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14mb - Air-Vac Engineering Company, Inc.

1. S S 12 SOF mc M 12 POD i 13 TOC MOOC AV SION TON 13 7 7 Operator Issues US MEE rv M 14 BOC XP ur 14 15 745 Operator P asa ayasa 15 DRS24C Series Manual Page 1 Section 7 Operator Training 7 Operator Training 7 0 Introduction The intent of this section on Operator Training is to provide a structured process to assist the operator in becoming familiar with the DRS24 Hardware and Software In addition to this information operator training must be supplemented by formal training from a qualified individual The DRS24 software is Windows based When the module is powered it automatically boots to the customized software Extensive software knowledge is not required The graphics interface is based on symbols icon or word buttons for operator functions Operators use the software to run pre tested pre approved profiles Automatic steps and helpful prompt messages provide clear operation Password protection restricts access to high security areas Software Basics Cursor The cursor looks like an arrowhead It is d
2. Z Move ABS Air C mm Z Move REL A Do Not Move Nitrogen Site Cleaning Noz Vac J Probe Time Motion Power Events Vision Lights Video Shwt Cool Air Injection ES r Alert v Speech Device Nozzle Separation s Control Miscellaneou Pulses Message nozzle to above board position R sensor Force System Units Actual Dest Range s Zero Force El Placement Removal J Auto Adjust W Display Only Diffuser System L Temp C R Temp C Low Low Disable Standard If ERROR Stop Process High Be High Average L R Temperature Single DRS24C Series Manual Page 43 Section 6 Software 6 2 1 6 Thermocouple System The Thermocouple system allows the operator to program process control thermocouples K type maximum of 8 This system provides the operator with several control options Monitor Skip Stop and Maintain These control options can be used in a variety of ways to monitor control or thermal profile applications Thermocouple control options can be changed from event to event Process Control Options e Monitor B This control option monitors a thermocouple channel during the process cycle Skip This control option monitors a thermocouple channel during the process cycle In additio
3. amp 9 amp o m LI m ES _ a 4 m 1057021 1057022 m ES 6 9 Le 9 e j e a T D Note Selected file names are temporarily 10 object s selected 75 8KB A copied into memory Copying Files ZW View Tools Help Undo Delete When all the necessary files have been selected click on the Edit menu followed by the Copy option cu Hor Lic CHEESE 77 pue Click on the pull down list box which should currently be Paste Shortcut displaying the Profiles folder This list box will expand to Select All Chl show all of the available choices Invert Selection E profiles Desktop Insert a formatted floppy disk 53 My Computer E Es Floppy 2 E Disk Adjust the list box upward until the 3 12 Floppy A drive 15 displayed 7 windows Click on this entry to activate the floppy disk drive J profiles Control Panel a Printers EN view Tools Help Fiecycle Bin Undo Copy x After activating the floppy disk drive the list box will collapse to a single line display Next iiis select the Edit option from the menu followed by the Paste option This will copy the selected files to floppy disk Select All Invert Selection The Copying message will be dis
4. nie Seperation HR Cleaning System ww 7 Acteal Sessor acum Pange us ure Ha iim se BAT Ferce Placemeat System Fisag Desi pasan snae P ien ee EX EX Farce Auto Adjust Display System select L Duan Syotem sum R ofr kk ped Temp C to 400 with tame Poe High selected I C F 5 T High Time 069 F Papam i Add Subtract Data C EERROR Sep Proce F Average Temp Single Tema Inc 06 e Click on the Teach icon to save e Click on the Thumbs up icon 3 Install nozzle and board Locate nozzle to bga position 4 Start the cycle Bring the nozzle to just touching the bga 5 Periodically manually activate the nozzle vacuum to remove the bga The process should take approximately 2 4 minutes Care should be taken not to prematurely remove the bga which may result in damage to the pads If unsuccessful the flow and or temperature settings may need to be adjusted 6 Turn off the vacuum with a collect
5. 128 129 63 Videos Screen 130 133 OG Reset Cycle Counter MENT psss 134 DEUD Mee E E E 135 140 05 Reset ODOEHIOE uui ODIT HE ERI 141 69 Protected System Security Access 142 145 6 10 Software Release Notes Summary III 146 DRS24C Series Manual Page 1 Engineering Company Inc AlFe VA C 30 Progress Avenue 203 888 9900 Seymour CT 06483 203 888 1145 DRS24C Version 4 43 Release Notes May 2004 New Modified Files File Action DRS24 Z Use c windows drs24 system buildx bat to install MESSAGE TXT Copy into c windows drs24 system overwrite the old file 00000023 DRS Copy into c windows drs24 profile NOTE A Backup should be performed before upgrading to any software version System Requirements 32 mb of Ram memory General Release Theme Air Vac WEB site Profiles build function for IR and K type settings Lead Free Profile setting Increase maximum profile limit to 9999 Vacuum removal sensor Site cleaning motion limit Increase IR sensor calibration range Item 1 Auto Build Screen IR probe indicator Problem In previous version the software incorrectly set the IR thermocouple indicator when
6. 24 dec MOS T ACPI NS HL IDEE QUOTES nO 25 2 0 site Solder Removal System 41015 00 OTT cisstexeeeses ense eeebev vs ese vae saeva eb ee 26 DRS24C Series Manual Page 1 Section 3 Installation 3 Installation CAUTION Pneumatic and electrical connections described in the following sections must be done prior to powering on the DRS24 3 0 Installation of Standard Machine Hardware 3 0 1 Pneumatic Connections Top and Bottom Heater Upper Heater Pneumatics e Connection A 1 4 diameter hose 1 8 male fitting e Pressure Setting B 80 psi adjust as required C e Air Nitrogen Consumption 3 scfm Bottom Heater Pneumatics Connection D 3 8 diameter hose 1 4 NPT male fitting e Pressure Setting E 60 psi adjust as required Air Consumption 25 scfm intermittent Double Diffuser 20 scfm intermittent Single Diffuser F C Bottom Heater Pressure Adjustment Upper Heater Push down to lock after setting it at 80 psi Pressure Adjustment Push down to lock after setting it at 80 psi E B A D IMPORTANT REFER TO SECTION 2 FOR FACILITY REQUIREMENTS OF DRS24 DRS24C Series Manual Page 2 Section 3 Installation 3 0 2 Electrical Connections External Cables Cable Connections Footswitch into Cycle Start Port A on back of module Trackball 9 pin connector B Monitor 15
7. wa we mam wp sa Ww Rats 0 bev Joint Hamp Cisl a n430 4 21 de SS eo So IET ele ce po ke T rper Artiaga Day r pep _ 3 38383 Ej 4f Note Upon entering the primary TST screen the system will automatically initialize the process parameters user adjustable to default setting These settings represent a good starting point The TST will adjust if necessary DRS24C Series Manual Page 92 RUNNING THE PROCESS SETTING THE CYCLE PARAMETERS Ei 69 xe ne Select A Nozzle Flow Rate uk Lan aua ren MRSS Pept gt 1 Use the nozzle EET NM ELE r rea rmn HH Ces rna rm flow rate help button r came to select the nozzle part number being used Dans Ada T Beare oe Hozzle Length gt 2 The flow rate will be automatically selected by double clicking on the nozzle part number Fa ta Pa Pa Pa Pa Option The user can also manually enter a flow rate for non standard nozzles or A5
8. F1 F2 20 fast 151B 9002 04 053 F4 F3 F9 4A BK AGC fast 149A T 9002 04 033 F4 F5 10A BK AGC fast 150A 9002 04 018 F6 BK MDL slo 1468 E 9002 04 038 220V ac Diff B right F7 BK AGC fast 147C caw 2 9002 04 031 F8 BK AGC fast 146C F7 9002 04 054 220V ac liaht 14 5V ac F10 1ABK AGC fast 1478 caw To 9002 04 015 2 Amps J1 Internally fused 6 3 A PS1 d bin Vision cube driver E 7 axis driver Solenoids x8 220V ac ower suppl I Bc ue Cooling Fans x2 I TB x4 Light tower Relay card 5 Amps PS2 F6 22 ac MASS FLOW CONTR 5 B power supply 15 4 Amps P PS3 uu on ard drive 220 2 mother board w cards 6 30 98 O O microscope lights 9 SUPPIY Speech module v8601 F10 Force Meas system O O Light tower 1 Amps DRS24C Series Manual Page 5 Section 10 Schematics 10 2 3 Power Wiring Block Double Diffuser 220 VAC DRS24 Power Wiring block Double diffuser 20 Amps 5 A 5 Amps Jl F1 F8 220V ac F2 controlle 20 Amps Diff A left controller Diff B right controller 4 Amps is 220V ac Top heater element F1 F2 KTK 20 fast 151B F4 9002 04 053 9 BK AGC fast 149A 2 Diff A left 9002 04 033 element F4 F5 10 BK AGC fast 150A 9002 04 018 F6 BK MDL slo 1468 9002 04 038 220 Diff B right F7 BK AGC fast 147C o X 35 2 9002 04 031
9. Speech Be Cool Air Injection Device Nozzle Separation Alert Message nozzle to above board position R sensor F Syst Dest Range s 0000 00 Zero Force El El El Placement Removal Auto Adjust W Display Only Diffuser System L Temp C R Temp C Low Low DD Average L R Temperature Single CDibable Standard Replace C Add Subtract Data If ERROR Stop Process DRS24C Series Manual Page 44 Section 6 Software 6 2 1 6 1 Thermocouple Action Radio Buttons The Teach screen provides the operator with the ability to quickly adjust or repeat an edit operation the information contained in the thermocouple control table This can be accomplished by first entering the desired information into the Data edit box Next the operator must select the required Action A radio button Replace Add Subtract The Add button uses the Data edit box value to increase the selected table field The Subtract button uses the Data edit box value to decrease the selected table field The Replace button uses the Data edit box value to overwrite the selected table field Note These Action adjustments can be quickly applied by positioning the cursor over the desired table field and clicking on the right mouse button Note The operator has the option of typing directly into a table field Thi
10. devices ZI Ih FL Nozzle Control Flow 26 000 DRS24C Series Manual Page 93 RUNNING THE PROCESS SETTING THE CYCLE PARAMETERS Eurer Toa 1 ra qa Fom Camel TA Fi Tess EMEN Ea ES ECL ee rua gs NE r T md Three thermocouples must mm mm be attached to meet the E minimum requirements Board Control 1 EU Target Start Max 090 060 120 gt 1 One thermocouple must be defined to measure the board temperature This sensor must be connected to T C 1 Device Top 2 fix gt 2 One thermocouple must be defined to measure the top of device temperature This sensor must be connected to T C 2 3 One thermocouple must be defined to measure the device joint temperature When multiple 3 thermocouples are selected and connected to 3 Wn dr 44 device joints the system will average results before making any control decisions 25 Dev Joint Ramp C s TIC 6 Average Actual 7 88 Adjacent Device s Independent Max 150 TC 3 TIC 45 7
11. eI IAE MT 2 TTD IU TUTTI 2 3 124 5 COMMUMCAIONS PTODIOBissses saeesusucsosesuveuu suos ds 4 22 Noor 02192 60090410494 4 12 3 Nozzle Does Not Pick Up Component 4 1206 4 12 5 Motor Driver Communication 5 4 12 6 Machine Alarm Conditions amp Alarm 5 9 L Force Problems E a 10 12 48 Printer and Voice Card 10 DRS24C Series Manual Page 1 Section 12 Troubleshooting 12 Troubleshooting 12 0 Troubleshooting 12 1 No Heat 12 1 1 Nozzle Heater If the upper heater is not putting out any heat run through some of the items on this list Verify that the process profile has not been inadvertently saved with no heat in that event Verify that the incoming air line 15 still connected Look for problems with the lines Verify that the incoming pressure is set for 80 PSI on both the Nitrogen and Air inputs to
12. v DRS24C Users Manual Part No 0024 00 160 Air Vac Engineering Company Inc 30 Progress Avenue Seymour CT 06483 Telephone 203 888 9900 Fax 203 888 1145 e mail solder sales air vac eng com Web WWW air vac eng com DRS24C User s Manual Part No 0024 00 160 Rev 03 01 www air vac eng com Section 1 Introduction Getting Started Table Of Contents I Introduction Getting Started LU ERS I IOy Yi 2 2 2 DRS A Unpack M 4 13 DRS24 Material Checklists DRS24C Series Manual Page 1 Section 1 Introduction Getting Started I Introduction Getting Started 1 0 DRS24 Overview The DRS24 represents Air Vac s latest technology for SMT rework and low volume assembly Considerable time has been spent in an attempt to provide in depth instructions in regards to the unpacking installation verification operation and maintenance of this system However due to the technical complexity of this system Air Vac and or its trained sales representatives must be involved with the installation and training of your new system Do not attempt to power up this system on your own If you have any questions please do not hesitate to call Air Vac Engineering Company Inc 30 Progress Avenue e Seymour CT 06483 e Tel 203 888 9900 e Fax 203 888 1145 e mail solder sales
13. Graph Process Information mf x1 Date 02 16 98 14 29 Temperature vs Time 500 0 450 0 400 0 o 3500 5 300 0 5 5 2500 2000 1500 Cycle Start 50 0 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 03 36 10 24 14 12 12 00 Event Time Profile Time Board O j e Install the NCAL 1 Temperature Calibration Nozzle into the machine e Plug the nozzle thermocouple into channel 1 e Click on the Cycle Start icon A to start the profile The profile will run a scaled sequence of various temperatures and flow rates and will plot the Upper Heater temperature red line and the NCAL 1 Nozzle Temperature green line After the initial scale up sequence the profile executes a cool down stage and then scales up the temperature and flow rates a second time This is necessary to insure that the machine has been properly heated prior to verifying the temperature accuracy DRS24C Series Manual Page 5 Section 4 Verification Allow profile to run when complete click on Export History this saves the graph and data points to the Export directory for analysis e Thumbs up out of profile go to Control Import Graph Data Scroll DAT files in upper box to last file it should be a Temp Scale Testing DAT file Double click on this file so graph is displayed Now click on uppe
14. 4 TIC 6 TIC 8 Option lf critical adjacent devices must be protected the operator can select and monitor these critical temperature locations Note A maximum of 6 sensors be used to measure Joint and or adjacent device temperatures DRS24C Series Manual Page 94 ACTIVATING THE THERMAL SMART TRACK TST CYCLE mE Cee H mamami HR eoe AER FS De ON HD Ne CU BR em res c Click on the cycle start button M MN AUAM to activate cycle TST cycle PF mm T wi uj amp rir Paz iris 4f Note The user can not make changes to the parameter set during the TST cycle Note Erroneous thermocouples can be unchecked discontinued feedback influence to provide a more true indication of the joint or adjacent temperature average 4f Note Sensors do not need to be checked to be graphically or digitally displayed A check should only be used when control feedback is required Reference Message Click On The Start Button To Begin Process Reference _ Cycle Process Control Decision Procedures The system will perform an automatic iterative process cycling and rule based thermal optimization In addition prediction algorithms are implemented to provide the system with
15. File Replace 1 This folder already contains a called 0000004 Would you like to replace the existing file AF 3 FT1KB modified on Monday March 09 1995 11 31 34 with this ane E 1 modified an Monday HM arch 09 1338 11 31 34 Yes to All Cancel DRS24C Series Manual Page 22 Section 6 Software 6 1 8 About DRS Options Contral Mew Save The About screen contains general information about Air Vac Engineering and the current software version Print Profile Backup Restore File Maintenance Pad About DAS Air Vac Engineering Company Inc DR524 Software Version 2 10 3 Progress Avenue seymour CT 06483 U S A Phone 203 888 9900 Fax 203 686 1145 Copyright 1997 DRS24C Series Manual Page 23 Section 6 Software 6 1 9 Exit Options Control It is very important to shutdown the DRS24 system correctly Click on the Options Bor menu and select the Exit option This will close the DRS24 software and shut down any Save As active devices vacuum air flow etc The Windows 95 Desktop screen will be displayed Print Profile k Backup Restore File Maintenance gt Note Pad About DAS Click on the Start menu located in the lower left corner of the screen Select the Shut Down the Computer option Shut Down Windows Click on Yes Button to start W
16. present operator with Teach screen The Teach screen allows profile control parameters to be quickly and easily adjusted A control profile is developed by LE Process combining together simple events to create a complex motion and control sequence Events have any combination of 1 motion 2 device control or 3 time Events can be added or deleted based on the application s processing requirements Import Graph Data Teach Build Photo Links Vision and Nozzle System Pos Rate Temp C C Sec Be m ZMove ABS Air Z Move REL Not Move Nitrogen inch e XIN Site Cleaning Vac Probe Vision Lights Video Jog Time sec Motion Power Events Foot Time Alert Speech Ext Device Nozzle Separation Alert Pulses Message Force System Actual Dest Range 0 Cumas Zero Force El El E Placement Removal Auto Adjust F Display Only Diffuser System L Temp F Temp BD c nien Iv Average Temperature Single 6 2 1 1 Teach Screen Button Summary 6 2 1 1 1 Teach Event The Teach event button is used to temporarily save any current event adjustments 6 2 1 1 2 Insert Event The Insert event button allows the operator to temporarily add a ne
17. DRS24C Series Manual Page 22 Section 3 Installation 3 1 5 Network Card CAUTION The machine should be powered off during installation of this option The Network A 15 factory installed by Air Vac in slot 1 as shown and requires no installation e Connect either an RJ45 connector or BNC connector into the Network Ports DRS24C Series Manual Page 23 Section 3 Installation 3 1 6 Bar Code Scanner Installation CAUTION The machine should be powered off prior to installing this option e Connect Bar Code Scanner A into PC Wedge e Connect Computer Keyboard C into PC Wedge e Connect PC Wedge B into keyboard connector port on rear of DRS24 A 4 C OOOOOOOOOO OOOOOOOOO0 OOOOOOOOO0 To DRS24 Keyboard Connector Port DRS24C Series Manual Page 24 Section 3 Installation 3 1 7 Micro Stencil Adapter Installation The Micro Stencil Adaptor 15 installed in the DRS24 in exactly the same way as nozzle Open Nozzle Locking Jaws B and remove the nozzle if installed with the GNT tool e Install the micro stencil adaptor and close the locking jaws Install the Pattern Specific Stencil C on the Micro Stencil adapter Microstencils must be purchased directly from Mini Micro Stencil DRS24C Series Manual Page 25 Section 3 Installation 3 1 8 Site Solder Removal System Installation e Attach silicone tubing to Fitt
18. s lt RATER TS TE Q 4 Tighten theta mechanism 1 Loosen set screw of ring Q Press rod to left side Retighten set screw 4 lt 15456 5 SS S A A Wn in Cleaning of nozzle vacuum tube C Q Use the stainless steel brush STB7 to clean C DRS24C Series Manual Page 9 Section 11 Maintenance 11 0 2 Process Related Preventative Maintenance Supply clean compressed air or nitrogen Do not allow the lines to be changed by unauthorized personnel WARNING Unfiltered air can result in the following problems premature heater failure contaminated flow meter vacuum pump and moisture exhaust in electrical compartment Unregulated air will shut off solenoid too high pressure or will not allow heater to activate too low Air requirement 85 120 psi 20 scfm clean dry compressed air or inert gas Change the nozzle with GNT1 or GNT4 tools only DO NOT GRAB at the bottom of the nozzle as it will damage the gas nozzle opening e Store nozzles in tray Do not drop nozzles force the SMD into nozzle Damage will occur to the nozzle nest or component not apply excessive flux Consider fume extraction system Remove the arrows from repair components They stick to the inside of the nozzle Do not clean nozzle in cleaning solution or degreaser with vacuum cup still installed Do not run the proc
19. For Help click Help Topics the Help DRS24C Series Manual Page 133 Section 6 Software 6 6 Reset Cycle Counter DRS Software Application Opticns Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Thermal SMART Track System The Reset Cycle Counter menu allows the operator to clear zero the cycle counter The cycle counter controls the number of consecutive cycles that can be processed without interruption When the maximum number of cycles is achieved the system will generate an alarm The alarm condition will continue until the operator selects this menu option U S 1 O M E H N E DRS24C Series Manual Page 134 Section 6 Software 6 7 Setup Setup The standard Setup menu allows the operator adjust machine related setup or control D parameters These options are only available to high priority operators Idle Process Counters Customer and Network Groups h Operator Password A Message Message Title Vision System 6 7 1 Diffuser Idle Selecting the Diffuser Idle from the Setup menu will present the operator with the Diffuser Idle Control screen This screen allows the operator to adjust the temperature and flow Left Diffuser Temp Right Diffuser Temp rate for the diffuser system left right These settings are global and will control the diffuser during all screens except the Ru
20. 90 p 100 0 0 110 Nozzle o A Set Point KE K Jog Functions sioj x System Status Memory N2 Foot Sw Air Alarm Cycle Busy Force System Grams mnm Actual Click On The Cycle Start Button To Begin Process Graph Process Information Date 04 02 98 09 22 T emperature vs Time 500 0 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 0 00 00 Event Time peu Temperature 06 24 02 24 04 00 04 48 05 36 Profile Time Eug 00 48 01 36 03 12 Power l 6 2 2 4 1 Nozzle System 07 12 l Control 08 00 08 48 03 36 10 24 11 12 12 00 0 0 0 0 0 0 j Numerical Process Information The Nozzle System upper heater graphically displays A N the following control parameters 40 60 40 70 Nozzle flow rate percentage set point A 5 yellow needle 90 Nozzle flow rate actual percentage B blue needle e Nozzle target temperature set point C white B Nozzle a number Nozzle actual temperature D red number Nozzle temperature ramp set point ramp red Set Point Actual number 252 TI EM C D E DRS24C Series Manual Page 58 Section 6 Software 6 2 2 4 2 Diffuser System The Diffuser System bottom heater graphically displays the following control parameters Left right diffuser flow rate target set point A light blue text
21. Save As Save option also allows the operator to make a copy of an existing profile The Short name 15 always automatically updated incremented to the next available sequence number see Save option Backup Restore _ The operator can change the long name to reflect the new functionality of the profile He The operator has the option to move new profile to a different group Note Pad About CAS E il New link names can be added at any time Note The original profile remains unchanged and The Long Name will automatically be completely intact appended using the This helps to insure that the Long Name remains unique The operator should edit the long name to reflect the new functionality of the profile The Short Name will automatically be updated with a new unique name Save The Link Names for Soldering Desoldering and Site Cleaning will automatically be cleared Link Name Short Name 1064001 DRS Link Name Soldering Desoldering Site Cleaning Long Name PBGA 225 256 Removal 068 thick board N1081X1081 Customer Group Air Vac Engineering Company Board Group Library Device Group Arrays Warning The operator should be careful not to allow exactly a long name that already exists system will allow identical long names to exist in the profile library DRS24C Series Manu
22. Air Vac Engineering Company Profile NotePad Files 256 Site Cleaning 100 thick board N845X845 256 Removal 100 thick board N845X845 CBGA 256 Soldering 100 thick board N845X845 CSP 46 paste application directly on spheres N28DVG 3 CSP 46 Removal N28DVG 3 CSP 46 site cleaning 56100085 N28DVG 3 CSP 46 Soldering AFTER flux solder paste on sphere application N28DVG 3 PBGA 225 256 Removal 068 thick board N1081X1081 PBGA 225 256 Removal 100 thick board N1081X1081 PBGA 225 256 Site Cleaning 068 thick board N1081X1081 PBGA 225 256 Site Cleaning 100 thick board N1081X1081 225 256 Soldering 068 thick board N1081X1081 PBGA 225 256 Soldering 100 thick board N1081X1081 PBGA 352 Site Cleaning 068 thick board N1396X1396 PBGA 352 Removal 068 thick board N1396X1396 PBGA 352 Soldering 068 thick board N1396X1396 SBGA 432 Removal 100 thick board N1589X1589 Board Groups Demo Board Profile Library Device Groups Area Arrays Demo Board Customer Group Leaded Devices Engineering Company Board Group Profile Library Device Group rea Arrays To make a profile selection click on the desired entry File list box then click on the Ok button to open this file DRS24C Series Manual Page 11 After selecting a file system will automatically take
