC 115VAC NEMA L6 20P Page 16 of 114 Configuration 2 1 Measure from X to Y This measurement should always be 208VAC to 240VAC 2 Measure from G to X This measurement will be 0 VAC 3 Measure from G to Y This measurement will be 208VAC 240VAC 0 VAC 240VAC 240VAC NEMAILG 20FP 1 Set the APR 5000 XL Main power switch to the on position 2 Turn on controller 3 On the desktop Double click the Oki icon Your APR 5000 XL Series Rework System is now ready for operation Using the Main X Y amp Theta Controller All Reflow Head movement is driven and controlled by t
65. roubleshooting Section of the the movement of the camera Operator s Manual 2 Ensure the serial cable is properly connected to the communications port on your computer 3 Ensure the serial cable is properly connected to the APR 5000 hardware 4 Ensure the Camera Box cable is properly connected 5 Ensure the APR 5000 hardware power is on 6 If you still experience problems please contact Technical Service Printer Error X See 1 Ensure the printer is properly connected to Troubleshooting Section of the the computer Operator s Manual 2 Ensure the printer power is turned on 3 Ensure there is an adequate supply of paper in the printer 4 Ensure the printer has adequate printing material ribbon toner etc 5 If you still experience problems please contact Technical Service Section of the Operator s Manual Operator s Manual OK International Technical Service help in resolving your system malfunction Page 105 of 114 Page 106 of 114 21 Nozzles Vacuum Pickup Nozzle And Accessories Nozzle NZA 490 490 IAPR Reflow Nozzle 49mm x 49mm Vacuum Pick Up Nozzle S O Accessories O FL APR 2 PCB Finger Long Pack 2 Page 107 of 114 VAC PI00 Vacuum Assist Plate double sided Kapton plate Qty 100 Page 108 of 114 22 Calibration Kit amp Spare Parts Listed below are the calibration kit and spare parts that are available for your APR 5000 XL Rework System APR XLVPUK APR TRM APR PAC A
66. rt COMA nn 114 Page 3 of 114 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 User s Manual before installation or operation of the APR 5000 XL XLS Heed all warnings on the system and in the operating instructions Vor Installation oder Inbetriebnahme des APR 5000 muss die gesamte Bedienungsanleitung gelesen und verstanden worden sein Beachten Sie alle Warnhinweise am System selbst sowie die Sicherheitshinweise in diesem Handbuch Use of the APR 5000 XL XLS 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 XL XLS do not operate until proper training has been obtained Das APR 5000 darf nur zum Entl ten und Platzieren elektronischer Komponenten auf Leiterplatten durch entsprechend geschultes Personal eingesetzt werden Wenn Sie mit dem ordnungsgem en und sicheren Betrieb des Systems
67. s 1000s Process File preheat yellow fixture apr5000 Process Type Placement 1005 198 398 598 798 Yacuum Cup PN at Nozzle PN 27 04 100 0 2 150 0 2 200 0 3 250 Chip Package TC 59 03 99 02 147 0 3 202 0 3 254 Component Ref Bia lies ciate a ee cre cc sissy asia esc Page 100 of 114 19 APR 5000 XL Thermal Calibration of Small Preheater Tools Required NZA 490 490 Thermocouple Probe Convection Thermal Calibration Fixture Procedure 1 Position the thermal calibration fixture as in photograph below Close corner calibration hole and open center calibration hole Page 101 of 114 Check central position of thermocouple to the calibration hole 2 Run thermal calibration for small heater and save setting by clicking Finish in software window During all calibration of heaters control air changes in room due to door or air condition changes in temperature This now completes the thermal calibration of the machine Note All offsets are saved into the machine and not the PC so a record should be kept of the offsets in profile window and can be save by print screen or copy and paste If new calibrations are done the old readings should be checked against the new and if any major differences occur this should be looked into as heaters may be getting old or reflow pumps These offsets are your calibration data for ISO9000 references 20 Trouble Shooting Grid amp Error Messages Troubleshooting F