23. Hold use to set to 55d Hold and use set to rLY Hold and use set to uP SC Hold and use set to 1 24 Hold and use set to 11 21 Hold and use set to 0 0 Hold and use set to 0 0 Hold and use set to off Hold and use set to VAr Hold and use set to Ct A Hold and use set to 391 Hold and use set to nonE Y to DRS24C Series Manual Page 20 Section 11 Maintenance gt Cal 9300 Function Menu and Parameters Level Press Y to access lt Function Function Menu Parameter Press to access lt Function Instrument Address Parameter Press to access lt Function Baud Rate Parameter Press to access lt Function Data Format Parameter Press to access lt Function Debug Mode Parameter Press Y to Save and Exit Program Mode Hold and press 7 to set to Hold and use 7 to set address to 1 or 2 Hold and use 7 to set to 19 2 Hold and use 7 to set to I8NI Hold and use 7 to set to off DRS24C Series Manual Page 21 Section 11 Maintenance gt Cal 9300 Function Menu and Parameters Level 1 Nozzle Press Y to access Function Menu Press to access Autotune or Park Press to access SP1 Prop band Press to access Integral time Press to access Derivative time Press to
24. Hold and use set to 200 Hold and use set to 0 5 Hold and use set to off Hold and use set to 1 5 Hold and use set to 0 3 Hold and use set to 0 Hold and use set to off Hold and use set to Hold and use set to off Hold and use set to Hold and use set to 0 Hold and use set to 2 0 Hold and use set to on of Y to Section 11 Maintenance Section 11 Maintenance gt Cal 9300 Function Menu and Parameters Level 2 Press to access lt Function Hold and press 7 to Function Menu Parameter set to 2 Press to access lt Function Hold and use 7 to Read output 90 Parameter set to Press to access lt Function Hold and use Y to SPI Manual output 90 Parameter set to off Press to access P lt Function Hold and use Y to Limit SPI Output Parameter set to 100 Press to access Function Hold and use 7 to Limit SP2 Output Parameter set to 100 Press to access Function Hold and use 7 to Main SP2 Mode Parameter set to nonE Press to access lt Function Hold and use Y to Mone Second SP2 Mode Parameter gt set to nonE Press to access Function Hold and use Y to Display Resolution Parameter set to 1 Press to access lt Function Hold and use 7 to Set Scale
25. 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 03 36 10 24 11 12 12 00 Time Event Time Profile Time DE Power Board mm ZI Note active thermocouple channels must be connected to a thermocouple sensor before process cycle 15 started Failure to do so will result in an alarm condition DRS24C Series Manual Page 60 Section 6 Software 6 2 2 4 4 Force System Not available on the DRS24R This system monitors and controls the activities associated with component force placement force removal or force adjustment The Force System graphically displays the following control parameters e Force target set point A white number e Force actual B blue number Force range C white number Force System Grams A Set Point Actual Range Note During force controlled activity placement removal adjustment operator should not touch any part of the machine DRS24C Series Manual Page 61 Section 6 Software 6 2 2 4 5 System Status The System Status provides the operator with a quick view of the cycle status This section also informs the operator if the machine is waiting for a response from the operator The Memory display shows free memory available to the DRS24 software These values will decrease over time and the system will automati
26. 3 Hex Head Screws 8 x 1 Phillips Screws e Amanda Cap white 2 8004BW e Grounding Kit 1 SCI e Pelican Drawer 1 8230 File Rods 1 8230 1 e Pelican Drawer Hanger 2 8231 CRT Holder with Angled Keyboard Holder 1 SP2535BW Nozzle Rack 1 5 3909 CRT Swing Arm 2 8417BW e Universal Bracket 2 8420BW e Power Beam 60 Double Sided 1 8645BW Trim Column Outside 54 grey 2 8022G e Trim 26 Inside grey 2 8018G e Trim 25 Outside grey 2 SP3761 10 e Trim 20 Outside grey 2 SP3761 11 DRS24C Series Manual Page 12 Section 3 Installation Frame Assembly Step 1 NOTE I Note the orientation and distinction of Right and Left Table Support Assemblies as shown e NOTE 2 Assemble Front Foot Rest Bar to the Right and Left Table Supports first Right Table x Screw with Washer Rear Stabilizer Panel Support Assembly 6 places see NOTE 2 Left Table Support Assembly Front Foot Rest Bar Leveling guides 4 5 16 x 750 Screw amp Washer 4 places DRS24C Series Manual Page 13 Section 3 Installation Table Top Installation Step 2 see NOTE 2 NOTE I Place Table Top onto Frame as shown NOTE 2 Two people will be needed to screw the Support Beams into place NOTE 3 Top must be in place so the two Support Beams can be screwed into it NOTE 4 Install all column trim where indicated by aligning trim with the top of the column and pressing into
27. C Nozzle Control Device s Pretest C Max 125 150 newtans Antamatic Els Force Placement Hester Stabilize Ewent Position Target Range Temp PH Time rec AEL Move Pre kiptinn Heat Event Aemovad Temp Time ex Temp Time ser Removal REL Mowe The default parameter screen is available from the setup menu hidden menu Setup Diffuger General System Communication Limits and Defaults General System Thermal SMART Track Automatic Profile Build Machine Offsets Motion Force Measurement Nozzle Flow Meter Cooling Ring Flow Meter Aun Screen Displays Vision System DRS24C Series Manual Page 105 Reference Thermal SMAHT Track Parameters 1 Device Joint s e Target e CoolDown C e s e Min Soak lt e Max Soak C e Soak s 2 Process e Dev Top Ramp C s Target 3 Nozzle Control e Preheat 4 Board Control T C 1 e Target e Start C Max C 5 Device Top T C 2 Max C 6 Adjacent Device s Max C DRS24C Series Manual Controls device joint temperature reflow Controls device top temperature ramp Controls nozzle preheat temperature Provides a consistent starting temperature for the board and controls the maximum temperature Controls device top maximum temperature Co
28. Delete File FAILED Delete File Was Cancelled File Open Continue With Delete HISTORY Delete HISTORY Failed Delete HISTORY Was Cancelled WARNING The Run Graph History File FAILED Load Device Please Wait Hotor positions may be adjusted Click n The Cycle Start Button To Begin Process Open Nozzle Clamps Close Nozzle Clamps Low Pressure Detected Load Nozzle Nozzle Preheat Has Been Activated DRS24C Series Manual Page 139 Section 6 Software 6 7 8 Message Title This screen displays all system titles These titles can be adjusted to better meet the communication needs of all the operators If a language other than English 1s selected this file can be converted Title Hotepad Ic x Edit Search Help Help Message Warning Message DRS Software System DRS24C Series Manual Page 140 Section 6 Software 6 8 Reset Operator To reset the system access to the production environment the operator must reset the operator Click on the Reset Operator option on the menu bar and the Operator Registration screen will be displayed Log in again followed Operator Registration with your security access code to gain access to the DRS24 machine DRS24C Series Manual Page 141 Section 6 Software 6 9 Protected System Security Access To access the Protected System Menu Options the operator must click on the Air Vac logo with the right mouse button
29. WM VN Site Cleaning Noz Vac Probe H Time sec Moon v Power Events Velocity Accel 24 Velocity Vision Lights Video Jog 000 Foot amp Time 1 K Speech Ea Device NNozzle Separatio Miscellaneous Control J Alert 2 7 Engineering Training Profile Message Force System Units Actual Dest Range F s oe IN Placement Removal Auto Adjust F Displ O R Temp C E Replace Add Average Single O Disz C Subtract Nata C If ERROR Stop Procg Q O R L M U amp V DRS24C Series Manual Page 4 Section 8 Engineering Training 8 2 1 Event Counter The Event Counter A indicates how many events are in the profile as well as the event being currently displayed The engineering training profile currently has eight events and event 1 should be displayed currently e The purpose of an event can vary from simply conveying a message to controlling the heaters or moving the nozzle to place or remove a device e Click in the Motion box B and then on the OK button as prompted The nozzle will move up to coordinates it has been taught for event 1 which in this instance 15 0 0 e Event 1 simply informs the operator of the name of the prof
30. e hen select Thermal Attachment on the Build Profile e Any file name can be selected e he long and short name will appear on the Build Profile screen e The file will be attached to the Build Profile for further profile completion DRS24C Series Manual Page 124 Reference Backup Restore Thermal Sequence The Backup and Restore options have been changed to utilize the LONG file name This allows a user to copy profiles without the need to know the short file name Backup 5 I gs T wire PHEZA 27 mm Soldering LOGS inh Shc bord SO E dra mum aL dms Acmaval JE me pines Epl pe S D SCT IL I L i RIED 3 B E ec BOYD Y mm wes Jae ER 1 35 mm Hems Ee kek dat be imam 15 mm Cleo riz ER T nu inch tick Beg T ES II I n PRS dra hick Gina s xd 5 P Seed c ek 3214 0 boo Ting 307 dca CE GA AIS lech Thick Grand 4333852 HISDI All links and thermal sequence files are copied The user can copy multiple files simultaneously The user can select any profile from and existing groups z
31. e Check the pressure regulators on the back of the machine to insure they read a minimum of 70 psi while the profile is running e Click on the Cycle Start button to stop the process e Close the right cover and fasten the rear hold down screw IMPORTANT REFER TO SECTION 2 FOR FACILITY REQUIREMENTS OF DRS24 DRS24C Series Manual Page 4 Section 4 Verification 4 3 Temperature Verification After the machine pressure and flow have been verified the next step 15 to verify heater temperature accuracy DISCONNECT THE BLUE FLOW METER HOSE FROM THE FLOW CALIBRATION FITTING AND RECONNECT THE BLUE UPPER HEATER HOSE FAILURE TO RECONNECT THE UPPER HEATER HOSE PRIOR TO RUNNING THE TOP HEATER WILL CAUSE THE TOP HEATER ELEMENT TO FAIL 4 3 1 Upper Heater Verification e Select Options from the menu bar Select Open File Group System System System Select the Temperature Scale Testing profile and click the Thumbs Up icon Click on Thumbs Up icon again The Run screen for the Temperature Scale Testing profile will appear as shown below Temperature Scale Testing 00000004 drs x Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Mumerical Process Information Nozzle System Diffuser System Thermocouple System System Status 50 60 n Memory 30 80 20 90 Set Point Set Point 10 100 ER 56
32. e During an actual process the heaters would be activated so that the pads would reflow prior to placing device This hot air solder leveling step helps prevent placement error caused by skewing of the component when the leads contact a curved ie unreflowed solder on pads surface e heaters are activated during this training profile During this step check the accuracy of your alignment efforts Lower and refocus the microscope so that you can see the front row of leads in relation to the pads Rotate the entire microscope assembly to view the opposite sides Note Rear side not viewable at board level Depress the footswitch until the yellow footswitch indicator goes off DRS24 Live Video ScaleToWinday About DR524 Proper lead to pad registration at board level Leads are approximately 025 above pads DRS24C Series Manual Page 10 Section 7 Operator Training 7 5 9 Automatic Placement Hands Off e The device will be automatically placed with aid of the Force Measurement System No operator involvement is required during this event however it is important that the operator keeps his her hands off the machine during this event as any contact with the system will impact the force reading e During this event the force set point should read 75 grams with a range of 20 grams and the actual force value will also be displayed A e After the automatic placement is complete the noz
33. filled after the TST screen LL Reference The system will automatically adjust the following nozzle positions Component pickup e Vision alignment e Starting force placement position 0 050 above board automatic 0 100 manual Component drop off 3 Record the short name for Short 1011001 DRS Ea profiling link capability LinkName Soldering Desoldering Link Name Site Cleaning 4 Click on the Thumbs Up icon to save Click on the OK of the Help Message to complete save The profile is now saved DRS24C Series Manual Page 114 COMPONENT REMOVAL TEMPLATE THE LINK PROFILE S TO THE THERMAL SEQUENCE PROFILE After saving the original thermal profile the DRS Software Application screen will appear DHS Sofiware Options q Histo Vic gt 1 Select Control Then select Automatic Profile Build The Build Profile Template Sequence screen will appear 2 Select the Component Removal Application Definitions T Fesserval Ctump nem Regs coment ck dedi assuming the Component E Piakin Replacement was first created redis Removal Retry allows 3 attempts to pocos vem remove the device if the device does not Qu Tema Pein pickup The flo
34. profile This parameter is used to display reflow temperature WSI SCCCEI BIIGGI I GE GII IIIGcSIENGNCNGTIFZGII IIIEGGCG GGCCG C IG ICI I I II_ISSEIIGC NBEISE that was defined in the profile Miscellaneous Control Continue Diffuser Idle DRS24 Release Notes Version 4 43 5 Lead Free Defaults Thermal Smart Track Enhancement When Lead Free check box 15 checked the lead free Smart Track default parameters will be displayed When the Lead Free check box is clear the standard reflow temperatures will be displayed Thermal SMART Track Automatic Temperature Profiling Save Rules Device Joint s Average Target CoolDown Reflow 5 Device Top T C 2 C f x Offset Board Control T C 1 Target CJ Start Max C 205 160 060 ED 230 000 090 065 120 Bo ries Jc Adjacent Device s Independent Tic 7 Min Soak Max Soak Soak 5 Max 140 170 060 Tic 8 170 TIC 3 Tic 5 Tic 7 Do Not Use WC 6 qc 8 Process Nozzle Diffuser Control Preheat Board Preheat Soak e Soak 5 Reflow 5 CoolDown 5 Reflow CoolDown Optimize eve e Temperature vs Time 300 0 25
35. 00 02 633 EEEEEEEE CO EEEEEEEEBEEEEEE 3 m Action Replace Subtract Data DRS24C Series Manual Page 51 Section 6 Software The Table Event Editor provides the operator with the ability to quickly adjust any information contained in the parameter control table This can be accomplished by first entering the desired information into the Data edit box Next the operator must select the required Action A radio button Replace Add Subtract The Add button uses the Data edit box value to increase the selected table field The Subtract button uses the Data edit box value to decrease the selected table field The Replace button uses the Data edit box value to overwrite the selected table field Note These Action adjustments can be quickly applied by positioning the cursor over the desired table field and clicking on the right mouse button Note The operator has the option of typing directly into a table field This 15 accomplished by clicking on the desired table field with the left button highlight table field The operator can then press the enter key to enable the table field edit mode At this point the operator can use the standard keyboard to adjust the table field information DRS24C Series Manual Page 52 Section 6 Software 6 2 1 11 L
36. 100X Portable Microscope Spray Adhesive Isopropanol Alcohol and Wipes 1 5mm Allen Wrench Profile for Precision Optical Alignment Procedure 1167126 drs under System System System Profile for Precision Optical Alignment Procedure Adjustment Process 1167127 drs under System System System Conditions Open profile 1167126 drs under Precision Optical Alignment Profile located in the hidden menu portion of the DRS24 software under System System System Prior to running profile make sure Glass Reticle Board is installed in fixture Use silicone cement to glue in place Make sure Glass Reticle Board Glass Component and Holding Fixture are completely clean of adhesive Carrier must be verfied to be flat within 0 003in in with blade nozzle Procedure Profile for Precision Optical Alignment Procedure 1167126 drs under System System System Spray mist of adhesive in air and wave Glass Reticle Board target through to lightly coat You need a lot less adhesive than you think Event 1 Install Glass Reticle Board in front center of carrier Event 2 Open locking clamps load Placement Nozzle and close clamps Nozzle holding mechanism lowers Event 3 Hold Glass Reticle Component under Placement Nozzle Make sure up is facing up Nozzle holding mechanism raises Event 4 Placement Nozzle vacuum is activated Event 5 Align reticles using vision system lock table Vision system is pres
37. A black check mark indicates the On condition active state For Example Vac The nozzle vacuum is off and live video camera system is programmed to be active Video 6 0 5 Radio Buttons Similarly radio buttons allow a functions or activities to be programmed Typically radio buttons are grouped together by related functionality Within a group only one option can be selected at a time C ABS C Z Move REL Function Do Not Move For Example The Vision and Nozzle System group located on the Teach screen provides 3 motion types Absolute ABS Relative REL and Not Move This can be used the following way After a component has been placed selecting the Do Not Move button will keep the nozzle from moving in subsequent events DRS24C Series Manual Page 6 Section 6 Software 6 0 6 List Boxes A list box 15 a multiple line display of information The operator can scroll through the list using the scroll bar to the right of the list box The operator can select any line within the list by moving the mouse to that line and clicking left button on that line Full List Box Files CBGA 256 Site Cleaning 100 thick board M845x845 CBGA 256 Removal 100 thick board N8455x845 CBGA 256 Soldering 100 thick board 845 8 45 CSP 46 paste application directly on spheres M28D 6 3 46 Removal MH28D YG 3 CSP 46 site cleaning 56
38. BN20 715 __ I7 CN3 C24V 94 BLI8S 787 00 I7CN3 C24V 922 BLI8S 18 I8CNXG G24AVrt 95 8 79 J8CN2CG 24Vrt 4 8 1847 12 0 O DRS24C Series Manual Page 23 Section 10 Schematics Esop 1 20 Relay CRI 1 Relay A2 TB11 24Vret Athena 1 extension wire Athena 2 extension wire Athena 3 extension wire 10 4 6 AC Wire Harness Small PI 0024 90 105 PIN WIRE COLOR TO LOCATION 1 70 vision lights P1 2 71 vision lights P1 3 CR1 P3 J2 52 Reset button 81 P1 4 CR1 P4 NO Reset button 51 1 5 Reset button s2 P1 6 1 14 2 Reset button s2 P1 7 IEC ac PLUG TERM P1 8 IEC ac PLUG TERM P1 9 AC HOT 2 3 P1 10 AC RET ATHENA 1 2 3 P1 11 IEC ac PLUG TERM P1 12 Light tower power P1 13 Light tower power 10 4 7 AC Power Transformer Connections 9002 10 006 LOCATION FROM WIRE TO LOCATION Vision xformer secondary Red 16 13 vision lights Vision xformer secondary Red 16 14 vision lights Vision xformer primary Yellow 20 TBI5 AC hot Vision xformer primary Yellow 20 TB16 AC ret DRS24C Series Manual Page 24 Section 11 Maintenance Table Of Contents 11 Maintenance 11 0 Preventative Maintenance Checklist amp Schedule 2 11 0 1 Preventative M
39. Options Control New Open Save Save Delete k Backup Profile Restore Thermal Sequence File Maintenance Print Mate Pad Exit and the profile motion file DRS must also be transferred to the destination machine When backing up profile thermal sequence automatically is added to backup DRS24C Series Manual Page 125 THERMAL SMART TRACK AUTOMATIC TEMPERATURE PROFILING SCREEN OVERVIEW Dharma SHARAT Track Automate uui Un 2 Board Carral 1 Target ra CoolDowa PC 5 TIC H3 Target Stan Max C 200 225 090 BIE cee s um um 7 ma um j A jacent Independent Hb Mim Soak Ej Soat fC Soak jej C oaa msn rnc Lam Fm FIN Bo rm we Tic as E ET Nozzle Control Tine Conn fern mas Soak s Flow amp 9 125 l E s E E aE Rapid Dev D gener SPACES larget Actunl
40. Sale Gea 062 thick bami B IE S PRAGA mm 24 Rc PAGE FZ mm Hermes Sim WET EE e amp ecthy on SER PHCA ETT LIE DE PRGA F Se peus irach thick s EIEEEI 35 mm Site Cirma PAGA 113 Remnva 862 Inch thick beard STRIS lees PAGA TIS 262 inod thick beard 95789985 CEGA 255 303 5 100 mech thick beard 255 404 00 ech thick CHCA 255 303 Exe Cleaning CHGA TOGA sj Restore Dries H HH 3 hz lech thick Beard DSTOBTAPSHI 1 a 1 062 lech thick amp EE E Missing Customer Board or Device groups are automatically added during the rebuild index messages Open Delete Backup and Restore options e The user can select any destination drive recognized by the system ZIP drive network drive e The user can choose between Profile and Thermal Sequence Thermal SMART Track files The user retains the flexibility to copy files directly using the Explorer tool The new backup and restore utilities will recognize any method of file transfer DRS24 tools or Explorer Profile Portability otandard profile portability is maintained If a profile has a thermal attachment both the thermal sequence file THL About DAS
41. Z Muawe Air 1 omm Z Mawe AEL Move f Nitrogen inch Pus Time 866 F Motion F ZPre Eventa 000 F Time roe rs si ELA 4 Vision Lights Haz Probe Air vides Jog Device Nozzle Separation Actual Senco l Adj Pos T Clear sensor Range 000 Adj Pulse 000 ooo Clogged Vacuum 6 Ed Force Placement System Aral Dest Range 4 eme nae co zem Fone El El Force Placement Aute Display Onby Dittuser Syetem Warunmm LT C RT E Threshold v MU 1 Coumber DIHI Time 000 Temp F Average Temp Single Actien Disah Standard C Add Subtract Data Stop Process DRS24C Series Manual Page 116 Reference DHS Set up Defaults Thermal SMART Track Automatic Profile Build DRS Setup Defaults Thermal SMART Track Automatic Profile Build grams newtons DRS24C Series Manual Page 117 HJ Reference Automatic Profile Build Parameters 1 Force Placement Controls force placement system Range 2 Heater Stabilize Event Provides a consistent starting
42. asfomer Air Vac Engineering Company Board Profile Library Device The Lead Free check box defines the reflow temperatures globally DRS24 Release Notes Version 4 43 3 Lead Free Defaults Smart Track Enhancement When the Lead Free check box 1s checked the lead free Smart Track default parameters will be displayed When the Lead Free check box is clear the standard reflow temperatures will be displayed The Smart Track values that are visible will be saved when the operator clicks on the Thumbs Up button The default values that are not visible will not be saved DRS Setup Defaults Thermal SMART Track Automatic Profile Build Thermal SMART Track Device Joint s Board Control T C 1 h EERRERRERERERERRRERRRERERRERERRERERRERERRERERREERRERRERRERRERREREERRE Target C CoolDown Reflow s Target Max s 205 160 060 090 1207 Min Soak Max Soak Soak 5 The Smart Track j 1 060 z 065 m IR Sensor nium Default variables that 1 free Nozzle and Process Control eee Device Top T C 2 default settings Dev Ramp 7 5 Target Soak Timeout Soak Temp Target C Max C i 1 50 300 250
43. choices The operator can select any line within the list box by simply clicking left mouse on that line The edit box will return to its original state with the new selection being displayed Board Group Profile Library BGA Conversion Files Demo Board LEADED DEVICES Protile Libra DRS24C Series Manual Page 8 Section 6 Software 6 1 Options View of the Options Menu DRS Software Application New Open Save Save History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Control Print Profile Backup Restore File Maintenance Note Pad About DRS Exit DRS24C Series Manual Page 9 6 1 1 New The New option located on the Options menu will automatically clear the current profile from memory and display the teach screen The system is ready to teach a new profile Section 6 Software Control ptio nz Mew Save Save Print Profile k Backup Restore File Maintenance Pad About CAS E xil Teach x Build Photo Links Vision and Nozzle System Pos Ehli s Dest 00 000 Z Move ABS C Z Move REL C Do Not Move t X gt N 5 0 Site Cleaning Events 1 9 Miscellaneous Control EA 7 Motion Velocity Accel 6 Velocity 20 Vision Lights C Foot Alert Power Time Speech
44. 1 4 18 with 3 8 hose diameter supplied Direct plumb e Upper Heater 90 130 psi 3 cfm clean dry air or nitrogen non condensing source 1 8 27NPT with 4 hose diameter supplied Direct plumb Operating Notes IMPORTANT Electrical e This system is designed to operate 220 VAC e Under full load conditions power must not drop below 208 V AC Full load is defined as DRS24 fully operating plus all other equipment down the line fully operating If 208 VAC 15 not met a back up transformer or another line must be connected Under general conditions expect incoming line voltage to drop approximately 3 10 volts e Under no load conditions power must not exceed 240 VAC No load is defined as DRS24 off and all other equipment down the line turned off Air Nitrogen With top amp bottom heaters operating at 100 flow system consumes up to 25 scfm 980 psi With all systems activated 70 psi must be maintained Requires both gas lines be direct plumbed no quick disconnect These requirements must be addressed prior to the Air Vac installation and training visit This will assure that you receive a productive training program within the scheduled visit time Physical Machine Operating Dimensions W x D x H 60 x 46 x 26 70 x 44 x 26 with workstation Note Hear frame of workstation features tall vertical columns 56 to support multi outlet power bar Machine Weight 250 Ibs Work
45. 22 24Vrt 196 BN20awg Lighttowerretum 24 24Vrt 9 BN20awg Right fan retum 26 79 BN 20awg 28 Ainl 86 WHhbk 20 J33 1 footswitch 1 20 P2 15 92 90 jwhred20 9 ____ Visioncubeout 0 wh re20 219 424 V 13 COMB relay bd Gump P2 23 J23 X jwhie ble 0 000 0 11 2 23 pin 24 JI2 pnD O 27 P228 128 P2209 0 Com 3 port Com 3 port pin5 2 NENNEN J18 sh B amp B cable shield Com3 port shield TC3 14 xmit DRS24C Series Manual Page 15 Section 10 Schematics 19 7 JI9 sh B amp B cable shield 1 and TC2 and are daisy chained pin 6 13 14 6 com Cable shield RP a NO 2 127 MDLMD2 29 292 MoterMDI DB Jj Com4portpin 9 2 MeterMDI DB X J30 2MD2 DB 20 9 3 MoterMDI DB Com4port pin 9 3 MoterMDI DB 7I0 3MD2 DB 22 19 5 MoterMDI DB Jj Com4portpin 19 5 MeterMDI DB J0 5MD2 DB 02 J9 sh Notconnected Com4porshield 21 Lighttower 17 20 K3Relaybord 19 Red 20awg__ K2 Relay board 0 Fanviio 130 MD2 132 137 139 7 2 HIT4
46. A Upati 160 Akyn anal Thermocouple System Force System Grams Caral C Nozzle Load Function B DRS24C Series Manual Page 6 Section 7 Operator Training 7 5 1 Install Vision Test Board Purpose To prompt the operator to install the vision test board with the QFP160 site 7 5 2 Place QFP into Loading Tray with Vacuum Probe Purpose To prompt the operator to place the QFP160 into loading tray The load tray will project forward and the probe vacuum will be activated Use probe with finger on hole to pick up the QFP160 e Place component into the QFP160 insertion tool on the loading tray e Release finger to release component e Once the QFP160 is loaded into pick up tray depress the footswitch until the yellow footswitch indicator on the run screen goes off 7 5 3 Automatic Component Pick up Purpose To allow the system to pick up the QFP160 No operator involvement is required The vision system will partially retract and the nozzle will descend to the component pick up position The nozzle vacuum will activate and the component will be picked up automatically 7 5 4 Verify Proper Pick Up Purpose To allow the operator to verify that the component has been picked up properly If the device is skewed in the nozzle after automatic pick up manually deactivate the nozzle vacuum r
47. NOZZLE DEFINITIONS Heflow Position is the selection that controls the motion which occurs during the removal replacement process Nozzle Definitions gt 1 Select the Raised or Contact mode inch C mm r Raised a Contact l he Raised mode uses a relative move 0 050 to back the nozzle away from the device during the reflow process The Contact mode does not use the relative move logic Nozzle Length The correct nozzle length must be selected as automatic component pick up alignment and placement positions are based using this dimension 2 Press the Asterisk Help icon to provide Nozzle Search Nozzle Length 0 000 screen to automatically ie cu BN present corresponding Nozzle Length to nozzle size Nozzle Part Nozzle Flow Rate gt 3 Highlight selected nozzle and click thumbs up icon Note Correct length will be transformed to Nozzle Length box 9 Nozzle Length 0 000 Option m Menu Option Automatic Profile Option The nozzle length Build Search Lists can be entered manually by The user can manually enter nozzle or Diffuser Idle clicking the Nozzle Length box device lengths for non standard types A E and entering value menu option has been added to access the search lists provided in the Automatic Profile Build screen The menu option allows entries to be added or remove
48. Soak S 60 4f Note Between Preheat and Soak and Stages Process Soak 5 gt 2 The Soak Stage will run until the Soak s m cmm daa idc Rid ET GOLD Message will state Waiting Device Joints Below User Define Soak Stage Then message will state Waiting For The Minimum Soak value 60 sec Temperature default setting is 1 The Soak Stage will start reached CoolDown s when the Joint temperatures have reached the Min Soak temperature setting 140 default setting 183 fuser Reference Real time Temperature value of solder joint s Dev Top Ramp Cis Target Actual Z Note The Soak indicator will be illuminated If more than one active Dev Joint Ramp C s checked thermocouple Average Actual channel is used the 4f Note Message will state Device Joints E system will average the are in User Defined Soak Stage values wr m ma wes gt Soak Stage will end when wa ree mm me as the time setting of the Process Soak T WEN maed eee a ekp a v y F s has been reached Device J oint s Average Soak s setting within 5 Mis iu wx PL 128 1 dear ESI riri T
49. Z1 01 10 07 97 DRS243 Flow Ramp 20 110 00000005 5 o d nmn tot 1 Temin 1 1 T 1 Ti T ras reg I u S us E uu E as s rr Tar 1 4 For Help press F1 DRS24C Series Manual Page 128 Section 6 Software 6 42 Alarm History Cycle History Alarm History The software continuously monitors the controlling sub systems If an alarm condition occurs for any process or hardware issue an Alarm file entry will be recorded Note This data logging feature 15 not optional The system records all alarm condition This file captures the following fields Field 1 The time of day the cycle was run Field 2 The date the cycle was run Field 3 The Alarm condition that stopped the cycle Field 4 The profile s Long Name Field 5 The profile s Short Name Alarm his Edit Insert Format Heh O4 22 09 20 97 No Activity Time Out cdqfp 160Nsoldering T T C oo0000zs DR5 OS 31 09 20 97 No Activity Time Out dqfp 160 s amp ldering 7 T C DO00000z8 DRS 23 07 09 32 97 Missing Tha rmocouple 7 Temp filew Last changes made using the TEACH screen TEMP DRS O9 a2 97 Missing Thekmocouple 7 Temp file Last changes made using the TEACH screen 23 09 09 22 97 Missing Thermocouple 7 Temp file changes made using th
50. operator to the Open Profile Notes screen Open Profile Notes Description CBGA 256 SITE CLEANING Component 256 SITE Location Flux NO CLEAN PASTE FLUX DO USE LOW SOLIDS FLUX Nozzle 845x845 Notes THIS PROCESS 15 DESIGNED RUN IMMEDIATELY FOLLOWING THE PBGA 225 REMOVAL PROFILE THIS 15 IMPORTANT TO INSURE THAT THE BOARD 15 IN THE PROPER POSITION AND 15 STILL HOT FROM THE REMOVAL PROCESS Application Notes CHECK TO INSURE THAT THE 56100085 15 CLEAR CHANGE TIP IF REQUIRED SENSOR OR THERMOCOUPLE MUST BE PLUGGED INTO CHANNEL 1 pM eee HISIHROCESSIS DE SIGNED OIBE HUN IIMME DIATELY a e PEO ORL TAO MFCR VOIR WAU THE ECOFCHIROSI TION ENDIISISTILUHOTEHORITHEI NUMINUM 2 CEE K ID SIP SSS ss 2 nee 3 2 2 2 2 Section 6 Software This screen is used to display general setup or process related information Clicking on the Ok button will take the operator to the Run screen DRS24C Series Manual Page 12 Section 6 Software This screen allows the operator to process an application In general this screen provides the operator with messages heating and flow rate information thermocouple readings and the overall progress of the cycle Please see the Run screen section for detailed information iCBGA 256 Site Cleaning 100 thick board N845X845 1067016 drs Graph Data Auto Sc
51. p ant uu moy gt e o 2 x 2 lt U 5 T O M R N A M E DRS24C Series Manual Page 16 Section 4 Verification Carrier Leveling 1 Attach the N Cal4 nozzle knife blade to the DRS Depower vertical motor if required 2 Unlock left and right carrier locks A tab which prevents carrier to hinge 3 Place the glass plate in the carrier arms 4 Center the glass from front to back of the carrier arms Lock the glass to the carrier 5 Center the glass under the nozzle from front to back and left to right Lock the carrier The blade of the nozzle should run from left to right as viewed from the front of the DRS 6 Lower the nozzle until the blade is just above the glass Do not hit the glass with the blade of the nozzle Note If the nozzle hits the glass plate raise the nozzle release the nozzle clamp and then re clamp the nozzle into place 7 Using the feeler gauge check level of nozzle to glass plate The left to right nozzle clearance to the glass plate must be 005 or less 8 To adjust raise the nozzle Go to the outside edge of the carrier assembly to make adjustments Loosen the four 5 32 allen screws C that hold the carrier arms to the carrier rail Adjust the 3 32 allen screws D 1 8 turn at a time clockwise moves the carrier up 9 Tighten the two 5 32 allen screws that hold the carrier arms Do not overtighten Repeat until the left to right nozz
52. 3 0 Installation of Standard Machine Hardware NUS 2 9422 Bl ttrical Connecnonse 3 3 0 3 Electrical Connections Internal Computer Connections 4 304 Elechical Conmieelions P OWeTu G B 5 TI Poes 6 30 0 7 IF TONTE COU 8 MEI Ire co moo P m 9 SR J o P PY TG I TM 10 OO oTi DN ao NL ma uw 11 3 1 Installation of Options S Mornkstaton Assembly ui aseseeesssekesvkvs 12 19 S12 A ulimeduPackase 0024 27 01 cacesesssssavssscetevev ve uve vay ER EEF ETE SERE ERR 20 DUNS MEE ER 21 JJ JTuaneBxtracdonMManuiold 120040 cssseessasecsuss c xs vuv sukusaves ovusessesevaves S vesect e 22 ENSE c 23 2430 Ode scanner 0024 00 TIU l
53. 3 off off Foot component insertion position Message Place device into loading tray with vacuum probe check polarity 4 off off 0 nozzle vacuum on component pickup 5 off off foot vision alignment position Message Align device lock table after alignment is complete 6 off off 0 Message Flux sit unless solder paste has been applied 7 off off 5 Message Position temperature sensor approximately 3 inches away from A 8 off off 0 skip Message Waiting for starting board temperature 9 off off 0 100 low force placement not shown Message Force placement 10 off off 0 100 low relative move Skip 11 off off 0 420 high Message Preheating board 12 off off 0 420 high do not move maintain Message Replay thermal reflow sequence 13 off off 0 off off Message Process complete Program is set to use the following setting based on selection Application Definitions Component Heplacement Nozzle Definitions Reflow Position Automatic Manual AutoForce Manual Pickup Pickup Placement Placement Raised Contact off c 125 125 125 125 off 96 35 35 35 35 E 0 seconds 60 60 60 60 skip Thermocouple c 60 60 60 60 maintain Thermo 9c 125 125 125 125 force placement 75 g 25 g 75 g 25 g 2 relative move 0 050 0 0 050 0 gt s skip Thermocouple c 90 90 90 90 DRS24C Series Manual Page 119 He
54. 350 0 300 0 T C Control 250 0 200 0 150 0 100 0 50 0 Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 40 24 11 12 12 00 vent Time G Profile g Power Board DE EA Se D es A of F E DRS24C Series Manual Page 65 Section 6 Software 6 2 2 10 Function Buttons G This section of the Run screen displays the function buttons that are available to the operator PBGA 225 256 Soldering 068 thick board N1081X1081 1011003 drs Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Numerical Process Information Cf Nozzle System System ERES EB System Force System System Status Me Set Point Set P Set Point FootSw o Actual Nozzle n m e e Set Point Actual EX ER EXEZ o Graph Process Information Date 04 02 98 09 22 emperature vs Time 500 0 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 T C Control Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 42 08 00 08 48 09 36 10 24 11 12 12 00 Event Time Profile Time DEREN Iv Power 6 2 2 10 1 Zero Force The Zero Force A button will clear any currently applied force that may have been generated during the X Y Z axis positioning E 6 2 2 10 2 Probe Vacuum The Probe Vacuum
55. 8 3 80 148 B a B B B z 9 3 BB 15B B B B B B B B Save 18 6 79 151 31 B 8 B B 8 11 6 79 15860 B B B B B save Bs 12 79 158 31 8 8 8 9 8 8 8 13 6 78 158 31 B B B B B B B Page Setup 14 78 151 3B B B Pr 15 6 78 151 31 B B B B B B 16 6 78 151 31 B a B a B B 17 6 78 151 B B B B B B E sit 18 6 78 151 B B B B 19 6 78 158 31 B B B B B 6 78 158 B a B 8 B B 21 6 78 158 31 B B B B B B B 22 6 78 19 B B B B B B B 23 6 78 149 31 B B B B B B B 6 78 149 31 B B B B B B B 25 6 78 149 B B B B B B B 26 6 78 149 31 B B B B B B B 27 6 78 1580 B B B B B B 28 6 78 1580 B B B B B B B DRS24C Series Manual Page 81 Section 6 Software 6 2 3 2 4 Run Data Point Summary Report This option allows the operator to print the graph data set summary This report will be organized by thermocouple channels and will list the same summary information that can be displayed screen using the Graph Data menu Note Selecting Print from the File menu will send the report to the default printer DRS24C Series Manual Page 82 6 3 Thermal SMART Track Software Reference Thermal SMART Track System Overview Xr cm H gt Purpose Elimination of tedious trail and error process development e Automatic thermal sequence optimization e Automatic combining of thermal sequ
56. Attach silicone hose with the barb fitting and plug the other end into Cooling Ring port on the rear of the pneumatics panel Click on 100 and start the airflow Adjust the value in the 90100 box up or down in increments of 5 until the float on the flow meter 15 at 9060 line Stop the airflow click on 900 and adjust 960 value in increments of 5 until you can barely feel back pressure building up at the output of the flow meter with your finger covering it You need to find the point where you can just feel the pressure and when you can t If you feel no pressure buildup you have no flow The point you want is where the flow is just off Now check the 100 flow again Go back and forth between 900 and 96100 adjusting the corresponding values until both are set properly i e the 60 is at the no flow threshold and the 96100 1s at the 6096 line on your flow meter e After you feel your values are set correctly click on thumbs up button to save your new settings DRS24C Series Manual Page 19 Section 5 Hardware Overview Table Of Contents 5 Hardware Overview Tl Di T NETTE TEE E 2 SWMEMEBODDIRECiEE MS LICINIUS 3 5 4 Viewmg Alipniment System 4 MEE GUESS SINT TU m 5 DRS24C Series Manual Page 1 Section 5 Hardware Overview 5 0 Electrical System Power Sw
57. R 22 Awg 22 Awg Y 22 Awg GN 22 Awg BL 22 Awg V 22 Awg GY 22 Awg 20 Awg TB2 1 CPU power J40 6 CPU power J40 5 CPU power J40 4 CPU power J40 3 CPU power J40 2 CPU power J40 1 CPU power J39 6 CPU power J39 5 CPU power J39 4 CPU power J39 3 CPU power J39 2 CPU power J39 1 Disk power J41 4 Disk jumper J41 4 Disk power J41 3 Disk jumper J41 3 Disk power J41 2 Disk jumper J41 2 Disk power J41 1 Disk jumper J41 1 Speech power Speech power Speech power Speech power J21 P37 digital board J21 P35 digital board J21 P33 digital board J21 P31 digital board J21 P29 digital board J21 P27 digital board J21 P25 digital board J21 P23 digital board J21 P38 digital board J21 P36 digital board J21 P34 digital board J21 P32 digital board J21 P30 digital board 21 28 digital board 21 26 digital board J21 P24 digital board J21 P50 digital board J21 P48 digital board J21 P47 digital board 7 comm DRS24C Series Manual Page 17 Section 10 Schematics 5 com 20 Awg K14 com 20 Awg K13 com 20 Awg K12 com 20 Awg com 20 Awg 10 com 20 Awg K9 com O 20 Awg K7 com 20 Awg K6 com O 20 Awg K5 com O 20 Awg K4 com 20 Awg K3 com O 20 Awg K2 com 20 Awg com 20 Awg Force block BL 22 Awg Force block GN 22 Awg Force block W 22 Awg Force block R 22 Awg Force block GY 22 Force block BL 22 NEN RS232 cable GY 22 Awg RS232 cable V 22 Awg RS232 cable Y 22 Awg B
58. REL D C Do Not Move Nitrogen inch Site Cleaning Noz Vac J Probe Events Power 6 21 Speech Be Vision Lights Video Cool Air Injection Device Nozzle Separation Alert Pulses Message nozzle to above board position R sensor Force System Actual Dest Range 0000 00 Zero Force E Placement Removal Auto Adjust W Display Only Diffuser System L Temp C R Temp C Low Low ID c nien Average L R Temperature Single gaon Disable Standard Replace CAdd Subtract Dat If ERROR Stop Process DRS24C Series Manual Page 39 Section 6 Software 6 2 1 5 3 Diffuser Heater Temperature and Flow Rate The diffuser heating system bottom can independently A B control flow rate and temperature the left and right side heating panels For example the left side panel can be used for soldering desoldering a component and the right side can be used for board cooling or solder pasting The diffuser heater temperature Temp C can be programmed from 1 C to 420 C Each diffuser panel has two programmable flow rates The Low flow rate is fixed at 4 0 scfm The High flow rate 15 fixed at 7 0 scfm During a normal run cycle the left and right diffuser temperatures are averaged together before being graphically plotted If separate heating cooling functions left right
59. Stop Process Summary 6 2 1 4 1 Zero Force Check Box The force system 15 very sensitive to change stable hands off no motion force sample must be present before any force placement activities are initiated Programming the Zero Force D check box checked can be used to reset zero the actual force value that is measured after completing any event Run screen motion Z or Vision The Zero Force option can be combined with force placement option to minimize event complexity 6 2 1 4 2 Force Destination and Range The force Destination 5 and Range C values allow the operator to fine tune the applied placement removal force A typical force placement example might be a target destination of 75 grams with a range of 20 grams Force can be measured in grams or newtons 6 2 1 4 3 Display Only Check Box The Display Only check box will allow the force value to be displayed programmed during the entire event Run screen There are no force control actions associated with this option DRS24C Series Manual Page 35 Section 6 Software 6 2 1 4 4 Placement Removal The Placement Removal check box G allows the operator to program a force placement removal event Force placement detects and controls a positive downward motion Force removal detects and controls a negative upward motion Typically negative force 15 created when component is being lifted before the required solder reflow tem
60. This option allows the operator to define several print related options In general the operator should match the options listed below Print Parameters Graph Window Background Plotting Area Background Border Iv Maintain Aspect Ratio Printing style Print graphs to max size Proportionate Exact Size Cancel 6 2 3 2 2 Print Graph Page This option allows the operator to print the Temperature vs Time plot for the currently loaded graph data set This report will be identical to the current screen display DRS24C Series Manual Page 80 Section 6 Software 6 2 3 2 3 Run Data Point Detail Report This option allows the operator to print the graph data set detail This report will be organized by seconds and will list all the data points that were used to produce the current Import screen display Note Selecting Print from the File menu will send the report to the default printer Report Notepad I Fie Edt Search Date 84 16 98 DATA POINT DETAIL REPORT Page 681 225 Soldering Rir Uac demo board 8141881 1811131 _DR5 C EXPORTS 86686082805 dat 15 24 B37 85 798 Hoz Dif 1 2 3 5 6 7 8 1 2 81 B 24 B B B B B B B 2 2 81 76 B B B B B B B 3 2 81 445 68 B B B B B 8 B 4 2 84 445 61 B B B B B B B Search 5 9 81 155 61 8 8 8 8 8 8 a Tem 6 2 81 111 61 B B B B B B 7 3 81 148 24 B B B B B B B
61. This will load the Protected System Menu Options DRS Software Application Pp x Opticns History Video Screen Utilities Reset Cycle Counter Setup Operator ccess r oin _ wJ Thermal SMART Track System C U 5 T O M R N A M 7 4 44a PE aaa 4 477 4 Q DRS24C Series Manual Page 142 Section 6 Software Setup Menu I General System The options in menu bar will change slightly The new options will have access to the protected system setup controls Communication Limits Defaults Machine Offsets hatian Force Measurement 6 9 1 General System Hozzle Flow Meter Cooling Flow Meter DRS Setup General System Ea Run Screen Displays Options Millimeters Open Graph Export Thermocouple s gt Rotate Logo Inches Notes History Vision System Single Diffuser i Force Bar Code Double Diffuser Motion Multi Media No Diffuser Speech Demo Cool Air Injection Cooling Ring Auto Cycle DRS24C DRS24R Language English Male French Male Spanish Male C German Male Speech RC Systems C Speech WAVE files Controls Screen Init Screen Time Out Pitch Audible Tone Operating System Low Memory Board Address dec DRS24C Series Manual Page 143 Section 6 Software 6 9 2 Limits and Default
62. are programmed the operator can disable the temperature average by clearing the Average L R Temperature C check box If this check box is clear the system will attempt to plot only the actual right diffuser temperature If the right diffuser temperature set point is programmed to zero current event the system will attempt to plot only the actual left diffuser temperature Note During the process cycle Run screen the diffuser event controls will override any global diffuser idle that may have been activated PBGA 225 256 Removal 068 thick board N1081X1081 1011030 drs Build Photo Links Vision and Nozzle System Rate 7 Temp C Sec Bo Z Move ABS Air C Z Move REL Do Not Move Nitrogen inch Pos Site Cleaning Noz J Probe Vision Lights Video Jog C Time 21 Speech Cool Air Injection Device Nozzle Separation Pulses Message nozzle to above board position R sensor Units Actual Dest Range s 0000 00 Zero Force ai El El Placement Removal Auto Adjust W Display Only Diffuser System L Temp C R Temp C Low Low BBY cris cris Average L R Temperature Single C Disable Standard 6 Replace C Add Subtract Data I If ERROR Stop Process A C B DRS24C Series Manual P
63. cable and pneumatic connections IMPORTANT DO NOT LIFT BY TROLLEY BOARD CARRIER SYSTEM OR UPPER BOX SECTIONS AS DAMAGE WILL OCCUR e Position module on a level surface which can provide adequate support for weight Lift Here 2 sides Remove any strapping and or packing securing board carrier and vision systems e Fill out and return cpu and monitor warranty cards DN DRS24C Series Manual Page 4 Section 1 Introduction Getting Started 1 3 Material Check List The following are checklists of items shipped with all DRS24C systems Machine Serial Number Description Part Number Hot Gas Reflow Module DRS24C 2D s Accessories Description Tool Kit 1 1002400040 Calibration Kit 1 00240005 DRS24 26BoardSuppotSet 171 004006 Footswith 0024 10 150 Air Hose 10 SIB 2 Hoses blue 3 8 yel blk 1 4 1 900 15013 Microscope Assembly 1 2200 280 Computer Monitor 17 11 904005 Computer Keyboard 11 9000801 Keyboard Extension Cable 171 9002005 Trackball 11 9000804 Trackball Extension Cable 11 90020802 Manual 11 004040 Windows CD 1 9000804 Spare Parts The following is Air Vac s list of recommended spare parts The recommended spare parts will only be included with the shipment if they have been ordered by the customer Air Vac recommends that all customers have these items on hand
64. gw Dev Remp T Tasget Actual TES nias Pracesa Optimization 1 5 TIENE D Jom Average Adiel C Pre Option Process Parameter Limit Protection The user will not be allowed to enter adjust process parameters beyond the system process min max limits A limit check is performed on all process parameters prior to activating the TST cycle 195 220 The user can enter a parameter value 150 175 directly through the use of the up or down 15 180 arrows 120 150 160 180 30 120 200 240 or the pop up numeric keypad KeyPad 150 183 9 150 60 100 150 1 200 1 100 Backspace Reference Globally Changing the Default Parameters This screen allows the operator to control the default parameters that are used by the Thermal SMART Track and Automatic Profile Build tools Warning Assistance from Air Vac should be made prior to changes to Global settings Note All profiles from this point will utilize the changed parameters All previous profiles will be saved using the previous settings DAS Sebup Oats Thee Track 2 uii Thermal SMART Track Device Joints Target PC 7C me a Board Contral TC Fi Target Min Saak Soak 14 Pracess Device Tap TC R Dev Ramp Target
65. represents 2 75 scfm A flow rate range between 15 and 19 allows a maximum temperature of 325 C Temperature ramp C Sec C controls the temperature set point increase per second The default setting for this control parameter is zero not in use The maximum temperature ramp is 50 C Sec 6 2 1 5 2 Air Nitrogen Option The pressure source connection for the upper heater can be Air or Nitrogen D Selecting the Air option automatically connects to the upper heater to the main air source large blue hose The main air source 15 also used by the vacuum and cooling systems Selecting the Nitrogen option automatically connects the upper heater to the secondary pressure connection smaller blue hose or yellow black hose This secondary pressure source 15 generally connected to nitrogen If nitrogen is not available this required connection must be made to air Note The secondary pressure connection typically provides a more stable flow rate environment and should be considered for all placement soldering events Note If nitrogen conservation is a critical facilities issue applications be programmed to only use the nitrogen option during process steps where stabile flow rate 15 essential PBGA 225 256 Removal 068 thick board N1081X1081 1011030 drs Vision and Nozzle System Rate Temp C Sec Pos 00 000 Pos Dest 00 000 Dest Bo Z Move ABS Air Z Move