68. s button allows the end userto modify the programmed height in Process Run K WE Metcal APR5000XL v1 02 Fie Edit view Help ee Vision Camera arzt Height ur nt f P Proce Set reflow nozzle height t F Coarse Use Action Buttons Enable operator control during process I mils ee ae C Fine Use Up Down Buttons Up Down Up lt Back C Profile Vision an E Vision Control Panel Head Speed Coarse and Fine Adjustment Allows end user to alter speed of head during a process Lighting Contral X amp xujp Top Lamp Bottom Lamp Lighting Control Allows end user to alter light setting to achieve optimum lighting for a given component m Camera Control Focus Allows end user to alter focus to achieve optimum visual on component Zoom Allows end user to alter zoom to achieve optimum visual on component o BD m p DE ee Restore Defaults m Copy Window screen prints the entire n image on screen Save Image saves picture l as a J PEG file Page 27 of 114 IMPORTANT All movements are recorded during Process Setup As a result any and all mistakes will appear in the Process Run A way to avoid editing Process Setup programs each time an error is discovered is by clicking the Enable operator control during process run This will allow the end user to modify the programmed height in Process Ru
69. sition Page 71 of 114 6 Pull camera out and zoom up to see picture below Focus in on the bottom calibration plate using focus control on software then drive head down to bring vacuum cup and calibration plate into focus Do not touch focus control again 7 Follow software prompts 8 Pick up top plate 9 Drive above camera and verify focus of bottom to top fixture 10 Use fine Z axis head control to adjust top plate in focus Do not use software focus control Only use the focus control to focus on the bottom plate Use lighting controls to see top then bottom plate clearer Example of unit Out of Calibration 11 Adjust the optical adjustment screws located on the side of the camera until the component image overlays the calibration plate image The screws should be turned in a clockwise direction to adjust prism if left loose the prism will not be held tight and may result in un repeatable placement errors as prism may move in camera movement The three screws are set in a triangle and a combination of the three screws will calibrate the calibration plates perfectly if care is taken Page 72 of 114 Optical Adjustment Screws Note The prism adjustment screws are adjusted as needed to overlay the top and bottom gun sight images Each of the three screws can be adjusted as needed to achieve this Camera shown is APR 5000 XL version 12 Follow the directions on the screen 13 Once the two plates are optically
70. tcal APRSOOOXL 1 02 File Edit View Help Cup Nozzle Camera Pickup Method Move forward centering fixture Insert plate or nest and set component pickup height 25 mils Process Setup Profile Vision Vision Control Panel When the fixture is in position and component oriented follow the prompts on the screen Use both coarse and fine adjustments to place the vacuum cup onto the component When the component is in position and the head is lifted up from the fixture remove the centering fixture and click Next Using the up and down keys on the APR 5000 XL system lower the head until the component has come into view and the over lay image of the component is directly above the solder pads Focus on the component Focusing Process Dim the component lamp top lamp Focus directly onto the PCBA and zoom into view Dim the PCBA lamp bottom lamp and increase lighting on component Using the action buttons drive the head down until the component comes into full view Do not adjust focus Focus will be driven by the height of the component Once bit the component and the PCBA have been set increase the lighting on the PCBA Eur oe re Your view should be in focus now Page 34 of 114 Oo Component Overlay zn aaa EB ZB ZH 2 D Vv d 2 3 Solder Pads D G g EE MEIITEIIILIETZ f SEE ELLE EL TZI EZ S ZEIT EE LE Z LU ZZ ES ZZE EEE RRR EE BeREBREBREREBREREA