66. temperature for the nozzle heater Temp lt Time sec e Flow 3 Nozzle Position e Reflow REL Move Motion required for nozzles that do not contact the device during reflow This position is measured as a relative move Removal REL Move Motion required to lift the device from the board This position is measured as a relative move 4 Post Removal Reflow Pre Motion Heat Event Event provides optional additional heat flow and is executed just prior to activating any removal motion Temp lt Time sec gt Note Flow rate is determined during the Thermal SMART Track session 5 Removal Retry Temp lt Parameter is applied as increment to the existing heater set point Time sec Parameter reflects the additional time that the retry attempt will use gt Note Flow rate is determined during the Thermal SMART Track session DRS24C Series Manual Page 118 Heference Component Replacement Template sf Note Thermocouple channel 1 must be connected and used to measure board temperature gt Note Both Diffusers are activated gt Note Board and nozzle must be installed gt Warning Assistance from Air Vac should be made prior to Global settings changes Upper Heater Diffuser Event Temperature Flow Time Temperature Flow Notes 1 off off 07 gt Message Stabilizing heaters 2 off off 1 do not move Message Heater off
67. will start when the Joint Temperatures have reached 183 c gt 1 The Process time of the Reflow Stage will begin Note The Reflow stage indicator will be illuminated Reflow Message will state Device Joints Reflow Stage Lee 18 HT LL Reference The Reflow Stage is defined as the time the Device Joint s Average Target CoolDown Reflow s 200 170 060 Process Soak s 3 gt 2 Reflow mwi will run until the solder joint temperatures reach the Device Joint s Target x temperature Dev Top Ramp C s Target Actual E Dev Joint Ramp Cis Average Actual gt 3 The Reflow Stage will end all heaters will be turned off on as m the initial cycle when the target of the Reflow Device Joints m cw Setting has been reached TES ST Process Soak s La camp p Im Tie Preece gti rots Reflow s Reference eA thermocouples are real time graphically displayed E T diffuser will remain on until the Board Control T C 1 CC setting is reached The diffuser will then turn off The board temperature will be in a maintain mode of
68. 0 50 0 0 00 00 00 24 00 48 01 12 01 36 02 00 02 24 02 48 03 12 03 36 04 00 04 24 04 48 05 12 05 36 06 00 Graph data can be automatically or manually captured during Run cycle DRS24C Series Manual Page 77 Section 6 Software 6 2 3 1 Graph Data Menu Option The Graph Data menu allows the operator to load the current cycle graph data into an analysis matrix This information is organized and displayed based on seconds Each row captures one second of the overall profile cycle This menu option 15 only available when the process is not cycling Column 1 A represents seconds Column 2 B represents the current event Column 3 C represents the diffuser temperature Column 4 D represents the nozzle temperature Columns 5 12 E represent the thermocouple temperatures B E Graph Data Matrix A TIC 1 Max Temp C Min Temp C Temp Slope Time Above 183 C Time Above 000 TIC 2 Temp C 4 Min Temp C Temp Time Above 183 C Time Aboveaae c tempstope Time Above Time Above 08 4 Temestepe Time Above Time Above 08 5 Max Temp MmTemp c Temp Siope Timeabove 183 Time Above 4 C 6 Max Temp MmTemp c
69. 03 6596 Pos 00 000 Des 00 000 PN J je r Note Ifthe Motion check box is selected checked the Z and Vision axis coordinates will be saved each time the Teach function 15 performed current event gt Z axis motion can be defined as an Absolute Relative Do Not Move event An Absolute C Z7 Mave REL Do Not Move the Do Not Move option prohibits any motion from occurring during the current event ABS move positions the Z axis directly at the specified motor coordinate A Relative REL move positions the Z axis a fixed number of pulses from the current motor coordinate Selecting DRS24C Series Manual Page 32 Section 6 Software 6 2 1 2 3 Z and Vision Axis Velocity Acceleration Buttons Q gt x S Velocity and acceleration parameters provide the ability to fine adjust the overall motion 4 Velocity controls maximum speed that axis will reach Velagity o Accel 20 Veloci achieve a maximum velocity set the axis parameter to 100 080 Acceleration controls length of time axis will need to reach maximum speed The Z and Vision axis share a single event acceleration parameter To achieve a maximum acceleration shortest time set the event parameter to 100 g Note The default values for velocity and acceleration are 50 DRS24C Series Manual Page 33 Sectio
70. 3 AC Power Harness 0024 90 102 FROM WIRE WIRE COLOR TO POSITION __ F 46 Black 114 SSR 02 TB17ACret 6 lighble Jl IO Athenart fis 9 FO 60 Black 18 08220 _ changes DRS24C Series Manual Page 20 Section 10 Schematics 10 4 4 Pneumatics Harness plug is J3 0024 90 103 FROM LOCATION WIRE COLOR TO LOCATION Z T ty oe NO eg oy 2 jRelyboad KONO 2 red 200awg bottom air low left 3 jRelbordKIONO 3 red 20awg nozzle vac 4 RelayboardKIINO 4 red 20awg site clean 5 Relayboard 2 5 red 20awg probe vac 6 Relayboard 6 red 20awg bottom air low right 8 Relayboard KISNO 8 9 9 red 20awg nozzle hot cold 19 LPBl Gigh 80 white green 20 awg SW13 1 low flow2 84 22 white lack 20 awg J4 5 MFC 841 BN20awg AQ MFC 26 AO0XRbdKICOM 26 gray20awg 7 15 l cool prop valve 27 0202 127 brownOawg TSL4 GND block LFUHI nozzle 79 Wh red 20 awg SW14 1 low flow 2 nozzle Wh red 20 awg SW14 2 low flow 12 298 brown20awg _ GND block TS1 3 2 S22Gightdifflow 29 brown20awg GND block TS1 3 153 2 nozzle vac 1307 brown20awg GND block 1815 S42 iteclean 31 brown 20awg GND block 1515 55 2
71. 323 brown20awg GND block TSI S 156 2 diff Low 13 brown 20awg GND block TS1 4 2 S7 2 deft diff High 94 brown 20awg GND block 1512 DRS24C Series Manual Page 21 Section 10 Schematics i SW11 2 LP1 end Brown 20 awg GND block TS 1 3 DI red 20awg DI AJ 1 20 ss S82 NZAIR 0 NENNEN NENNEN s changes Terminal strip definition T SI located in the pneumatics section TS1 1 mass flow return TS 1 2 24Vregret TS1 3 24Vregret TS 1 4 24Vregret TS1 5 24 Vregret T S2 located in the center casting section TS2 1 5VDC TS2 2 5VDCret TS2 3 24Vreg TS2 4 24Vregret TS2 5 2 proxy signal 2 TS2 6 proxy signal 2 TS2 7 AINS light barrier bd output signal TS2 8 AIN3 machine function button signal DRS24C Series Manual Page 22 Section 10 Schematics 10 4 5 DC Power Harness plug J2 0024 90 104 22 24Vrt 9 BN 20awg TB9 Light tower return _ 124 BT Right fam 2 6 Ble20wwg TB7Gightans 12 8 Ainl digital board pin 866 wh bk 20 J33 l footwith 12 15 12 20 12 29 F 4 BN20 80 SSR 8 BN20 82 6 85 BN2 TB 1 52 15 88 V20 76 c cc cc 2 45 19 V20 TBA PS2COM I5Vcommon 90
72. Alert Message Force System Units i Zero Force Actual Placement Removal Diffuser System L Temp 99 etw Action Replace C Add Subtract Data Disable Standard C If ERROR Stop Process DD Average L R Temperature Temp Bo Dest 00140 00000 000040 EJ Auto Adjust C Air C mm Nitrogen inch NozVac Probe Video Jog Device Nozzle Separation Range Display Only R Temp 99 DD Single DRS24C Series Manual Page 10 Section 6 Software The Open option is used to load an existing profile from a library Selecting the Open option will display the Open Profile screen Save s Three group categories are available to organize profiles into common or related processes e Customer e Board Backup Z Restore Device File Maintenance New groups can be easily added to expand the profile library organization gt Note Pad About DAS The profile list can be adjusted by changing the group selection combination Exit Clicking on the down arrow of a group list box will display a window with all the available options for that group Use the scroll bar to view any additional entries beyond those that are currently displayed Files Profiles listed under a specific Customer Board Device group Customer Groups
73. DRS24C Series Manual Page 100 gt 1 If the first profile did not meet criteria additional cycles will automatically be performed Allow cycles to occur IT LIED aa Lr SEP i Deer Aere Ti nce m ERE Deska Pep 00 Do ed K apani rA Pru Note No manual adjustments be made par rer 77 ges u ii LO Reference Saye cays PSSI Ves rus d Fc e The board temperature must record below oe ren 60 prior to start e The board radio indicator will illuminate EDE Bm F BN N h LL Reference e Rule see below which governs will be indicated a ims 4 Be 1 E TE COE Came SION HI ER DA Bd dE DO Finn e he Data 1 2 3 radio indicator will illuminate Note Data 2 and 3 will illuminate if or LL Reference Waiting for the minimum board when additional cycles are required temperature message will appear gt 2 If When successful thermal profile parameters have been met the illumination of Optimize indicator will change to the Done indicator Optimize Up to 3 additional cycles
74. ESO 24 11 10 Diffuser 25 11 11 26 DRS24C Series Manual Page 1 Section 11 Maintenance 11 Maintenance 11 0 Preventative Maintenance Checklist amp Schedule Note Please refer to the following pages for details Daily Weekly Clean carrier area of fallen parts Wipe painted surfaces with cleaner Clean nozzles with flux remover and soft brush and replace vacuum cup or o ring if required Report any problem to supervisor or machine maintenance department Clean microscope and vision system optics Wipe flux from table arms and rails Apply a film of light oil to the X and Y rails to avoid corrosion Replace vacuum filter of Site Solder Removal System Manually lower vertical movement to bottom of travel Check Upper Heater temperature verification see Section 4 3 1 Check flow rate verification see Sections 4 2 1 and 4 2 2 Replace nozzle vacuum filter Clean the fan cover filters on the two back fans Drain water and oil from air supply filters Three to four times per year Note Check for play in carrier Y bearing Check for play in carrier X bearing Check perpendicularity of carrier see Section 4 2 Check diffuser to carrier parallelism see Section 4 3 Clean and lubricate vertical shafts Check microscope lights Check for wobble in nozzle
75. Halogen Bulb Osram 11 14045 Halogen Bulb Lamp 14 5V 90W EPX 1 1452101 Switch Bulbs 28 volt 12 1632101 Assortment of silicon cups 1 VCASST Assortment of silicone o rings 1 ORASST Heating Element 2000W Double Diffuser 1 0024220422 Heating Element 3500W Single Diffuser 1 002422047 Heating Element 1000W Nozzle 7771 002490116 2 Vacuum Tube 11 002491100 Filter Element 10 11 Temperature Controller 11 900211015 DRS24C Series Manual Page 5 Section 1 Introduction Getting Started Options The following machine options may be included depending on whether they were ordered by the customer Description Work Station site Solder Removal System Multi Media Package Non Contact Temperature Probe Precision Optical Alignment Kit Adjustable Area Array Insertion Tool Extended Carrier System Network Card Micro Stencil Adapter Cooling Circuit Thermocouple Organizer set of 5 Fume Extraction Manifold amp Hose Assy Air Purification System Bar Code Scanner 1 1002400150 Expanded Recommended Spare Parts For users with three or more systems Description Qty Temperature Controller Cal Solid State Relay Motor Driver with Encoder Motor Driver Vision Heating Element 1000W Nozzle Heating Element 3500W Single Diffuser Heating Element 2000W Double Diffuser Heater Head Harness Solenoid Valve 3 way 9001 1
76. Left right target temperature set point B white numbers Left right actual temperature C light blue numbers Left right idle temperature D white numbers A D iffuser Sy Set Point Note Diffuser Idle is controlled by the process profile The 400 Idle may be discontinued after Run screen completes the initialization steps C D DRS24C Series Manual Page 59 Section 6 Software 6 2 2 4 3 Thermocouple System The Thermocouple System has maximum of eight thermocouple channels Only pre programmed active channels will be displayed Each channel will display an actual B and a set point A temperature Each thermocouple channel has an identification number C positioned between the set point and actual displays When a thermocouple channel is controlling the process the T C Control D LED will change to yellow A PBGA 225 256 Soldering 068 thick board 1081 1081 1011003 drs x Graph Data Auto Scale Graph Load Process Lik Fle View PhotoLinks Expay listoyLoadFuydion SE Numerical Process Information 10 xi Nozzle System Diffuser System ermocoupld System Force System System Status 50 60 Memory 40 70 Grams EB 2 3 ir Set Point Actual Nozzle9 o Set Point EE ER ESE Graph Process Information Of Date 04 02 98 09 22 Temperature vs Time 500 0 450 0 400 0 D T C Control Temperature
77. NOZZLE LOAD ICON WHEN FINISHED CLICK ON THUMBS UP ICON CLICK ON CYCLE START ICON BEGIN PROCESS Date 64 81 98 PROFILE NOTES REPORT Page 002 PEGA 225 256 Removal 868 thick board HiBB1x1881 1811838 dr5 PLUG THERHOCOUPLE SENSOR INTO CHANNEL 1 DIFFUSER SHOULD BE HEATED IN IDLE MODE PRIOR TO RUNNING THIS PROCESS Process Limits 4 k 2 DRS24C Series Manual Page 18 Section 6 Software 6 1 7 Backup Restore general overview Control Mew The Backup Restore option uses the standard Windows 95 Explorer tool to display and manage files in the Profiles library directory For complete details on using Explorer Save please refer to your Windows 95 user manual save Print Profile Warning The Undo function may restore all deleted files from the recycle bin Obsolete Profiles and other files may be inadvertently copied back to the Profiles C drive Backup Restore directory File Maintenance Pad About CAS l File Short Names are stored in the Profiles directory The first four characters of ES the Short Name are taken from the DRS24 machine serial number The remaining numbers represent a 1009005 unique file sequence number The TEMP DRS is a copy of last profile that was changed a Teach function This file is automatically updated Temp The file FILE DAT is the index file for the Lon
78. Photo Links Vision and Nozzle System Rate Temp C Pos 7 Dest 00 000 Dest 00 000 o0 0 o0 L ea The profiles reflow temperature Replay Thermal Sequence Z Move ABS Air mm jm Do Not Move Nitrogen inch C Z Move REL zo u g xx gt N Control sec Motion Iv Z Power Events 000 Foot Time Miscellaneous Control Velocity 6 Accel Velocity Vision Lights Noz Vac Probe ua San Video Jog Site Cleaning System Actual Sensor Auto Adj 2 Vacuum Clear Sensor Range 000 Adj Pulse 000 Clogged 000 Vacuum 96 000 Thermocouple System Force Placement System Actual Dest Range EESTI TREES s 0000 00 0000007 0000 00 0 0 5 50 000 Zero Force om acement Auto Adjust V Display Only Description a ET Vacuum Retry Component Actual Sensor Location Low Sensor Threshold 000 E High Bel High Counter 000 Time 000 ux E R Temp Single Temp Incr 000 Nozzle it Notes Device Nozzle Separation Edit Application Notes Miscellaneous Control Removal System Application Notes The solder reflow temperature parameter is set manually for a
79. Profile Notes Page The Profile Notes button allows the operator to refer to any application related notes that may have been setup by the process engineer The operator can not access these notes while a cycle is active Open Profile Notes Ea Description COMPONENT REMOVAL Component PBGA 225 255 272 324 27 MM Location Flux Type Nozzle N1081 1081 INSERTION TOOL 4 1081 1081 Notes PLEASE NOTE NOZZLE MUST BE LOADED BEFORE RUNNING PROCESS THE FIRST TIME AFTER NEXT SCHEEN RUN APPEARS DO NOT FOLLOW THE INITIALTEXTIVERBAL PROMPT TO CLICK ON THE START CYCLE ICON Application OPEN TOOL BAR JOG FUNCTIONS MENU OPEN AND SELECT NOZZLE LOAD ICON Notes Ed WHEN FINISHED CLICK ON THUMBS UP ICON CLICK ON CYCLE START ICON TO BEGIN PROCESS PLUG THERMOCOUPLE OR NON CONTACT SENSOR INTO CHANNEL 1 DIFFUSEH SHOULD BE HEATED IN IDLE MODE PRIOH TO RUNNING THIS PROCESS 4 2 2 1 __ _ L E KU M FUNG WO UT Ld 0422 042 2 4 _______ 2 DRS24C Series Manual Page 56 Section 6 Software 6 2 2 3 General Run Screen Layout The Run screen is organized into the following sections Numeric Process Information A Profile Event Alert Foot Switch Messages B Graph Process Information C Event Time D Event Counter Process Time Button Functions G Software Hardware Communication Link Error Status H Bar Code Board Serial Number Tracki
80. Site Clean OFF Hoz Deu Separate OFF Hoz Cold Air OFF Force Force Place NO Force Adjust Force Target Force Range Cooling Ring T C 1 Honitor Temp Control UP Speech Alert T C 2 Hot In Use Temp Control UP Date 84 61 98 PROFILE PARAMETER REPORT Page 002 225 256 Removal B68 thick board N1881X1681 18011636 drs Speech Alert T C 3 Hot In Use Temp Control UP speech Alert DRS24C Series Manual Page 17 Section 6 Software 6 1 6 Print Process Notes Photo Links This option functions identically to the Process Control Parameters report Fracess Control Parameters Process Notes 7 Photo Links Report Notepad File Edit Search Help Date 54 01 98 PROFILE HOTES REPORT Page 01 PEGA 225 256 Removal H68 thick board N168141681 1811838 dr5 Customer Group Air Vac Engineering Company Board Group Profile Library Device Group Area Arrays Solder Desolder Link 1611663 Site Cleaning Link 1811817 DRS COMPONENT REH DURL PEGA 225725672727324 27 HOHE PLEASE NOTE NOZZLE HUST LOADED BEFORE RUNNING PROCESS THE FIRST TIHE AFTER NEXT APPEARS DO FOLLOW THE IHITIRLTEST UERBRL PRUHPT TO CLICK DH THE START CYCLE 68741681 INSERTION TOOL H 818815180881 OPEN TOOL TO JOG FUNCTIONS MENU OPEN AND SELECT
81. Verification and Adjustment 20 90 only Making Flow Sensor 20 90 Verifications and Adjustments Atthis point the 100 Flow Sensor value has been set For each of the remaining radio buttons 20 90 location C the operator should run through a similar verification and adjustment procedure that was just completed for the 100 Nozzle Flow Sensor value the blue needle is too high decrease the value by increments of 5 in the appropriate 20 90 Nozzle Flow Sensor box location H If the blue needle is too low increase the value by increments of 5 in the appropriate 20 90 Nozzle Flow Sensor box location Note After completing this calibration procedure the operator should quickly run through all of the Flow Sensor ranges 20 90 The purpose of this step is to assess the overall performance of the flow system Select the Thumbs Up icon to save changes and exit the Flow Adjustment screen DISCONNECT THE BLUE FLOW METER HOSE FROM THE FLOW CALIBRATION FITTING AND RECONNECT THE BLUE UPPER HEATER HOSE FAILURE TO RECONNECT THE UPPER HEATER HOSE PRIOR TO RUNNING THE TOP HEATER WILL CAUSE THE TOP HEATER ELEMENT TO FAIL DRS24C Series Manual Page 11 Section 4 Verification 4 5 Vision Alignment Verification and Adjustment The LTP Beamsplitter Vision System is calibrated at Air Vac prior to shipment However physical movement such as shipping and continual use require that th
82. advanced forecasted projections of thermal targets The system will begin by running the default or user adjusted process parameter set After this initial cycle the system will begin an automatic iterative thermal optimization session A maximum of 3 additional optimize cycles be executed Thermal target set points may be automatically adjusted before the start of each optimized cycle The system may not need to run all 3 optimize cycles to achieve the desired thermal results During an active cycle the system is constantly monitoring and controlling the following process parameters e Device top temperature and ramp e Device joint average temperature and ramp e Nozzle heater temperature and flow rate e Board temperature e Diffuser heater temperature and flow rate e n addition a temperature maintain mode may be implemented to extend the time for a particular process stage i e soak reflow All thermal and flow control functions are executed multiple times per second helping to maximize the thermal adjustment response time The system displays several real time process values e Device top temperature and ramp e Device joint average temperature and ramp e Thermocouple sensors maximum of 8 e Graphical plotting and digital display e Soak time e Heflow time e Reflow cool down time device joint temperature avg gt 183 C e User defined cool down time device joint temperature avg lt 183 C This time defin
83. against the device joint average temperature e P Waiting for the minimum board temperature e WS Waiting for the minimum soak temperature 5 Above the minimum soak temperature e WRWaiting for the minimum reflow temperature e R Above the minimum reflow temperature e HC Cool down above 183 C UC Cool down above the user defined cool down temperature 1 Seconds 7 User defined T C 4 2 Nozzle heater temperature 8 User defined 5 3 Nozzle flow rate 9 User defined T C 5 4 Board temperature 1 10 User defined T C 7 5 Device top of package T C 2 11 User defined T C 8 6 User defined T C 3 DRS24C Series Manual Page 110 AUTOMATIC PROFILE BUILD Ps rl the o Application Daftaltiene 4f Note Pressing the Thumbs Up icon C Component Heremesl Component Replacement the Import Thermal Sequence Reports Remeval amp Pickup screen will present the Build Profile screen Pickup amp wen Placemeai The system will default to the Component Manual Placement Replacement program NMurzlefieNniBnns 2 Prositien The Component Replacement will be f 1 Contact defaulted to the Automatic Pickup and Auto O Force Placement mode Mozzle x cx Devine Height gt
84. alignment to be time tracked and graphically plotted DRS24C Series Manual Page 47 Section 6 Software 6 2 1 8 Build Photo Links The operator has the ability to link multiple photo captured video images to a control profile The same photo image can be linked to multiple profiles The maximum number of photo links per profile is 49 Selecting the Build Photo Links menu Teach screen allows the operator to adjust the existing photo link list j Add Entry The operator must enter the exact photo bitmap name without the BMP extension into the Bitmap File box The operator must click on the Add Entry button to temporarily insert file name into the existing photo list Delete Entry The operator must highlight click the entry to be deleted The operator must click on Ed ai the Delete Entry button to temporarily remove the file name from the existing photo list Build Photo Links Photo Link Information AP BGA 225 Clean Site BGA 225 Damaged Site Note Photo images are available to the operator from the Run screen DRS24C Series Manual Page 48 Section 6 Software 6 2 1 9 Application Notes Miscellaneous Control This screen allows application specific notes to be entered These notes are made available to the operator during the Run cycle In addition there are a few miscellaneous profile control parameters apply to all events Edit Application N
85. are saved during the Teach function Also the operator can use this check box to suspend any future motor activity allowing event selection to be quickly and easily completed up down event buttons Additionally this check box can be used to re synchronize the actual and destination motor coordinates Z and Vision axis A Y Display A These motor coordinates represent the actual position Pos Pos for the Z and Vision axis Display B These motor coordinates represent the destination event position for the Z and Vision axis These coordinates B are taught during the profile motion development phase Usage When the Motion check box is clear default the destination positions B will not be adjusted each time a Teach function is performed This mode allows the operator to quickly scroll through the events without having to wait for motor synchronization When the Motion check box is selected checked the destination positions B will be adjusted each time a Teach function is performed Caution should be used during this mode of operation because motion may occur and destination motor positions will be adjusted by Teach function When the Motion check box is toggled from a clear state to a checked state the Z and Vision axis will be repositioned using the destination coordinates This motion will include a complete Z and Vision home axis procedure A Warning Message is displayed to the operator before any moti
86. button will activate or deactivate the special vacuum probe port used with component handling tool DRS24C Series Manual Page 66 Section 6 Software 6 2 2 10 3 Nozzle Vacuum The Nozzle Vacuum button will activate or deactivate the nozzle vacuum When this function 15 active the button background will be display in green 6 2 2 10 4 Nozzle Device Separation vacuum tube helps to separate the component from the nozzle When this function 15 active the button background will be display in green The Device Nozzle Separation button will activate a small volume of air back through nozzle 6 2 2 10 5 Site Cleaning Vacuum The Site Cleaning button will activate a special vacuum port used for site cleaning The site cleaning tool requires a vacuum source to remove the molten solder from the site When this function is active the button background will be display in green 6 2 2 10 6 Cycle Start Stop 4 Cycle Start Stop button is used to activate or terminate the process cycle This button will display a green background when the cycle is active or a gray background when the cycle is not active Clicking on the button when the background 15 green will terminate the cycle 6 2 2 10 7 Thumbs Up OK Exit This button will exit the Run screen and return the operator to the Main screen DRS24C Series Manual Page 67 Section 6 Software 6 2 2 10 8 Multi Media M
87. code to gain access to DRS24 machine DRS24C Series Manual Page 145 Section 7 Operator Training Table Of Contents 7 Operator Training DAY 2 EET Nc 2 e Operator Registration sessist 3 Ved e E E T EE A A OE E EE E 3 7 4 Main Screen Options Open Directory Files 4 7 5 Running the Operator Training QFP160 Profile 5 6 Jv Do E 7 79771212 7 es M 67 2 7 VOT i Ful Ey 7 29920 omen uu taa dele dives 8 7 5 6 Viewing the Component Leads and Pads 8 POT WIS MI CVI Mn 9 Z368 CheckAlenmeni at Board ca sasaqa 10 AE AMONG CI 11 7 6 Process Tips TOT T 72 onun sn Susu S D SS S S D S SS 12 ZO NEM NI Sauna S cas oes a Cale SS S s 12 O OST 66 ECT
88. cone Check nozzle clamp must open completely and hold and snap closed Rebuild if necessary Run wire brush through vacuum tube Check for air tube cracks at heater head cap and insulation on wires inside Check for tie wraps tube input to hold vacuum hose around hose and tube through vertical supports Check vision alignment verification see Section 4 5 Perform daily weekly and monthly preventative maintenance schedule Maintenance is based on normal usage Depending on environment and usage the maintenance schedule may need to be adjusted If machine is moved the installation see Section 3 0 and verification see Section 4 should be repeated Proper electrical input 208 240 VAC 50 60 Hz and air supply 90 130psi MUST be provided DRS24C Series Manual Page 2 Section 11 Maintenance 11 0 1 Preventative Maintenance Schedule Procedure Daily e Self explanatory Weekly Q Clean Microscope and Vision System Optics Wipe eyepieces mirror and vision system prism A with alcohol Q Remove and clean polarizing filter B Q Clean bottom of vision prism Unclip to remove polarizing filter Note Filter block drops down Q Wipe flux from table arms and rails Q Apply a film of light oil to the X and Y rails Remove flux on Supports etc DRS24C Series Manual Page 3 Section 11 Maintenance Q Replace the two vacuum filter elements A of Site Solder Remov
89. copying the auto profile template When changing from IR to a non IR thermocouple profile on the auto profile build screen the non trigger events were not being updated correctly This software issue has been corrected DRS24 Release Notes Version 4 43 2 Item 2 Lead Free Defaults Enhancement Lead Free default check box defines reflow temperature globally for the software When new profiles are created this will be the default reflow temperature If the Lead Free check box 15 checked lead free reflow temperature will be displayed in the Solder Reflow edit box If the check box 15 clear the standard reflow temperature will be displayed The software will save the current displayed value when clicking on the Thumbs Up button The solder reflow values that are not visible will not be saved DRS Setup Limits and Defaults Maximum Temperatures The Solder Reflow edtt Default Force Limits box will show the regular solder reflow temperature Nozzle C Time sec Diffuser C Placement Site Clean Force hen the lead es check MILI NM 2000 00 g 1000 00 00 W box 15 clear or Lead Free Default Flow Rate Limits Reflow temperature when Nozzle Flow Sensor Nozzle C L Diffuser R Diffuser C the check box 1s checked 100 100 100 005 Solder Reflow C Y v Lead Free id Defaults Default Temperature Limits Default Groups
90. equal the Device Joint s Reflow s time The system provides a 10 second success window 3 The Cool Down Stage will end when the Process Cool Down s 183 c senses the joints to be under 183 c Dele kawaq JT Haman Kj ram 44 Tanja inan if Pan 3 m BEN d UM T bien T nas w Fin 1 Note The Data indicator will be illuminated DRS24C Series Manual After the Cool Down Stage the first automatic profile cycle is finished If all thermal profile parameters have been met on the first pass the Done Indicator will a be illuminated If all thermal profile parameters have not been met the Optimize Indicator will be illuminated Optimize T Reference The CoolDown time is the time between the joint temperature at 183 to the defined cooldown temperature 170 default setting This will automatically be transferred to the profile Page 99 Reference Activating Thermal SMART Track Cycle Parameters to meet Auto profiling Reflow Done Criteria Optimize Device 2 gt 1 setting of top of package Device Top was not exceeded fx
91. er De EEBEEEEERBEREEEEREBEESEEEEEREEREE C Subtract e Once you select the menu item you will be brought into the appropriate section of the table e Enter the changed value in the data box then click in the box es you wish to change using the right side mouse button You should see the changed values in the table e After all changes are made click on Thumbs Up to return to the Teach screen Changes made in the table editor are saved automatically so you do not need to click on the Teach icon however be sure to use Save or Save As to permanently save changes DRS24C Series Manual Page 9 Section 8 Engineering Training 8 7 Tips on Editing a Profile The Motion box B page 4 must be checked in order to properly teach the desired Z axis vision coordinates in an event e The upper heater flow rate be set between 15 and 100 in 1 increments The flow setting represents a percentage of 2 75 scfm 100 Excessive flow rates can disturb the formation of the solder joint and negatively impact adjacent devices The required flow rate 15 typically a function of nozzle size the smaller the nozzle the lower the flow rate e The upper heater temperature can be set between degree celcius 420 degrees celcius in 1 degree increments A typical maximum temperature is 300 degrees e Typical diffuser settings are as follows Temp Board preheat stage 400 Soak Ramp Reflow 325 H
92. for play in carrier Y bearing Bring the carrier to the forward most position center carrier and lock in place Remove the four screws A left amp right sides holding the board carrier set carrier aside Remove the four screws B left amp right sides holding the diffuser mounting plate double diffuser or dovetail single Lift straight up and slide to back Lay on top of diffuser Inspect cable Make sure cable clamps are tight Clean rail OO Ooo Q Remove the four screws C holding the x bearing rail Q Lift and move the carrier assembly to the back of the machine O O O DRS24C Series Manual Page 6 Section 11 Maintenance Q Remove left bearing A Be careful so that balls do not fall out Q Remove right bearing Do not loosen center screw cam Q Use 3 in one oil or similar to lightly lubricate bearing A B Reinstall right bearing Do not tighten completely Slide back and forth Reinstall left bearing from front of machine Slide back and forth Tighten Press right bearing against rail Set cam until almost tight Tighten top and bottom screws Check the y bearing for excessive play by twisting the bearing plate left and right There should be less than 1 16 play in the assembly Do not over tighten Table will not move with y drive or bearing will be damaged if it 1s too tight Continue to X bearing procedure DRS24C Series Manual Page
93. functions associated with that button are disabled 6 0 2 Edit Boxes Edit Boxes allow information to be entered by placing the cursor over the top of the box and clicking on the left mouse button Characters are entered directly from the keyboard or from the Name pop up keyboard keypad DRS24C Series Manual Page 4 Section 6 Software Clicking on selected edit boxes teach screen will generate a popup keyboard keypad Characters may be entered directly from the physical keyboard or by clicking on the screen key buttons After the desired information 15 entered the operator must press the enter key physical keyboard or click on the thumbs up button to complete the entry Screen Keyboard dee BackSpace T EISE jsp bd dp ds Li Screen Keypad Clear Backspace DRS24C Series Manual Page 5 Section 6 Software 6 0 3 Spin Buttons Spin Buttons are used to directly modify information within an edit box By clicking left button on or holding down repeat the up or down button the edit box value will increase or decrease respectively Note If desired the operator can alternatively use the popup keyboard keypad to directly enter a value 6 0 4 Check Boxes Check boxes are generally used to program a DRS24 function or activity Inactive Clear state m A blank check box indicates the Off or the inactive state e Active Black state
94. lights vacuum cups and tubing Air Vac agrees to repair or replace any or all such equipment that may prove to be defective within the warranty period without expense excluding shipping to the owner This warranty shall not apply to any products that have been repaired or altered except by Air Vac Engineering Services under warranty shall not affect an extension of the warranty period nor will a new warranty period be granted for the parts which were replaced repaired The title of the replaced parts will automatically pass to Air Vac Air Vac reserves the right to reject replacement under this warranty where in the sole opinion of Air Vac the defect is due to obvious misuse and or improper maintenance of the module or any part thereof The express and or implied warranty of Air Vac is limited to the replacement and or repair of any item defective in material and or workmanship Other damages if any direct or consequential are expressly excluded from this warranty Air Vac shall be liable under this warranty only if 1 Air Vac receives notice during the appropriate warranty period 90 days or 1 year as applicable 2 The products are operated in accordance with the supplied documentation and 3 Such products are to Air Vac s satisfaction determined to be defective When contacting Air Vac for warranty inquiries please provide the following information Order number which the parts were shipped Model and serial number of the product
95. m om Ple dai mp Des Jong Ramp 2 8 Fee Actual Eos Thermal Profile Graph Screen Board Preheat Soak Reflow Cool Down Done Optimize Nozzle Board Dev Top Actual real time setting of thermocouples Indicates cycle board is above Board Control T C 1 Start C setting Indicates cycle board is in the Preheat between Start C and Target C settings Indicates cycle joints are in the Soak between min Soak C and max Soak settings Indicates cycle joints are in the Reflow between 183 C and Target C settings Indicates cycle joints are in the Cool Down between Target C and Cool Down C settings Indicates the cycle is successful and finished Indicates the cycle was unsuccessful and will restart Upper Heater temperature setting Board temperature Top of package 2 temperature Joint temperature Device Joint s Average Target C Cool Down C Reflow s Min Soak C Max Soak C oetting for maximum joint temperature in reflow event Setting for minimum joint temperature during reflow event oetting for time of joint temperature over reflow in reflow event Setting for minimum joint temperature during soak event oetting for maximum joint temperature during soak event Soak C Setting for time of joint temperature in soak event between min and ma
96. m EZ E Db IRSE S GI Temperature DRS24C Series Manual Page 70 Section 6 Software 6 2 2 12 1 Graph Data Menu Option The Graph Data menu allows the operator to load the current cycle graph data into an analysis matrix This information is organized and displayed based on seconds Each row captures one second of the overall profile cycle This menu option 15 only available when the process 15 not cycling Column 1 A represents seconds Column 2 B represents the current event Column 3 C represents the diffuser temperature Column 4 D represents the nozzle temperature Columns 5 12 E represent the thermocouple temperatures B O E Graph Data Matrix A TIC 1 Max Temp C Min Temp C Temp Slope Time Above 183 C Time Above 000 TIC 2 Temp C 4 Min Temp C Temp Time Above 183 C Time Aboveaae c tempstope Time Above Time Above 08 4 Temestepe Time Above Time Above 08 5 Max Temp MmTemp c Temp Siope Timeabove 183 Time Above 4 C 6 Max Temp MmTemp c remestepe Vrimeabove 183 Time Above 4 C 7 Max Temp Mintempc Wempsipe time Above 183 Time A
97. machine see section 3 Installation Measure both legs of the incoming 220V ac line to insure the voltage is within tolerance of the heating element 210 232 VAC Check fuse F3 and replace if blown Measure the resistance of the upper heater element It should be 52 ohms See section 11 Maintenance for details on how to checkout the heating element Replace the element if required Verify that the athena controller programming has not been corrupted see section 11 7 Maintenance Verify the athena control communication 12 1 2 Diffuser Heater If the diffuser heater 15 not putting out any heat run through some of the items on this list Verify that the process profile has not been inadvertently saved with no heat in that event Measure both legs of the incoming 220V AC line to insure the voltage is within tolerance of the heating element Follow the flowchart on page 3 DRS24C Series Manual Page 2 Section 12 Troubleshooting DRS24 Diffuser Heater Flowchart Check Air at 80 PSI Replace fuse check athena controller fuse blow programming again yes Ohm out heater 26 reprogram 15 controller from haie left to right Heater did replace athena contoller program correct does JS heater work problem follow heater working yes Put athena back to original location switch wires on TB21 with wires on TB22 switch plugs in wir
98. or if you are unsure of what to do Alarm Control ji Maximum Time 1 Process Cycle History 1 Motion Communication Link 1 Hun Graph History 1 Force Communication Link 1 Hun Export History 1 Temp Communication Link 1 Temperature Limits 1 Cycle Counter 1 Flow Sensor 1 Low Memory 1 Low Pressure Process Thermocouple 1 1 Activity Time Out 1 Force Removal Press ENTER key to stop audible alarm 1 Force Placement 7 7 2 Process Limits Various limits are incorporated to provide safe operation Consult a supervisor if a limits message appears on the Run screen and stops the process DRS24C Series Manual Page 14 Section 7 Operator Training 7 7 3 Reset Operator When the operator physically leaves the system we advise you to activate the Reset Operator option from the menu bar This prevents unauthorized usage when you are away from the machine Note The reset operator screen will appear automatically if the unit has not been activated after 15 minutes DRS Software Application Opticns Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Thermal SMART Track System Operator Registration GS operator WA e U 5 7 8 Operator Maintenance Daily Clean carrier area of fallen parts e Report any problem to supervisor Weekly or as needed Clean microscope and vision system optics with lens clean
99. or the table it sits on when force placement is occurring e Check that the vertical tension brake screw 15 properly adjusted With the machine powered down manually raise the Z axis to the top of the travel Tighten or loosen the adjustment screw so that the nozzle head just starts to drop down under its own weight then tighten just enough so it won t slip down Check the vertical bearings the Z axis shaft s Remove the heat shield and manually lower the Z heads all the way to the bottom of the travel The black bearing housing bracket should contact the bottom stainless plate if not check to see if the gold vertical linear bearings are bottoming out on the shafts before the housing reaches the bottom If this is the case these linear bearings must be pushed up with a screwdriver or similar prying device e Enter Set up Force Measurement and VIEW the Force Sample value in the box This should be fluxuating around a certain point by 300 Apply a downward force to the diffuser directly under the nozzle DRS24C Series Manual Page 8 Section 12 Troubleshooting and see if this value increases If you see characters other than numbers this means the force board needs re programming Call Air Vac Technical Support NOTE Make NO attempt to calibrate the force system This requires a special calibration weight and a procedure that must be followed TO THE LETTER e Call Air Vac Technical Support DRS24C Series Man
100. pin connector Keyboard connector D Speaker connector E Optional Connect camera cable to video adaptor plug The adaptor plug connects to the Video Port F on the back of the module Note Cable should be tie wrapped to top of module as shown in section 3 0 4 Optional Connect either an 45 connector into the Network Card Through Port G Note Tighten all external cable screws with a screwdriver C DRS24C Series Manual Page 3 Section 3 Installation 3 0 3 Electrical Connections Internal Computer Connections CAUTION Internal electrical components are extremely sensitive Only qualified technicians trained in handling static sensitive components should be allowed to open compartments Do not proceed further without a ground strap All internal connections were made and checked at Air Vac however internal cards and cable connections are subject to partial or complete disengagement during shipment Failure to check the internal cards and cable connections may cause damage upon initial power up Remove the rear locking screw and open the left white box with the DRS24 logo e Check all of the computer cards to insure they are properly seated Check the SIMM modules cards to insure they are they are properly seated e Check all internal cable connections to insure they are properly connected e Close the left white box but do not reinstall the locking screw at this time DRS24C Ser
101. power up profile is running Please verify these pressure readings and if either gauge reads something other than 80 psi change the pressure by Note Unlocking by pulling upwards the Pressure Regulator Adjustment Controls C Turning the control clockwise to increase the pressure and counter clockwise to reduce the pressure Once the Pressure Gauge reads 80 psi lock by pushing downward the Adjustment Control Go to the hidden menu and then open Post Power Up Profile Click on the Cycle Start button to stop the process Close the right cover and fasten the rear hold down screw Both the Upper Heater and Bottom Heater must be off during this process C B AIR 3ULATOR NITROGEN A j JER AIR Rit e Back of DRS24 Machine DRS24C Series Manual Page 3 Section 4 Verification 4 2 Post Power Up Voltage and Pressure Verification Select Options from the menu bar e Select Open File Group System System System Select the Post Power Up Voltage and Pressure Verification profile and click on the Thumbs Up icon e Click on Thumbs Up again to advance to the Run screen Lift the right white box cover with Air Vac logo Verify that the machine voltage reads 208 or higher A Click on the Cycle Start button to begin the process Re check the machine voltage while the process is running to verify that the voltage is not dropping below 208 while in process
102. process Run screen Examples LS Note The Teach button must be selected to temporarily save any control parameter event adjustments 6 2 1 4 7 Force Placement Removal Procedures Standard Force Placement Step 1 Program a Z axis component position that is slightly above the board Select the Zero Force check box Step 2 To the same event the operator must enter a Destination B and a Range C force value The Range value allows a tolerance to be applied to the force placement accuracy Step 3 All events beyond the actual force placement event steps 1 2 must be designed to eliminate any Z axis motion This 1s accomplished by checking the Do Not Move radio button Note Standard force placement does not consider any force changes that may occur during subsequent heating events DRS24C Series Manual Page 36 Section 6 Software Force Placement Auto Adjustment Step 1 Program a Z axis component position that 1s slightly above the board Select the Zero Force check box Step 2 To the same event the operator must enter a Destination B and a Range C force value The Range value allows a tolerance to be applied to the force placement accuracy Step 3 events beyond the actual force placement event steps 1 2 must be designed to eliminate any Z axis motion This is accomplished by checking the Do Not Move radio button Step 4 Any event that has the Auto Adjustment check box selected will allow
103. this is acceptable Bowden continue to next step Sequence Gontel Shot EJ Option If the user wishes the Manual Pickup and Manual Placement may be selected LI Reference Component Replacement Component Replacement Automatic Pickup The template will automatically include all events to pick up the device using the bga Automatic Pickup C Manual Pickup Auto Force Placement The template will automatically include a near place approximately Force Placement 10 from the board followed by an auto force C Manual Placement placement of 100 grams 20 grams t Option Manual Pickup The template will include an event which will present the nozzle The operator will prompt to manually insert or position the bga to the nozzle This will be a footswitch event Press the footswitch to proceed with the sequence t Option Manual Placement The template will include an event which will present bga and nozzle just above the board approximately 10inch immediately after the alignment event The operator will be prompt to manually position the bga to board This will be a footswitch event Press the footswitch to proceed with the sequence sf Note The operator has full control over the placement process the automated features are not activated after the operator completes these steps DRS24C Series Manual Page 111 AUTOMATIC PROFILE BUILD
104. to terminal strip Cut wires to length reinstall thermocouple plug yellow wire red wire and connect heater wires to terminal strip no polarity e Perform steps 1 4 of heater test Diffuser requires no calibration Close all access panels and screw shut before turning back to production DRS24C Series Manual Page 14 Section 11 Maintenance 11 5 Temperature Control Module Replacement Reprogram e Disconnect the machine main power Open the right box assembly by removing button head screw on left rear of box Locate the temperature controller that requires replacement Each heating element utilizes a separate temperature controller Remove the controller by depressing both sides of the display and pulling the controller out of the casing sleeve e Place the new controller in the housing making sure the connections on the bottom of the controller line up with the connector and the end seats fully Reconnect the machine main power The programming instructions for the diffuser and upper heater applications have some differences Please refer to the programming instructions sent with your replacement temperature controller for details Right Diffuser Single Diffuser Controller ADD03 Left Diffuser Controller ADD02 Nozzle Controller ADDO0I DRS24C Series Manual Page 15 Section 11 Maintenance 11 6 Athena XT16 Programming Instructions The four buttons for programming the Athen
105. touching then back off Raising front lowers back chase your tail Tighten the 2 1 8 allen screws Note Do not over tighten screws This will warp diffuser mounting plate e Place the board support back on the diffuser and slide under the glass Check for firm contact with the glass in four corners e Repeat steps on all 4 corners of the diffuser until no more adjustment is needed DRS24C Series Manual Page 25 Section 11 Maintenance 11 11 Vacuum Ports System Input Regulators both nitrogen and air inputs Diffuser Condensation Chamber A and Nozzle Condensation Chamber B Bleed off any water built up in the condensation chamber e Inspect the chamber for excessive dirt Take corrective action on the input air line if excessive dirt is found Nozzle Vacuum Filter C Keep the nozzle vacuum glass tube free of contaminants Change felt filter FI AE as needed Site Clean Vacuum Filter D Keepthe site clean glass tube free of contaminants Change felt filter FI AE as needed For internal vacuum pump locations and part see the manifold assembly section of the manual A B D C DRS24C Series Manual Page 26 Section 12 Troubleshooting Table Of Contents I2 Troubleshooting 120 Tro ubl sho0lliD i o 2 IX No ICAL 42 252 29399999945914991298299499998 94 0990989041 9909 92994 99098099199 8 09 6098 99 89 0 9 26 0 0005 2
106. wed nm F z Pfs p pin Cmimi 127 e une ww eme c ES seconds ___ EMEN E prd _ portem aT T r Berl 1 Process S I pak s m Soak s a Peers STE 060 Dis c E BS RO CHEN HIJO CH SE ODIO EI ES ES NEHE Bd O4 Gs BS RADO PLENE ael p amc Foro Af Note The cycle will continue unless the adjacent device or device top max settings have been exceeded LI Reference joint temperatures board top of device and any other active thermocouple will be graphically displayed e he diffuser will remain on until the Board Control 1 Max setting is reached The diffuser will then turn off The board temperature will be in a maintain mode of the setting When a temperature of 5 C lower than the setting is sensed the diffuser will be reactivated DRS24C Series Manual Page 97 ACTIVATING THE THERMAL SMART TRACK CYCLE REFLOW STAGE Joints go from 183 c and the Target Temperature The default settings are Target 200 s 60 2 Note Between Soak and Reflow Stages Message will state Waiting for the Minimum Reflow Temperature Then Message will state Device Joints Are Below Reflow Temperature gt 1 The Reflow Stage