71. ted use Process Setup Guided process development Not intended for repeated operation Process Run Intended for repeated operation of a developed process End User can be provided with minor fine adjustment privileges Choose from one of the following options e New Removal Process Setup mode for creating a removal process for shields BGA CSP and micro SMD components e New Placement Process Setup mode for creating a placement process for shields BGA CSP and micro SMD components e Modify Existing Process Setup mode for modifying an existing placement or removal process for shields BGA CSP and micro SMD components e Manual Setup mode that allows the end user to import existing thermal plots not Processes and operate the APR 5000 XL manually W Metcal APR5000ZL 1 05 05 File Edit View Help Process Setup Choose the action you would like to perform New Removal Process C Manual This feature allows the end user to toggle between the Profile and Vision Page 24 of 114 New Removal Process Type in the necessary information such as Chip Package Component Ref location of component on PCB and PCB Desc PCB description and choose the amount of heating your PCB needs by either picking Large preheater or Small preheater Wu Metcal APRSOOOKL 1 02 File Edit View Help Initialize Oo f Cup Please enter the following information for this res Chip Package im Component Ref L
72. urate 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 five zone full convection 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 pro file 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 Page 9 of 114 Ay 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 Seien Sie wahrend des Betriebs des Gerates vorsichtig Wird das System fur einen anderen Verwendungszweck eingesetzt kann es zu ernsthaften Personensch den kommen Lesen Sie diese Bedienungsanleitung vor der Inbetriebnahme sorgf ltig A caution The main power cord is a means for disconnecting the APR 5000 XL XLS from an operating energy source Equipment must not be positioned in a
73. uts are not to be altered or tested coc u Page 54 of 114 System setup ees Physical ly pull Temperature Calibrations Closed loop options Camera Our Security ar Calib l Test pa Profile ty oftware albrat on eS wHo rotile Check mark Digital Input Fewlow Head toggles from UP Action Buttons pore 000 Camera Home T Down Action Buttons se switch to Camera 5 es N20 Heater EOT switch I Head EOT switch C NZL Bypass C NEM M2H Temp IW Head Safety Switch IY Solenoid Lock switch IY Camera Home switch Camera EOT switch Overheat MainPreheater i 110 220 Airflow 0 00 Inputs are not to be altered or tested cet u Notes Page 55 of 114 System Setup 2x Temperature Calibrations Closed loop options Camera TC Security Software Calibration Test Airflow Profile Digital Input Rewlow Head UF Action Buttons T Down Action Buttons Next Button IM Head Home switch Head EOT switch IY Head Safety Switch IY Solenoid Lock switch IY Camera Home switch Camera EOT switch I Overheat hw 110 220 Airflow 0 00 Click this button to check for vacuum pressure at the pipette If the vacuum pressure is low or cannot lift a component check the vacuum hoses and J f N2Of Heater i NZL Bupass C NEM M2H Temp Motor is at idle 0 00 Md ainPreheater Airflow Analog Input MEERE vacuu
74. zu m mo MWEEEBHKELIKIZIHZIH ee eee ee ed PEZES BEEE E ES If the image is not over laid correctly press one of the yellow buttons located on either side of the APR 5000 XL body and using the joystick orient the component into position ee e w g TFE ESEESE e E E a amp eo m a ee m u As prompted focus the PCBA and use the UP Down keys to place he component in focus Page 35 of 114 Using the action buttons lower the head into position Use the Coarse button to lower the component to the PCB The head will lower to approximately 2 inches form the PCB At this point you will need to click Fine to continue Proceed until the component has touched the PCBA and the component is in position Adjust reflow nozzle height using the same up and down keys Metcal APR5SOOOXL 1 02 File Edit View Help ve Vision Camera Set reflow nozzle height W Ei 25 mils Process Setup Note OK International s patented reflow nozzle allows the nozzle to touch the PCBA with minimal clearance from the nozzle body 010 This increases thermal efficiency and reduces spacing issues that may exist The reflow nozzle can also reflow components when spaced up to 3mm from the PCBA This can be very helpful when reworking densely packed PCBAs Click Next to release the component Follow prompt on the screen to Create Profile WS Metcal APRS5OOOXL 1 02 File Edit view

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