107. 0 Schematics 10 3 Electrical Connector Definitions continued CONNECTOR CIRCUIT TYPE CONNECTOR TYPE uU Y ss J42 Hard drive power 4 pin PC power cable cable 147 I2Vpowerlghs 2 J C J49 Motherboard 2lpinsinsalled DRS24C Series Manual Page 13 Section 10 Schematics 10 4 Electrical Wiring Definitions 10 4 1 Overall Wire Harness Part Numbers HARNESS PART NUMBER HARNESS DESCRIPTION 1 3 2 p3 3 p3 4 P3 5 P3 6 P3 7 P3 8 P3 9 P3 10 3 11 3 12 P3 13 P3 14 P3 15 P3 16 P3 17 P3 18 P3 19 P3 20 P3 21 P3 22 P3 23 p3 24 DRS24 Main harness DRS24 AC power harness DRS24 pneumatics harness DRS24 DC power harness DRS24 Wire harness AC power switch small NO7 RELAY BD RELAY BD NO9 RELAY BD NOIO RELAY NO11 RELAY NO12 RELAY BD NO13 RELAY BD NO14 RELAY BD 15 RELAY BD Com2 relay J2 25 15 NO6 RELAY BD J2 22 15 J21 7 AIN4 LP1 RPI 5 pullup res J21 9AINS LP2 RP1 6 pullup res Earth ground LFAI SWI2 1 LFA2 SW 12 2 LFB1 SW13 1 LFB2 S W 13 2 Com return A 21 13 AINT DRS24C Series Manual Page 14 Section 10 Schematics P325 25 NO REBDAO 326 J26 JNOI GELBDAO2 527 17 egret 18 3 B amp B female DB25 B amp B female DB25 P 28 BEN 4 BEN H18 7 B amp B female 0825 2 BEN w was NE
108. 0 0 200 0 183 user Dev Top Ramp 150 0 Temperature Process Optimization Analyze Rule p 100 0 Target Actual Dev Joint Ramp 50 0 0 00 00 00 20 00 40 04 00 01 20 01 40 02 00 02 20 02 40 03 00 03 20 03 40 04 00 04 20 04 40 05 00 Average Actual 1 2 3 Data DRS24 Release Notes Version 4 43 6 Item 3 Setup Vacuum Sensor Stop Enhancement the Teach screen the nozzle vacuum sensor value is displayed while the nozzle vacuum 15 activated This 1s the sensor value that is used during the Vacuum Sensor Stop event This type of event 15 used to stop the nozzle at the top of the component prior to applying force into the board or component Removal System Vacuum Retry e gt Actual Sensor 0000 Sensor Threshold 000 Counter 000 Time 000 Temp Incr 000 Vacuum Sensor Communication Blocked Tool Vacuum Pickup 456 500 When the actual sensor reading drops below the vacuum pickup set point located on Communications Setup Page the motion will stop and the process will continue to the next event Process Sample Delay 5000000 Sensor Delay Max Adjust Cnt 10000 250 Teaching a vacuum sensor stop event makes use of the vacuum sensor default setting as the trigger setting However if th
109. 1 007 Power Supply 24V Cosel 900210 004 Power Supply 15V Astrodyne 19002 10 010 Power Supply Computer 9002 10 007 Halogen Bulb Osram 140015 Halogen Bulb Lamp 14 5V 90W EPX 145210 A D Board 1 110 19002 08 040 ISA Dual Serial Parallel IDE Comm Expander mE 9002 08 035 Card RS485 Converter B amp B 9002 08 010 Amplifier 24 Bit Force Measurement Force Board 9002 08 030 Pressure Switch 0 15 PSI Low Pressure Sensor 02002 0100 01 126 Vacuum Transducer Nozzle HAV 128 Vacuum Transducer Probe ss AVRO46H Vacuum Transducer Site Clean HAVI4H Filter Felt FIAE Proximity Switch Assembly 0024 10 040 Z Belt need on belt 106880 Z Motor Belt 1084600 Please note the configuration of machine when ordering these parts DRS24C Series Manual Page 6 Section 2 Facility Requirements Technical Specifications Table Of Contents 2 Facility Requirements Technical Specifications 2 0 Electrical Pneumatic Physical DRS24C 2D amp DRS24C 1D 2 2 l Component ReguiremenlsSu uuu u evt u o PEPPER COR NEE ERT 3 22 Component Positioning Adjustments 3 23 Internal V acum S uu
110. 1 Save Video Image The Save Video option will allow the operator to review capture a live video image The operator must first setup the live video image After completing this task the operator can freeze or capture the video snapshot 6 5 1 1 1 Setup Live Video Image DRS24 Video Maintenance DRS24 Live Video Bet Video Snapshot About DRS24 Live Video 1111111117 PELLI DRS24C Series Manual Page 130 Section 6 Software 6 5 1 2 Step 2 Get Video Snapshot Select the Get Video Snapshot menu to capture the video image DRS24C Series Manual Page 131 Section 6 Software 6 5 1 2 1 Save As Photo images can be permanently saved and linked to specific profiles The same video snapshot can be used by several profiles The Save As option will allow the operator to copy the video snapshot to the DRS24 photo directory The operator must be sure the correct directory has been selected before completing the Save As option Photo images must be stored in the following directory C WINDOWS DRS24 PHOTO default Save Save In BGA225 balls To save the bitmap enter name of BGA225 COMPONENT bitmap in the File name edit box and click BGAZ25 SITE on the Save Button To exit the Save As screen click on Cancel File name untitled Save 256 Color Bitmap 6 5 1 2 2 Exit To exit the Save Video Image option select the Fil
111. 100085 M28DvG 3 CSP 46 Soldering AFTER fluxfsolder paste on sphere application M28D vG 3 PBGA 225 256 Removal 066 thick board N1061 1061 PRGA 225 256 Removal 100 thick board N1061 1061 PRGA 225 256 Site Cleaning 066 thick board 1081 1081 PBGA 225 256 Site Cleaning 100 thick board M1081X1081 PRGA 225 256 Soldering 066 thick board 1081 1081 PBGA 225 256 Soldering 100 thick board 10811081 PRGA 352 Site Cleaning 066 thick board N1395X1 395 PBGA 352 Removal 066 thick board N1395X1395 PRGA 352 Soldering 066 thick board 1 3961396 432 Removal 100 thick board 1589 1589 To select an entry the operator can highlight the line click and then select the OK button Up Thumb The operator can also select an entry by double clicking on the line DRS24C Series Manual Page 7 Section 6 Software A pull down list box is very similar to a full list box except that this control is displayed on a single line and provides a pull down arrow By clicking on that arrow the list box expands to display several lines of information on the screen After making a selection the list box collapses back down to one line Pull Down List Box Customer Group Air Yac Engineering Company Board Group Profile Library Device Group Area Arrays For Example By clicking left button on the down arrow the board group list box will expand to show more of the possible
112. 230 240 Preheat Reflow Timeout Wait for Reflow djacent Device s 125 300 400 Max Units grams inch newtons mm Automatic Profile Build Force Placement Heater Stabilize Event Nozzle Position Target Range Temp Flow Reflow REL Move 0075 00 0025 00 125 060 035 0 050 Preheat Wait for Soak Reflow Temp 480 250 400 Min Heater Increment Max Heater Increment 0 004 PostRemoval Reflow Pre Motion Heat Event Removal Retry Temp C Time sec Temp Time sec Removal REL Move 300 015 010 020 0 200 p em Defaults The Lead Free check box defines the smart track default values DRS24 Release Notes Version 4 43 4 Lead Free Defaults Teach Screen Enhancement software will display the current reflow temperature of the current profile on the teach screen new profile will display the default reflow temperature The profiles reflow temperature can be set manually on the notes page This reflow temperature will be saved as part of the profile and 1s used to define the reflow line on the run screen graph This parameter does not impact the profile or the system performance Teac LED Adjustment Build
113. 24 provide an easy to use process for operators who will use the Run Screen to simply execute pre developed process profiles Engineering 5 responsibility for the DRS24 is far more involved Engineering personnel will focus largely on the Teach Screen to create or modify profiles for various devices Engineering must then test the profiles using the Run Screen to verify that the profile works as desired Prior to proceeding further engineering personnel should review the Teach Screen information in the software section 6 of this manual Information in this section is designed to supplement not replace hands on training from a qualified Air Vac sales person or representative Please use caution as you become familiar with the system DRS24C Series Manual Page 2 Section 8 Engineering Training 8 1 Modifying a Profile Teach Screen Creating a profile from scratch takes a tremendous amount of work however modifying an existing profile can be done quickly and efficiently Your DRS24 system includes two main profile libraries for area arrays and leaded devices These pre established profiles can be found under the Customer Group Board structures shown below Open Profile NotePad Files CBGA 256 Site Cleaning 100 thick board N845X845 CBGA 256 Removal 100 thick board N845X845 CBGA 256 Soldering 100 thick board N845X845 CSP 46 paste application directly on spheres N28DVG 3 CSP 46 Removal N28DYG
114. 3 CSP 46 site cleaning with new site tool CSP 46 Soldering AFTER flux solder paste on sphere application N28DVG 3 PBGA 225 256 Removal 068 thick board N1081X1081 PBGA 225 256 Removal 100 thick board N1081X1081 PBGA 225 256 Site Cleaning 068 thick board N1081X1081 PBGA 225 256 Site Cleaning 100 thick board N1081X1081 PBGA 225 256 Soldering 068 thick board 1081 1081 PBGA 225 256 Soldering 100 thick board N1081X1081 PBGA 352 Site Cleaning 068 thick board N1396X1396 PBGA 352 Removal 068 thick board N1396X1396 PBGA 352 Soldering 068 thick board N1396X1396 Customer Group Air Vac Engineering Company Board Group Profile Library Device Group Area Arrays Profile NotePad Files Engineering Training Profile PLCC 68 Removal 068 thick board 954 954 PLCC 68 Soldering 068 thick board 954 954 QFP 160 or 208 Removal 068 thick board HOT BAR NOZZLE QFP 160 or 208 Removal 068 thick board N1103B1103 HOT GAS NOZZLE QFP 160 or 208 Soldering 068 thick board HOT BAR NOZZLE QFP 160 or 208 Soldering 068 thick board N1103B1103 HOT GAS NOZZLE SOCKET 44 Removal 068 thick board N654J654 SOCKET 44 Soldering 068 thick board N654J654 SOIC 20 Removal 068 thick board N30A51 SOIC 20 Soldering 068 thick board 30 51 Temp File Last changes made using the TEACH screen warm up Custo
115. 4 C HYS 02 C SPr 20 dPnG Hi e Press the Mode button to exit and save DIFFUSSER I D 02and03 Gn 01 06 rAtE 00 rSEt 02 C HYS 02 C SPr 20 dPnG nL DRS24C Series Manual Page 17 11 7 Cal 9300 Function Menu and Parameters Level 1 Diffuser Press Y to access Function Menu Press to access Autotune or Park Press to access SP1 Prop band Press to access Integral time Press to access Derivative time Press to access Derivative approach Press to access Cycle Time or on off Press to access Offset manual reset Press to access Setpoint lock SP1 Press to access Setpoint Ramp rate Press to access Derivative approach Press to access Soak Time Press to access Adjust SP2 Setpoint Press to access Setpoint lock 5 1 Press to access Setpoint Ramp rate DRS24C Series Manual lt Function Parameter lt Function Parameter lt Function Parameter Function Parameter lt Function Parameter lt Function Parameter lt Function Parameter Function Parameter lt Function Parameter Function Parameter Function Parameter lt Function Parameter Function Parameter lt Function Parameter lt Function Parameter Hold and press 7 to set to 1 Hold and use to set off
116. 67020 1067021 1067022 1067023 1067024 1067025 Small lcanz a a 8 List 1067026 File Temp Details 51 object s 358KB 2 Amangelcons Line up Warning It is critical to periodically backup the entire contents of the Profiles directory Failure to perform a regular full backup may cause total loss of all customized profile development work Refresh Options DRS24C Series Manual Page 19 Section 6 Software 6 1 7 1 Backup files to disk amp C WINDOWS drs24 Profiles File Edit View Help Selecting Files The pull down list box should be displaying Profiles folder If not click on the pull down list box to show all of the available choices 00000003 00000004 00000005 0000 011003 1011013 ce e 99 9 EX l 4 amp To select a single move cursor over desired file and click on the left mouse button This will highlight the file icon e r e n3 E ce n3 EE ET e 9 9 _ _ e o e co 9 9 s 9 Multiple selections be made by holding down the control key Ctrl while simultaneously clicking on the desired file ES Ld m ES 4 4 ES
117. 7 Section 11 Maintenance Three to four times per year To correct for play in carrier X bearing Q Loosen rear bearing and remove Lubricate bearings Loosen set screws small A of front face of carrier bar Loosen screws of front bearing and remove Lubricate bearing Re install rear bearing and tighten Install front bearing Tighten set screws Tighten screws of front bearing Slide rail Movement should be firm but not stiff Check tension by twisting rail Reattach the x bearing rail Reattach the diffuser and board carrier Check perpendicularity of carrier see Section 4 2 Check diffuser to carrier parallelism see Section 4 3 d d d d d d a a A Q Clean and lubricate vertical shafts Q Remove heater cover LJ Remove all grease from bearings and shafts top and bottom with alcohol Brush on and wipe a Apply silicon vacuum grease on shafts and bearings To correct wobble in nozzle cone Q Remove heater shield Q Loosen nut under plate of center front bearing C Q Adjust nut under center bearing Do not over tighten bearings will separate Q Retighten nut under plate C Adjust Nut e 2554640 NR p Y Q A4 4 V V AS A t AS SS SKS S 00 lt Loosen Nut inm DRS24C Series Manual Page 8 Section 11 Maintenance To correct nozzle clamping mechanism LJ Disconnect power Q R
118. A 0 141 143 MDI JI5 P3 New 9 51 00 2 MDI JI5P4 New X J294Lledheightret 5lg 151 DRS24C Series Manual Page 16 Section 10 Schematics 5 log ret Computer PS Computer PS Computer PS Computer PS Computer PS Computer PS Computer PS Computer PS Computer PS Computer PS Computer PS Computer PS Computer PS 12V 142 4 Computer PS 12 158 3 Computer PS 12Vret 1423 Computer PS I2Vret 158 2 1422 Computer PS 5Vret 158 1 21 Computer PS 5V_ 158 4 159 3 159 2 159 1 20 120 P2 120 3 J20 P4 Relay board J20 P5 Relay board J20 P6 Relay board J20 P7 Relay board J20 P8 Relay board J20 P9 Relay board J20 P10 Relay board J20 P11 Relay board J20 P12 Relay board J20 P13 Relay board J20 P14 Relay board J20 P15 Relay board J20 P16 Relay board J20 P17 Relay board J20 P19 Relay board J20 P20 Relay board Com 5 J38 6 J38 5 J38 4 J38 3 J38 2 J38 1 J37 6 J37 5 J37 4 J37 3 J37 2 J37 1 J58 4 BN 20 R 18 Awg R 18 Awg R 18 Awg W 18 BK 18 Awg BK 18 Awg BK 18 Awg BK 18 Awg BL 18 Awg Y 18 Awg 18 Awg O 18 Awg Y 18 Awg Y 18 Awg BK 18 Awg BK 18 Awg BK 18 Awg BK 18 Awg 18 Awg R 18 Awg Y 18 Awg 18 Awg BK 18 Awg 18 Awg BK 22 Awg BN 22 Awg R 22 Awg 22 Awg Y 22 Awg GN 22 Awg BL 22 Awg V 22 Awg GY 22 Awg W 22 Awg BK 22 Awg BN 22 Awg
119. BlocksDouble DISP ETATE E ER Eo 6 1024 COMMUNICATION ySIOHlosuensessasssuvuredutiuT sus ESAME Deed Esa 7 1023 Harness Wiring Block Single DUTUSEE er E REPAS ESKETECRN TERRENI EEOT TER SS E 8 10 2 6 Main Harness Wiring Block Double Diffuser 9 252 Pneumatics Pieci cal 10 279 11 10 3 Electrical Connector Detfinitions 12 13 10 4 Electrical Wiring Definitions IOS I Overall Wire Harness Part NUIMDCTS asa VE REN 14 10 4 2 DRS24C Main Harness 0024 90 101 14 19 1045 AC PoWwerHarmmesstO074 00 102 i5sdsaue DPENTUSOAP RN POE SEE ERE EE MER IPS 20 1044 Pneumatics Harness 0024 90 103 21 22 1045 DC PowerHarness 0024 90 10 e Vauban us ev veto esae eds 23 24 10 4 6 Wire Harness Small 0024 90 105 24 10 4 7 Power Transformer Connecti
120. CAUTION HIGH VOLTAGE CONTENTS SUBJECT TO DAMAGE BY STATIC ELECTRICITY DISCONNECT POWER DO NOT OPEN BEFORE OPENING EXCEPT AT APPROVED STATIC FREE WORK STATION DRS24C Series Manual Page 5 Section 9 Safety 9 4 DRS24 System Alarms The following alarms to the DRS24 system will halt the process until the problem has been corrected and the alarm is cleared Maximum Time Motion Communication link Force Communication link Temperature Communication link Cycle counter Low memory Process Thermocouple Force removal Temperature limits Flow sensor Low Pressure No activity Time out Force placement Computer must be rebooted to clear The various alarms are explained in further detail in the Software section DRS24C Series Manual Page 6 Section 10 Schematics Table Of Contents 10 Schematics 10 0 Computer C ard Locations 2 10 1 Computer Connection 3 10 2 DRS24 System Block Diagrams VIS ORE R OPE RUPEE EIS DLE EP 4 10 2 7 Power Wirnng block MIngle Diffuser REPE ERE TEE PEVERSO PA VER RREEU PUE 5 1023 JPowerWinnp
121. E stop is employed to eliminate unwanted turn on after an E stop e Operator safety warning labels and markings are employed e Diffuser safety shields have been included to minimize operator exposure to the heated diffuser plates Gas nozzle handling tools has been included and should be used when handling hot nozzles DRS24C Series Manual Page 2 Section 9 Safety 9 1 General Safety Machines and tools of Air Vac can only be used with maximum efficiency and safety by well trained personnel Do not attempt to operate or maintain this system without proper training from qualified personnel 9 1 1 Machine Operation e Both the top and bottom heating elements be programmed to reach temperatures as high as 420 C Use caution near heated surfaces including the nozzle and the diffuser plates e Always use the gas nozzle handling tool when installing or removing nozzles Always cover the diffuser plates with the safety shields when the diffuser is not in use but 15 being heated in the idle mode The nozzle and vision systems are powered by stepper motors and are programmed to move during operation Use caution near these two moving areas e Observe the legal and specific national regulations concerning accident prevention and protection of the environment e Observe the general safety regulations concerning working with solder and flux Fume extraction should be seriously considered 9 1 2 Maintenance As a b
122. ER 8 ooo T 8 8 4 Saving Changes Permanently es asess 55 Testing the Revised Profile es eosassssssssssssss 8 S06 Table IE 9 5 7 Tips on Editing a Profile s oseeseseosassossssssssss s 10 8 8 Process Parameters for Leaded Devices 10 11 57 ABCA grill T mmm 12 PEOGOSS TIS 12 SACL 12 XY T L e usa u asss 12 SEU ME Gas AO T 0yussssmqastassayssyahupapashusupakasqaysacyakaqayaskusqakqusqashaskosstasskusatasutaspssasspasaas 12 CAA DO TRU a asiya 13 qO 13 gd OO MICTOSCOPE VISION SS 13 DRS24C Series Manual Page 1 Section 8 Engineering Training 8 Engineering Training 8 0 Introduction The DRS24 is a technically advanced system designed with a high degree of automation and process control The features and capabilities of the DRS
123. Engineering Training UPPER HEATER DIFFUSER ww NOZZLE RATE TEMP RATE TEMP CYCLE TIME ee S E S S 3 16 discrete N19DV 10 15 9 32 discrete N28DV 10 15 15 300 LO 300 10 15 Soldering 15 300 LO 300 10 15 Soldering 15 300 LO 300 10 15 Soldering 15 300 LO 300 10 15 Soldering 20 300 LO 300 10 15 Soldering 20 300 LO 300 10 15 Soldering 20 300 LO 300 10 15 Soldering 30 300 LO 300 25 35 Soldering 30 300 LO 300 25 35 Soldering 30 300 LO 300 25 35 Soldering 30 300 LO 300 25 35 Soldering 30 300 LO 300 35 45 Soldering 40 300 LO 300 50 60 Soldering 40 300 LO 300 65 75 Soldering 20 300 LO 300 35 45 Soldering 30 300 LO 300 35 45 Soldering 60 300 LO 300 25 45 Soldering NHB1187B1187 40 300 LO 300 20 30 Soldering 20 300 LO 300 10 15 Soldering 30 300 300 20 30 Soldering 20 300 LO 300 15 25 D DRS24C Series Manual Page 11 Section 8 Engineering Training 8 9 Area Array Profiles e The profiles in the area array group were based upon thermal profiling processes where thermocouples were installed into the area array pads Contact Air Vac for further information on thermal profiling e area array profiles utilize a preheat soak ramp reflow cool down sequence The temperature flow rate time parameters differ for each profile due to component size and board thickness e One quick approach to developing a customized area array profile is to attach a thermocouple to the bottom side of the board
124. F8 BK AGC fast 146C F7 9002 04 054 220V ac liaht F10 1A BK AGC fast 1478 9002 04 015 2 Amps J1 Internally fused 6 3 A PS1 2 Vision cube driver E Z axis driver Solenoids x8 220V ac power supply Cooling Fans x2 I 4 Light tower Relay card 5 Amps PS2 F6 ac mos MASS FLOW CONTR power supply 15 pon D24WIRE6 flo F9 Power supply REV 2 220V ac 5 12 12 mother board w cards 6 30 98 microscope lights g Speech module 8601 F10 Force Meas system C O Light tower 1 Amps DRS24C Series Manual Page 6 Section 10 Schematics 10 2 4 Communication Control System AMI SERIAL MOTHER Top heater BOARD XT16 MODEL Athena 16 controller 2400 baud 5232 5485 position O1 to RS485 ID NO 01 Diffuser A Athena controller position 02 Diffuser B ID NO 02 Athena controller position O3 19 2K baud 5232 ID 03 Vision Z axis RS232 HBM AD101 force measurement control D24combl flo 3 20 98 DRS24C Series Manual Page 7 Section 10 Schematics 10 2 5 Main Harness Wiring Block Single Diffuser p J41 5 J42 cro Tes J39 Power 2 mother board i Strain guage 421 Pneumatics section RTD ADA1110 I O module halogen I fan function button TC3 Edo _ Nozzle add 01 ISA bu
125. Hozzle 22h 2 BIBI um Device Joint s Target 200 gt 2 Target setting of joint s was achieved Dev Joint Ramp C s Average Actual Reflow 5 gt 3 Time over reflow was within the reflow Reflow s defined c CoolDown Device Joint s Average Reflow is CoolDown 5 183 user C gt The first run is basically an information gathering cycle Many times cycle will not be optimized on the first run The Optimize Indicator will be illuminated ze x uisa Wa E Dau Dekor Cj 18 His hi la Bas SZ E fe s E 7 ged ao Bn 1 T Drea rji adipe mr ilis T Mam 0 ta T uw pom CEXR I meam T en vU y zl Pu Eu LJ Reference If successful thermal profile parameters have been met P mE EA the first pass the Done indicator will be de E c illuminated am Lu i titi ui 1 2 3 E
126. IGH Cool down 5 HIGH The diffuser should be idled at 200 degrees low flow when not in use Failure to idle the diffuser can impact process repeatability typical force target is 75 100 grams with a 20 gram range 8 8 Nozzle Flow Rate and Temperature Guidelines for Leaded Devices The correct nozzle flow rate and temperature is a function of the component and assembly physical and thermal characteristics e The intent of the nozzle is to provide heat transfer to the solder joints while minimizing heat exposure to the die and adjacent components e The gas flow setting must be varied according to the gas nozzle openings The temperature is generally set to a constant 300 degrees e develop custom profiles for leaded devices edit one of the removal and replacement profiles in the Air Vac Profile Library Leaded Devices Group according to your requirements These profiles include preheat of the assembly and nozzle to help insure process repeatability e The following some general reflow guidelines for various leaded devices Please note that these settings assume proper preheat of the assembly and nozzle as described above Reflow cycle time will vary based on board thickness Soldering cycle times assume a hot air soldering leveling step prior to reflow Editing existing profiles in the leaded devices group will insure that all of these requirements are considered DRS24C Series Manual Page 10 Section 8
127. K 22 BN 22 R 22 O 22 Y 22 GN 22 BL 22 22 22 W 22 BL 22 Y 22 Y 22 Y 22 BN 22 O 22 BL 22 Y 22 Force bd BL 20 Force bd BN 20 K14 comm K13 comm K12 comm comm K10 comm K9 comm K8 comm K6 comm K5 comm K4 comm K3 comm K2 comm comm KO comm J23 12 Force board J23 24 Force board J23 11 Force board J23 9 Force board J24 6 J24 5 J24 4 124 1 124 2 124 3 J23 10 Force board J23 23 Force board Com2 3 Com2 5 Com2 9 LPT2 1 LPT2 2 LPT2 3 LPT2 4 LPT2 5 LPT2 6 LPT2 7 LPT2 8 LPT2 9 LPT2 10 LPT2 11 LPT2 12 LPT2 15 J25 11 126 12 126 2 J26 3 J25 1 J23 18 J23 25 J23 3 force J23 2 force J23 7 force J25 12 speech J25 2 speech J25 3 speech J25 4 speech J25 5 speech J25 6 speech J25 7 speech J25 8 speech J25 9 speech J26 4 speech J26 5 speech J26 12 5Vret 125 12 speech 5v 4 7 5 Vret 125 12 speech Speaker out Speaker out 12V 12V ret DRS24C Series Manual Page 18 Section 10 Schematics x 10 235 BLD B amp B 148 1 148 2 2 24Vret Vision prox 157 1 Vision prox J57 3 Z prox J56 1 Z prox J56 3 J21 5 Function button J36 Function button J36 Function button J36 Light switch Microscope lights Log Gnd TB2 Log Gnd TB2 J15 4 J16 2 5V O relay board Dig bd Dig bd Dig bd Dig bd DRS24C Series Manual Page 19 Section 10 Schematics 10 4
128. LU Reference The diffuser settings are l 420 c at high flow Note top of device joint and any active checked thermocouple will indicate live real time values GE RM Devic Ton TK O Q3 Preheat Stage Will Tages Cl Cien l FCR Taipe rr rr end when the Target nu SO na temperature of the Board SP a TMG NH r 1 4 ness Control 15 reached F rr um s Tm Harriet CaM Board Control T C 1 Target Star 090 Heat fa i ae 1 um Darie s pni jeer Cy H ss 1 LL Reference All thermocouples are m 88 real time graphically displayed xcv Hang Peta Aches iem pu DRS24C Series Manual Page 96 ACTIVATING THE THERMAL SMART TRACK CYCLE SOAK STAGE LL Reference e soak stage is defined as time the joints are between maximum and minimum temperature for a period of time Min Soak Max Soak C Soak 15 eThe default settings are Min Soak 140 140 060 EE EBE
129. Maximum Parameter gt set to 450 Press to access lt Function Hold and use 7 to Set Scale Minimum Parameter gt set to Press to access lt Function Hold and use 7 to Select Input Sensor Parameter gt set to tC K Press to access lt Function Hold and use 7 to Select Display Units Parameter gt set to DRS24C Series Manual Page 19 Section 11 Maintenance Cal 9300 Function Menu and Parameters Level 3 Press Y to access Function Menu Press to access SP1 Output Device Press to access SP2 Output Device Press to access Sensor Burn out Press to access Reserve Outputs Press to access Reserve O P LED s Press to access Span adjustment Press to access Zero Adjustment Press to access Set Monitor Press to access Read Monitor Press to access Read Tune Data Press to access Software Version Press to access Reset lt Function Parameter lt Function Parameter lt Function Parameter Function Parameter lt Function Parameter lt Function Parameter Function Parameter Function Parameter lt Function Parameter lt Function Parameter Function Parameter Function Parameter Function Parameter Press to Save and Exit Program Mode Hold and press 7 to set to 3
130. Note If the component leads and pads are not in the same viewing plane manually raise or lower the nozzle to adjust the height of the component leads e Figure 1 is an illustration of proper lead to pad alignment in the vision system with the leads dark properly centered over the pads No vision adjustment is required in this case Figure 2 is an illustration of incorrect lead to pad alignment in vision due to theta error Vision adjustment 15 required in this case I H H H IH H H I H H H 1111 Figure 1 Figure 2 Ifthe leads and pads are not aligned in the vision system after alignment at board level loosen but do not remove the two 1 5mm Set Screws E which hold the two Vision Adjustment Disks F in place e Rotate the disks until component part is aligned Slowly and carefully retighten the set screws while continuing to view the alignment This will insure that no movement of the cube occurs while tightening the Screws Rotate polarization filter pads should move less than 4 of a pad on a 20 mil Part If not replace DRS24C Series Manual Page 13 Section 4 Verification 4 5 1 Precision Optical Alignment Instructions Purpose To align DRS24 vision system placement accuracy to 0 001 or better Items Required Precision Optical Alignment Kit P N 0024 92 010 Placement Nozzle P N 0024 92 050 Glass Reticle Board with 0 00025 target scaling Glass Reticle Component Holding Fixture
131. Reason for warranty Products cannot be returned to Air Vac without authorization please call for an RMA Heater Limited Life Warranty Air Vac Engineering Company warrants the heaters for a period of ninety 90 days from date of shipment Air Vac agrees to repair or replace any or all such equipment that may prove to be defective within the warranty period without expense excluding shipping to the owner This warranty shall not apply to any products that have been repaired or altered except by Air Vac Engineering Services under warranty shall not affect an extension of the warranty period nor will a new warranty period be granted for the parts which were replaced repaired The title of the replaced parts will automatically pass to Air Vac Air Vac reserves the right to reject replacement under this warranty where in the sole opinion of Air Vac the defect is due to obvious misuse and or improper maintenance of the module or any part thereof Heating element life is affected by several factors temperature airflow condition of incoming air water and oil contamination and overall process cycle These products are considered a consumable item length of useful service will vary based on the conditions under which they are run Higher temperatures and or lower flows will cause shortened life The express and or implied warranty of Air Vac is limited to the replacement and or repair of any item defective in material and o
132. The board description from the Profile Notes page Field 6 The profile s Long File name Field 7 The profile s Short Name B icm his M ordPad X Bie 22 14 09 30 97 DRSsg4 UNTITLED DRS 22 15 09 3n0 97 CC UNTITL D DB3 22 31 09730 97 DR par 06 0 V UNTITIEDP DRS emer 2C UNTIT IED DRS 22 35 09 3D0 97 l pnR za P UNTITLED DRS 22 38 09 30 97 DRS24 q n16D aining removal profile oodooo02 prs 22 40 09 30 97 17 DRS24 O 160 training removal profile qfpiS0 training removal 11 1 00000002 88 curro doo ctm atu dqfipi5n training removal profile 00000008 training removal profile D00000002 DRZ 23 33 09 30 97 DRS24 qfpi60 training removal profile O0000002 DRS3 D5 21 10 01 97 DRS324 UNTITLED DR3 05 25 10 01 97 DRS24 UNTITLED DRS 20 48 10 07 97 DRS243 Flow Ramp 20 110 00000005 5 20 52 10 07 97 DR3243 Flow Ramp 20 11051 100000005 81 20 53 10 07 97 DRS243 Flow Ramp 20 110 00000005 5 20 54 10 07 97 DRS243 Flow Ramp 20 110 00000005 5 20 55 10 07 97 DRS3243 Flow Ramp 20 11051 100000005 81 20 58 10 07 97 DRS24 Flow Ramp 20 110 00000005 5 20 59 10 07 97 DRS243 Flow Ramp 20 110 00000005 5
133. Training 8 2 4 Activating Vision System Advance the event counter to event 4 The vision system will extend outward to the vision position The event message should read Activating Vision System Make the following changes Click in the Noz Vac box I to turn the nozzle vacuum on Click in the Vision Lights box J to program the vision lights to come on during the Run mode note Vision lights will not come on in Teach mode unless you activate the vision icon Change the event timer from a time based event with zero time to a footswitch event by clicking in the Footswitch radio button K By making this a footswitch event the operator has as much time as necessary to align a device Whenever an event has an unknown duration make it a footswitch event Click on the Teach icon after the three changes are made 6 2 5 Force Placement Advance the event counter to event 5 The vision system will close and the nozzle will lower to approximately 100 above the board The event message should read Force Placement Hands Off During This Event Make the following changes Click in the Zero Force box L to activate the Zero Force function Click in the Placement Removal Box M to activate the Force Placement function Click in the Force Destination box N Clear the zero value and type in 75 note that this 1s grams of force Click in the Force Range box O Clear the zero value and type in 20 Click on the Teach icon t
134. a XT16 are Access Up Down v Mode V CAUTION heaters must be off during programming of athena controllers Test function after setting changes e Press Access button once so lower display SV flashes AcCD and 01 to 05 AcCD means menu 01 to 05 are the programmable pages e Press Up button until AcCD alternates with 05 menu page five and press Access button to scroll through settings If settings need to be changed use Up and Down buttons to find proper settings SnSr cA OUt1 htP OUt2 CLO Col t nor A1Pd Pr A2 HL Lo A2 Pd Pr A2 OP off Unlt C Press Mode once press Access once AcCD should flash with 05 Press Down to get AcCD 04 Press Access button to scroll through settings in menu level 04 e d no nozzle 01 Jeft diffuser 02 right diffusser and single 03 bAUd 24n8 CAL L USED FOR NOZZLE TEMPERATURE ADJUSTMENT DO NOT TOUCH AT THIS TIME CAL H SPAN FACTORY SET DONOT TOUCH e Press Mode once Access once AcCD 04 should be displayed Press Down once to get to menu level 03 CY t1 00 SP tt off LSP L less than zero 18 USP L greater than 420 1349 DRS24C Series Manual Page 16 Section 11 Maintenance e Press Mode once press Access once press Down once to get to menu level 02 CAUTION Nozzle and diffuser settings are very different in level two use correct settings NOZZLE LD 01 Gn o1 65 rAtE 01 rSEt 0
135. access Derivative approach Press to access Cycle Time or on off Press to access Offset manual reset Press to access Setpoint lock 5 1 Press to access Setpoint Ramp rate Press to access Derivative approach Press to access Soak Time Press to access Adjust SP2 Setpoint Press to access Setpoint lock 5 1 Press to access Setpoint Ramp rate lt Function Parameter lt Function Parameter Function Parameter Function Parameter lt Function Parameter lt Function Parameter Function Parameter Function Parameter Function Parameter Function Parameter lt Function Parameter Function Parameter Function Parameter Function Parameter lt Function Parameter Hold and press 7 to set to 1 Hold and use Y to set off Hold and use set to 200 Hold and use set to 0 2 Hold and use set to off Hold and use set to 1 5 Hold and use set to 0 2 Hold and use set to Hold and use set to off Hold and use set to 0 Hold and use set to off Hold and use set to Hold and use set to Hold and use set to 2 0 Hold and use set to on of Y to DRS24C Series Manual Page 22 Section 11 Mainten
136. age 40 Section 6 Software 6 2 1 5 4 Probe Vacuum Check Box The Probe check box B allows the operator to program a special vacuum port used for the probe handling tool The probe handling tool helps to minimize any potential damage to the component during the load removal procedure Programming this check box checked will activate the vacuum for the current event Run screen A clear check box will deactivate the vacuum for the current event Run screen 6 2 1 5 5 Device Nozzle Separation Check Box The Device Nozzle Separation check box D allows the operator to program a small volume of air back through the nozzle vacuum tube This puff of air helps to separate the component from the nozzle Programming this check box checked will activate the air flow for the current event Run screen A clear check box will deactivate the air flow for the current event Run screen 6 2 1 5 6 Nozzle Vacuum Check Box The Nozzle Vacuum check box A allows the operator to program nozzle vacuum The operator can use this device control to pick up or release the component at the appropriate process time Programming this check box checked will activate the vacuum for the current event Run screen A clear check box will deactivate the vacuum for the current event Run screen 6 2 1 5 7 Cool Air Injection Check Box Not available on the DRS24R The Cool Air Injection C check box allows the operator to program an air flow bypass of t
137. aintenance Schedule Procedure 3 9 11 0 2 Process Kelated Preventative Maintenance quissecceesisuiveeeeseskesseueexsvessec essesivsussbue v eee usas ovde Pd 10 COMP M 1 112 Herter amp u uuu rat en m 12 11 3 Upper Heater Assembly amp Element Replacement 13 G 13 11 3 2 14 114 Diffuser Heater Replacement u Ye pua FUSE ea eeu eer 14 11 5 Temperature Control Module Replacement Reproeram 15 11 6 Athena XT16 Programming Instructions 16 17 11 7 CaL 9300 Settings Diffuser Nozzle 18 22 11 8 Y Axis Bearing Adjustment 23 IL9 u u uuu EEE E EEEE E
138. air vac eng com WWW air vac eng com The DRS24 is designed to provide automated rework and low volume assembly of virtually any surface mount component including BGA s QFP s CSP s connectors sockets PLCC s and specialty components on a wide range of assemblies The system provides a high degree of automation including automated device pickup and removal motorized beam splitter vision automatic placement using a precision force measurement system with real time display and software based process control of virtually all rework parameters allowing the operator to follow a clear simple procedure If complex functions are performed they will be largely transparent to the operator For the process engineer the controls and features of the system provide the flexibility and capability required to meet today s packaging and assembly challenges Profiles and procedures can be easily modified to meet specific requirements A concise logical teach function allows profiles to be quickly and easily created or modified DRS24C Series Manual Page 2 Section 1 Introduction Getting Started 1 4 Warranty General Air Vac Engineering Company warrants its equipment for a period of one 1 year from date of shipment on all parts materials and labor costs required to repair the system except for component parts that are considered wear and tear items which are warranted for ninety 90 days These include but are not limited to heaters belts
139. al Page 16 Section 6 Software 6 1 5 Print Process Control Parameters NES Control Mew This option requires a control profile to be open Selecting this option will format the currently open profile parameters display report using NotePad tool Save Save In addition the operator will be prompted to enter the number of lines per page Printers l Print Profile can be configured in many different ways Some trial and error may be required to correctly identify the printable lines per page Backup Restore File Maintenance Selecting the Print option from the File menu will Send report to default printer Hate Pad About DAS Process Control Parameters Process Notes Photo Links Report Notepad File Edit Search Help Date B4 61 938 PROFILE PARAMETER REPORT Page 801 PEGA 225 256 Removal 1 868 thick board H188151881 1B1103B_ rs Euent 1 Plastic Ball Grid Array 225 256 272 Removal Profile Event Control Time 83 Speech ON Alert OFF Nozzle Rate Hozzle Temp BH Hozzle Ramp LDiff Flou LDiff Temp agg Left Right Average RDiff Flow OFF RDiff Temp Z fixis Motion Absolute Z fixis Power Hozzle Axis Pos 809 Hnzzle Wel 050 Nozzle Accel 050 Uision fixis Pos 86 682 Uision Uel 05 B Uision Accel 656 Vision Lights OFF Live Wideo OFF Hitrogen OH Nozzle Wac OFF Probe OFF
140. al Syste Flux vapors in the vacuum pump will result in insufficient vacuum operation Unscrew glass jar Unscrew stem to remove and install new filters NOTE Filter elements must cover holes on stem A Back of DRS24 Q Manually lower vertical movement to bottom of travel Bearing may rise causing movement to not to extend fully Note De power vertical mechanism or machine prior to procedure Q Firmly rotate left vertical movement knob A to lower heater until nozzle just passes board support segments o9 06 zA A 005059000000960909 06 005056900000095090900 9696809000000 5020505 09 52089000008 0080505 00500900009009950909 06 OO 50620000007 SO S Os 002929090600095090406 005029000000996096906 00205090000009209090 ORO 040590060900950909 o590000009509 00000009 DRS24C Series Manual Page 4 Section 11 Maintenance Monthly Check Upper Heater temperature verification see Section 4 3 1 Check flow rate verification see Sections 4 2 2 and 4 2 2 Replace two nozzle vacuum filters A Unscrew glass jar Unscrew stem to remove and install new filters Note Filter must cover holes on stem Clean the fan cover filters on the two back fans B Drain water and oil from air supply filters C Ooo C Back of DRS24 DRS24C Series Manual Page 5 Section 11 Maintenance Three to four times per year To correct
141. ale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Numerical Process Information um uuu nnum pru Nozzle System Diffuser System Thermocouple System Force System System Status Memory lig Grams Set Point Foot Sw Air Em Cycle 7 mm EE Click On The Cycle Start Button To Begin Process Graph Process Information Date 04 01 98 08 15 Temperature vs Time 500 0 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 T C Control Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 03 36 10 24 11 12 12 00 Time EventTime PrefleTime Power Boara DRS24C Series Manual Page 13 Section 6 Software 6 1 3 Save Options Control The Save option is used to save a new profile or re save an existing profile Save Save x BH Print Profile d Short Name B 27 E Backup Restore Link Name Soldering Desoldering File Maintenance _ IG s Link Site Cleaning Pad D T Long PBGA 225 256 Removal 068 thick board N1081X1081 About DAS Customer Group Air Vac Engineering Company Device Group Arrays 6 1 3 1 Short Name The Short Name A is used to uniquely identify the profile The Short Name is automatical
142. amp should now open fully and hold and snap closed when released Nozzle Clamp Assembly 5 3 3 1 10 55 27 T a w rs 14 is 16 TE 4 11 2 1 D 1 15 Bi 12 oe JIE Ji 6 8 T 9 17 DRS24C Series Manual Page 11 Section 11 Maintenance 11 2 Heater and Control Testing Note Steps 3 and 4 of this procedure should be performed to test heater being replaced and after replacement to insure proper installation and prevent premature failure Disconnect 220vac power Open right hand box by removing button head screw located on left rear side of box swing left side up to open on hinge Check fuses nozzle heater 3amp left diffuser F4 10amp right diffuser F5 10amp Athena controllers F8 0 5amp Locate terminal strip inside front of lower casting The switched power lead to the heaters are terminal 23 for nozzle terminal 22 for left heater terminal 21 for right heater terminals 20 19 18 are common returns for nozzle left diffuser right diffuser respectively First check resistance of heater elements nozzle heater terminal 20 to 23 should be 52 5 lohm left diffuser terminal 22 to 19 and right diffuser single also terminal 21 to terminal 18 should be 26 3 ohms Now set ohm meter to highest range connect meter leads to terminal 24 ground to terminals 23 22 and 21 any read
143. ance 11 8 Y Axis Bearing Adjustment e Bring the carrier to the forward most position center carrier and lock in place Remove the four screws holding the board carrier set aside Remove diffuser mounting plate double diffuser or dovetail single e Locate the 4 access holes to the x bearing plate Use a 3mm allen wrench to completely loosen the screws holding the x bearing rail to the y bearing block e The x bearing rail and assembly are now free of the y bearing block Lift and move the carrier assembly to the back of the DRS along the cables in order to access the y bearing block e Tighten the two 3mm allen screws holding the left bearing to the y bearing block e adjust the y bearings loosen the two 3mm allen screws that hold the right side bearing to the y bearing block Tighten a small amount on the 3mm allen an adjustment cam in the center of the right side bearing Retighten the two 3mm allen screws holding the right bearing e Check the y bearing assembly for excessive play by twisting the bearing plate left and right There should be less than 1 16 play in the assembly Do not over tighten Table will not move with y drive or bearing will be damaged if it is too tight e The bearing assembly is adjusted correctly when the left to right play is less than 1 16 Also check that bearing assembly moves freely from front to back e Repeat steps 6 8 until no more adjustment is necessary e Reatta
144. asic rule disconnect the main 220 Vac power before servicing the machine or when the machine 15 taken off line Only use the tools for their defined purpose Never remove or disable any DRS24 safety features or software Make sure that all electrical devices are leakage current protected and are stored and used dry dust free surroundings The machine contains static sensitive devices Use caution to avoid static discharge when handling DRS24 machine parts e Use original spare parts only DRS24C Series Manual Page 3 Section 9 Safety 9 2 Additional Safety Precautions e Upper heater housing protects the upper heating element marked with hot label e Diffuser plate surface can be hot protective covers are marked with hot label Flux vapors can be hazardous to operators fume extraction should be employed Flux liquid is flammable and hazardous to operator health and safety Nozzle and vision motion can cause injury to the operator 9 2 1 Handling of Hazardous Solder and Flux Products AIR V AC does not supply the solder or flux products with the DRS24 system The end user of the DRS24 system should follow proper handling and disposal instructions for the materials as supplied by their vendors 9 2 2 Nozzle Changeover Safety Equipment Requirements When changing out the part specific gas nozzle use the special nozzle removal tools GNT1 GNT4 that are supplied in the tool kit of the system w
145. ats incoming air heating element with imbedded thermocouple for process temperature control 4000 watt double diffuser convection preheater Two independent temperature zones with automatic flow adjustment 12 x 20 actual combined size heaters controlled via a closed loop auto tuning PID controller Self calibrating to 5 degrees 2 10 Automatic Flow Adjustment Mass Flow Controller Programmable software control for nozzle heat output From 0 4 to 3 0 scfm seamless adjustment Accuracy and linearity 1 F S repeatability typ 0 1906 of full scale DRS24C Series Manual Page 4 Section 2 Facility Requirements Technical Specifications 2 11 Alignment System LTP Beamsplitter Vision 2 12 Illumination Green White LED s 2 13 Safety 2 14 Microscope Optics Stereo Microscope Patented alignment system for simultaneously viewing the component leads while super imposing the PCB pads on top of each other LED sensor for height reference and polarizing filter for pad contrast adjustment Software controlled independently adjustable vision lighting intensity provides enhanced optical contrast during alignment UL and ULC Listed E194087 CE where applicable Leica M3 binocular with adjustable 10X eyepieces MZ6 1 6 zoom magnifier seamless adjustment custom focusing ring DRS24C Series Manual Page 5 Section 3 Installation Table Of Contents 3 Installation
146. besides the original can occur The system considers and applies the 3 adjustment rules in a sequential manner The following list defines the 3 adjustment rules that may be applied during the optimize adjustment session Only one rule can be applied per optimize cycle Rule 1 The targeted device joint average temperature was not achieved Attempt to increase device maximum temperature by 5 C If the device top maximum temperature is currently implemented the rule is skipped Rule 2 The actual reflow time was less than the target reflow time minus 10 seconds the system provides a 10 second success window To compensate the system will consider the actual cool down time Next the system will compute the necessary time extension to achieve the targeted reflow seconds This time extension is implemented using a device joint average temperature maintain mode The heating and flow sub systems will be pulsed on off to maintain the current device joint average temperature rather than simply turned off when the joint temperature is reached as in the original cycle Rule 3 The target device joint average temperature was not achieved If the targeted device joint average temperature is at the minimum the rule is skipped DRS24C Series Manual Page 101 CYCLE COMPLETION DECISION The system will automatically detect a completed optimized thermal cycle The Optimize LED represents an 1 The system reviews the results of ea
147. bove 08 TIC48 Max Temp C Temp siope tipe above 183 Time Above 2 C L K J F G H 1 DRS24C Series Manual Page 71 Section 6 Software The summary section of this screen provides the operator with the cycle analysis details This information is organized separately for each thermocouple channel The following categories are calculated Maximum and minimum F G temperature Max Temp C Min Temp e Temperature slope H 5 e Time above reflow D Time Above 183 C In addition a programmable temperature analysis column Time Above C allows the operator to temporarily modify adjust the time above reflow analysis calculation Selecting the Resample Data button K will re process the cycle data using the new analysis data Selecting the Up Thumb button L will exit the Graph Data screen and return the operator to the Run screen DRS24C Series Manual Page 72 Section 6 Software 6 2 2 12 2 Auto Scale Graph Menu Option The Auto Scale Graph menu allows the operator to display the entire cycle data set on a single graph window During the cycle a 12 minute graph window is maintained and displayed Many process cycle times including final alignment time may extend beyond this 12 minute window This menu option is only available when the process is not cycling 6 2 2 12 3 Load Process Link File Menu Option T
148. cally detect a low memory condition Alarm screen e N2 LED D indicates green the secondary pressure input nitrogen when required available has been connected to the upper heater Air LED indicates green the main air source has been connected to the upper heater FootSw LED indicates yellow the DRS24 machine is waiting for a foot switch response from the operator e Cycle LED G indicates the process has been activated Busy LED H indicates yellow the computer is actively controlling motion force temperature or flow rate Warning When this LED is ON the operator should not touch the machine or interrupt any event activity Alarm LED indicates the status of the controlling sub systems red LED indicates an alarm condition A B C ER EE Foot Sw Air D G 1 DRS24C Series Manual Page 62 Section 6 Software 6 2 2 5 Profile Event Alert Foot Switch Messages B This section of the Run screen displays system foot switch messages or pre programmed event alert messages Messages are used to inform the operator when machine interaction 1s required or to communicate the general progress of the profile cycle PBGA 225 256 Soldering 068 thick board N1081X1081 1011003 drs Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Numerical Process Information 10 x Nozzle System Diffuser Syste
149. cation process required for the Bottom Heater DRS24C Series Manual Page 6 Section 4 Verification 4 4 Flow Rate Verification and Adjustment Once the pressure verification is complete the gas flow rate should be verified Accurate gas flow through the nozzle is critical for achieving repeatable results The DRS24C incorporates a Mass Flow Controller with closed loop control to monitor and regulate gas flow rates The two areas of flow verification include the Nozzle Flow Controller which controls actual flow rates and the Nozzle Flow Sensor which controls the Computer Digital Flow Display Nozzle flow verification is required for initial installation or any time the machine 15 disconnected and or moved 4 4 1 Nozzle Flow Controller Verification and Adjustment 100 only Materials required Scribed reference flow meter supplied with machine Initial conditions e Machine power must be turned on for a minimum of 30 minutes Pressure to upper heater must be set precisely to 80 psi 5psi Set Up e Disconnect the Blue Hose A from the Flow Cal Fitting B e Connect the Blue Hose C from the Flow Meter into the Flow Cal Fitting B Meter exhausts to atmosphere Flow Meter KS A 2 2 Z B C WARNING Be certain all hoses are inserted into fittings completely A bad connection can result in a burned out heater or erroneous calibration readings DRS24C Series Manual Page 7 Secti
150. ce will not pick up not clean nozzle in cleaning solution or degreaser with vacuum cup still installed not apply excessive force into nozzle nest DRS24C Series Manual Page 12 Section 8 Engineering Training 8 10 4 Software e Open the appropriate software profile and be sure to follow all set up notes Footswitch must held until yellow radio button goes out Not touch apply any pressure to the machine during the force placement event 8 10 5 Thermal Conditions e Preheating of the nozzle will provide more consistent results e While soldering heating of the solder leads just above the pads and heating of the solder prior to placement at board level will promote better bonding between the bottom of the lead and top of the pads e Heating the pads prior to placement will diminish lead stress and possible misalignment Lowering the flow rate for soldering process relative to the desoldering process may offer better solder joint quality e For very dense assemblies a lower than standard flow rate and higher than standard temperature may required The solder melt trend occurs from the corners of the gas nozzle to the center joints except for extreme heat sink joints e Operator observation of the transition of solder reflow is a good means to monitor the process Clear inspection optics allows quality observation which may contribute to enhancing overall assembly
151. ch cycle completed cycle to determine if the targeted Optimize thermal results were achieved If the desired results can not be achieved the system will attempt a maximum of 3 additional optimize cycles gt 2 The system will illuminate the Done LED e when the optimized session has finished Note If an optimized cycle can not be achieved the system will report this condition to the user Note If the system fails to reach the required minimum soak or reflow temperature targets the cycle wil be terminated and the user immediately informed Message will state Above the minimum soak temperature or m z DO x x ee Dub DS Above the minimum reflow temperature Time gt 3 Activity Time Out The system provides time out protection against unachievable process results The system is designed to perform thermal process optimizations unattended After a cycle completes and a period of inactivity occurs the system will produce a time out alarm and exit the Thermal SMART Track screen Alam Con gt Press the Thumbs Up icon to reenter the Madman Tine Process History Thermal SMART Track screen Motion Communication Link Hun Graph History Upon reentering this screen the system will j Aan Export automatically reload the current data sets generated du
152. ch the carrier and x bearing rail to y bearing block make sure carrier is perpendicular to y axis rail before tightening e Attach the diffuser assembly and board carrier to the x axis plate Do not overtighten diffuser plate and carrier can be distorted e Check board carrier and diffuser leveling DRS24C Series Manual Page 23 Section 11 Maintenance 11 9 Carrier Leveling TOOLS N cal 4 Nozzle M Inch plate glass 8 x 10 Inches square 532 Allen 3 32 Allen Note All screws referred to as wrench size needed for procedure Attach the N cal 4 nozzle knife blade to the DRS Place the 8 x 10 x 1 4 plate glass in the carrier arms Center the glass from front to back of the carrier arms Lock the glass to the carrier Center the glass under the nozzle from front to back and left to right Lock the carrier The blade of the nozzle should run from left to right as viewed from the front of the DRS Lower the nozzle until the blade is just above the glass Do not hit the glass with the blade of the nozzle Note If the nozzle hits the glass plate raise the nozzle release the nozzle clamp and then re clamp the nozzle into place View the gap between the bottom of the blade and the top of the glass The gap should appear even across the span of the blade If the gap is off adjust as follows Determine whether the right or left side of the blade has the greatest distance between the bottom of t
153. d Additional entries must be 21 Length 0 000 properly positioned in the defined E columns Tabs should be used to separate the data fields Customer and Network Groups k Operator Message Title Vision System Automatic Profile Build Search Nozzle Device DRS24C Series Manual Page 112 AUTOMATIC PROFILE BUILD NOZZLE DEFINITIONS Device Height The correct device height must be selected as automatic component pick up alignment and placement positions are based using this dimension 1 Press the Asterisk Help icon to provide Nozzle Search Device Height 0 00 screen to automatically present corresponding Device Height to nozzle size Device Search gt 2 Highlight selected nozzle and click thumbs up icon Note Correct length will be transformed to Device Height box Device Height 0 000 E Option Menu Option Automatic Profile Build Search tate The user can manually enter nozzle or 52 2 27 device lengths for non standard types Setup Operator Option The device height menu option has been added to access Diffuser Idle can be entered manually by the search lists provided in the Process Counters clicking the Device Height box Automatic Profile Build screen The and entering value menu option allows entries to be added Erupe gt or removed Additional entries must be E son prop
154. ded Devices EL DRS24C Series Manual Page 4 Section 7 Operator Training 7 5 Running the Operator Training QFP160 Align and Place Profile The training profile 15 intended to provide training of the DRS24 hardware and software Programming liberties have been taken to allow step by step instruction The settings are not intended for an actual program as no reflow occurs Please follow all instructions in the profile notes page below prior to running the training profile Profile Notes Description OPERATOR TRAINING 160 ALIGN AND PLACE Component QFP 160 PROVIDED WITH THE SYSTEM Location 150 SITE ON VISION ALIGNMENT BOARD PROVIDED WITH THE SYSTEM Flux Type Nozzle d 110361103 PROVIDED WITH THE SYSTEM Notes INSERTION TOOL AT103B1103 PROVIDED WITH THE SYSTEM Application OOO _______ Notes e Select Thumbs Up to advance to the Run screen DRS24C Series Manual Page 5 Section 7 Operator Training The Run screen should now appear as shown below Select Load Functions A Click on Nozzle Load icon B and follow the prompts to properly load the nozzle N1103B1103 provided with the system The insertion tool A1103B1103 must be placed in the loading station prior to this process e Once the nozzle is loaded select the Thumbs Up icon to close the load function window and then click on Cycle Start C to start the training profile
155. directly underneath the BGA device Soldering the thermocouple into via 15 recommended The temperature of this thermocouple typically is within 10 degrees of the BGA joint temperature 8 10 Process Tips 8 10 1 General e Use proper height adjustable chair to allow comfortable viewing of microscope at top and bottom position e Nitrogen will improve solder joint appearance and quality particularly with no clean flux In addition nitrogen can reduce or eliminate the need for pad preparation after a leaded device has been removed e Use same flux type as in production in paste form for rework Do not mix flux or solder types not open electrical compartments 8 10 2 X Y Table Do not lean on or apply excessive force on carrier Carrier coplanarity to nozzle is critical e Use board supports where possible Hold assembly gently with board clamps and side arm locks 8 10 3 Gas Nozzles e Select the proper gas nozzle e Use the GNT handling tools to hold Hot nozzles Do not grab nozzle at bottom Damage may occur at gas openings Gas openings must be correct to transfer heat to assembly Use gas nozzle handling tools e Store nozzle in tray Do not drop nozzles Do not run process without a vacuum cup in the nozzle Vacuum cup provides insulation to device Be sure vacuum cup is large enough to pick up device e Remove arrows from repair components Vacuum port will be closed when arrow 15 held Devi
156. e TEACH screen TENP DRS 23 25 08 22 97 Missing Thermocouple 7 TEMP DRE 235 47 09 22 97 Low Pressure Temp file Last changes made using the TEACH screen TEMP DRS 00 53 09 24 97 Force Placement 00 31 09 26 97 Low Pressure 01 44 09 27 97 Motion Communication Link OFP160 Removal Training 11 00000001 3 02 04 09 27 97 Motion Communication Link OFP160 Removal Training Profile Oo000001 DR5 02 35 09 27 97 Temperature Limits QFP160 Removal Training Profile gO0000001 DRS 02 55 09 27 97 Motion Communication Link OFP160 Removal Training Profile OO000001 DR5 09 25 o7 Pressune l 23 27 09 30 97 Motion Communication Link qfpi60 training removal profile OO000002 DR5 23 26 09 30 97 Motion Communication Link qfpi60 training removal profile oOo000002 DR5 23 26 09 30 97 Motion Communication Link dqgfpi1560 training removal profile OOO00002 DRS 23 26 09 30 97 Motion Communication Link dqfpli60 training removal profile oooogoo02 DRS 23 29 09 30 97 Motion Communication Link dqgfpli50 training removal profile ooo0o00002 DR5 For Help press F1 DRS24C Series Manual Page 129 Section 6 Software 6 5 Video Screen Utilities Video Screen Save Video Image Modify Video Image Print Screen The Video Screen Utilities option will allow the operator to capture or modify video images 6 5
157. e Vision System be periodically verified to insure placement accuracy Select Setup Main menu then Vision System from the Main menu screen The Vision Adjustment screen will appear as shown below B D F Jog Vision Axis Z Axis 1 inch Power C e Install the Vision Alignment Board supplied with system with the 208 site into the carrier Use the Down Arrow Key A to lower the head Unlock clamping fingers and install the N1103B1103 nozzle supplied with system Feed QFP208 supplied with system into the nozzle Use caution so as not to bend the leads Activate Nozzle Vacuum Select the Power Check Box to remove the v This will depower the Z Axis Manually lower the device until it is just slightly above the pads e Align the QFP208 at board level by using the X Y and Theta adjustments while viewing through microscope Once the front side of the device 15 aligned pivot the microscope to the two sides and continue the alignment process Once the device is aligned at board level lock the table to prevent future movement Select the Vision Alignment icon D The device will automatically move to the vision position Be sure the microscope is in the top position then focus on the board DO NOT MOVE X Y OR THETA DURING VISION VERIFICATION AS THE DEVICE HAS ALREADY BEEN ALIGNED AT BOARD LEVEL DRS24C Series Manual Page 12 Section 4 Verification
158. e menu and click on the Exit option About DAS24 Save 7 Load Yideo Images 6 5 1 3 About Ar ac Engineering Company Inc The About option will display the version number for the Save Live Video program Seymour CT 06483 U S A Version 1 00 Phone 203 888 9900 203 888 1145 DRS24C Series Manual Page 132 Section 6 Software Video Screen Utilities Save Video Image Video Image Print Screen 6 5 2 Modify Video Image The Modify Video Image menu will allow the operator to load WINDOWS95 Paint tool a video snapshot from the default photo directory C WINDOWS DRS24 PHOTO These images can be modified by adding text or graphics to better clarify how the video snapshot can be used E compl Paint Edi Image Options Help 1 1086524 Live Video Close UT ru Pod PARTY ab k hh d n k w w TST 4 r 4 a gt 5 ee an 5 x 4 4 LE 3 doi E x H a TOFP1000197 20 s s k PS ossi ig LEITET NN LE kn k Mu X Mas sasawa ETETEN mam 111188001 OL 2 L a
159. e nozzle fails to seal to the component or the default vacuum sensor parameter 15 too low the force system 1s also active during this event and will stop the nozzle like force placement event This was done to prevent the nozzle from being driven into the board The software adds a default force settings into the event automatically but can be raised or lowered as necessary If the force destination 1s set to zero 0 the software will automatically skip to the next events Force Placement System 2 2 7 Actual Dest Range 0000 00 01 25 00 0000 00 Item 4 Max Adjust Counter Enhancement This feature has been added to prevent the nozzle from backing away from the board or being driven into the board for an Vacuum Sensor Communication infinite This feature requires the Blocked Tool Vacuum Pickup vacuum sensor being installed and active If 456 500 the adjust counter 1s exceeded an alarm condition exists and the process will be stopped Process Sample Delay 5000000 Sensor Delay Adjust Cnt 10000 2 250 DRS24 Release Notes Version 4 43 7 Item 5 Max Profile Database Enhancement In previous versions the maximum number of profiles was limited to 999 profiles This has been increased to a maximum of 9999 profiles The DOS file name has been increased from 7 digits to 8 digits The first 4 d
160. e the green LED lights are lit on the two drivers Check that your DB25 cable is plugged into the port expander and that the ribbon cable that connects that port to the expander card is plugged in Shut down Windows95 re boot and try motion again in set up vision system screen Call Air Vac Technical Support 12 6 3 Force Com Link The communications link between your computer and your force board located in the left side box 15 not functioning e Check in the teach screen if you get a force reading and if it changes when weight is applied to the carrier Make sure DB25 connector is plugged into the force board Check 3 wire yellow violet gray 10 connector is plugged into COM2 pins on the motherboard gray wire closest to pin 1 e Shut down Windows95 re boot and test again Check to see if the red LED power light 15 lit on the front bottom of the board If not make sure the white 4 pin wire connector is connected If it is connected and the light is not on un plug and check for 12V DC across the black and yellow wire 165 amp 167 Call Air Vac Technical Support 12 6 4 Temperature Com Link Verify that the temperature controllers have power Check to see if any error messages are displayed on the controller Load NO Error L Error H Verify 9 pin connector on is plugged in Check 25 pin connectors on the B amp B converter Verify 12V DC to the power plu
161. emove heat shield Q Spread carrier arms far apart Q Remove 3 screws A of the heater head cap Note all washer and spacers of the heating element must go back in the right order Heating element is keyed Remove heating element Check heating element for cold joints or burnt areas Q Use spanner wrench turn counterclockwise to loosen heater tube Lift tube to remove Clean tube Q Runa2 5 mm allen wrench down the vacuum tube C and carefully straighten Remove housing carefully rotate tube Remove nozzle ring D Clean all areas of anti seize Apply pressure stand on it with your foot on nozzle ring and housing to seat Remove spring clip and fingers Clean all areas of anti sieze 0 Inspect for wear File burrs at top of fingers if necessary Apply anti seize at the two contact points E as shown Reassemble Move assembly up and down Check if all pem nuts are in place If not plate must be replaced Clean brass ring G of anti seize Apply anti seize at curved surfaces of top Apply a light bead around the outside Reassemble in reverse order Slide back into machine nozzle clamp goes in front Carefully bending vacuum tube to hold assembly in place D G ETT p E B p d lt UN ES ams Li ss LU es
162. en screws Note Do not over tighten screws This will warp diffuser mounting plate e Place the board support back on the diffuser and slide under the glass Check for firm contact with the glass in four corners e Repeat steps on all 4 corners of the diffuser until no more adjustment is needed C D B A 0 000 Glass Plate i 0 005 Diffuser s sess a Board Support DRS24C Series Manual Page 18 Section 4 Verification 4 8 DRS24 P Cool Verification Process The following procedure is for setting and verifying the P Cool option on a DRS24 Remove the silicone hose from the proportional valve located under the computer plate and inside pneumatics panel in the left side box Hook up the pressure gauge to the P Cool valve with the supplied silicone tubing and barb fitting In the hidden menu in the DRS24 software enter Setup Cooling Ring Flow Meter and turn on the valve by clicking on the 90100 button then clicking on the green cycle start button Adjust the regulator to 20psi Turn the valve off by clicking on the red cycle stop button when you re done Re attach silicone hose and cable tie to the barb Click on 90100 then click on the green Cycle Start button Let the air flow for 15 minutes to warm up the electronics in the proportional valve as well as stabilize the airflow e Next take the flow meter that came with your DRS24 and remove the blue tube and barb fitting
163. ence and motion control data to provide a complete process profile e Maximize profile repeatability and standardize process development Overview e Artificial intelligence systems combined with an in depth knowledge based profile development strategy automatically creates a thermal profile This profile is based on user defined target parameters including board temperature soak duration package temperature package ramp rate joint temperature and time over reflow e Automatic adjustment and control of heater temperatures gas flow rates and duration on a real time basis during process development e Automatic iteration procedure utilizes information learned from previous runs to optimize the process e Automatic profile build feature combines the optimized thermal sequence and all motion and vision related steps including component pick up alignment and placement e Makes process development based on trail and error a thing of the past Process Transfer e Profile portability remains a primary consideration of any new Air Vac software release Customers can continue to be confident that profiles will transfer accurately and easily from machine to machine All the powerful profile editing tools remain available regardless of the technique used for building a profile DRS24C Series Manual Page 83 Reference Feature Overview Process Control Elements Process input parameters user adjustable e Device joint target tempe
164. enoid Diffuser low right solenoid LP1 Top Heater Diffuser high right solenoid LP2 diffuser Nozzle Cold Hot solenoid Nozzle Puff off solenoid Upper heater Mass flow controller Heater Control Solid State Relays P cool Proportional Valve Left Diffuser Low flow switch Right Diffuser Low flow switch D24pneu flo 10 16 97 Upper Heater Low flow switch DRS24C Series Manual Page 10 Section 10 Schematics 10 2 8 Pneumatics Air Block 3A1VA 1vNOIL13OdOMd 2 11002 ONIN 9N11002 1 Es 499 0 1 319NY 1000924 sawa 31 25 83604310 7 2 as 83503410 1331 c St 137 i 3115 440 3304 NANYA a B NEUTER wm E 31220 ee 221 1031 I 52 31 241 I 1804 NIV 8102 N31V3H 401 dh lv SL 4 u31V3H 401 p s Lx Y H 8311081N02 014 SSVM 401 41 154 08 NJJOYLIN 154 09 Page 11 DRS24C Series Manual Section 10 Schematics 10 3 Electrical Connector Definitions CONNECTOR CIRCUIT TYPE CONNECTOR TYPE DETAILS ww i 2 2 PowerDC CPC 7 pin J3 P3 Pneumatics CPC 37 pin 27 used DRS24C Series Manual Page 12 Section 1
165. ented Event 6 Note 2 height may need slight manual adjustment Glass Reticle Component is positioned near Glass Reticle Board Event 7 Do Not Touch the Machine or Table Glass Reticle Component is placed using force placement system Event 8 Unlock Carrier and slide forward place 100X Portable Microscope carefully over reticle and check placement Note You will see crosshairs of component over black and white rings of target Starting and including center bulls eye count each black and white ring to center of crosshair Each ring including center bulls eye is 0 00025 Add up ring count to find placement error Placement Nozzle retracts Event 9 If adjustment is required go to linking icon for next procedure Event 10 DRS24C Series Manual Page 14 Section 4 Verification Adjustment Procedure Profile for Precision Optical Alignment Procedure Adjustment Process 1167127 drs under System System S ystem Slide Board with component back under nozzle Event 1 Move x y carrier to center Placement Nozzle over Glass Reticle Component Lock carrier Placement Nozzle lowers Event 2 Do Not Touch the Machine or Table Glass Reticle Component is placed using force placement system Event 3 Manually raise Placement Nozzle 54 to separate Glass Reticle Component from Reticle Board Break adhesive bond manually if necessary carefully Event 4 Align reticles using vision s
166. er kit e Wipe painted surfaces with cleaner e Wipe flux from table and carrier arms Clean nozzles with flux remover and soft brush Replace nozzle vacuum cup if required e Replace vacuum felt filter of glass jar for nozzle and site clean vacuum Quarterly Advise maintenance to perform preventative maintenance procedures DRS24C Series Manual Page 15 Section 8 Engineering Training Table Of Contents 8 Engineering Training 5 0 I i Lu eoso IRE Cod psu PAP PR TOP PHI 2 51 Modifyins Ton UNPUPPN REO UN EEL TNDUR IIS 3 5 2 Teach Seren OVerview or sn eR P PEE pesa PERO OE EU PRIM UNIES SUPPE 4 Gad ET 5 UP LAS IONIC 5 9 9 06 0 9091 6 VISION DV 6 OZ Gu uuu u ua uu GUTER 6 c 7 Healer Teomperaluires and TOW RUO iisipin s 7 62 P e ce 7 OANA vak Y EEEE REEE
167. er the priority of event processing Some device control elements should be activated before the current event is processed For example it is important to activate nozzle vacuum in the event prior to the component removal motion event PBGA 225 256 Removal 068 thick board N1081X1081 1011030 drs Build Photo Links Vision and Nozzle System Pos 00 000 Rate 29 C Dest 00 000 S A I C D Not e Nitrogen inch 0 N Site Cleaning Noz Vac F Probel Power Events Velocity Accel Velocity 26 Vision Lights Video Jog l a Alert Speech Device Nozzle Separation Alert Message nozzle to above board position R sensor Force System Units Actual Dest Range s 0000 00 Zero Force El El El El Placement Removal Auto Adjust Display Only Diffuser System L Temp C R Temp C l 200 Low 200 6 Low Standard cris Replace Add Subtract L mmm mmm mmm mmm ee ERROR Stop Process J dg DRS24C Series Manual Page 38 Section 6 Software 6 2 1 5 1 Nozzle Heater Temperature Flow Rate and Temperature and Ramp The nozzle heater temperature Temp C be programmed from 0 C to 420 C The nozzle flow rate Rate A can be programmed from 15 to 110 100
168. ered operator list Operators are grouped into three categories Operator Control Priority High priority These operators have access to all screens Caution should be ev taken when defining these operators i Critical machine parameters can be mo VM ANCE adjusted or corrupted OPERATOR Medium priority These operators can perform the following maintenance functions e Vision calibration Backup restore e Diffuser idle In addition these operators can run existing profiles Low priority These operators can only run existing profiles 6 7 6 Password Edit Password ES This screen is used is used to modify the password associated with each operator priority level Low Priority Password Medium Priority Password High Priority Passwod DRS24C Series Manual Page 138 Section 6 Software 6 7 7 Message Text This screen displays all system messages These messages can be adjusted to better meet the communication needs of all the operators If a language other than English is selected this file can be converted Message Notepad Edit Search Help Changes Have Hot Been Saved Continue 7 Security Access Failed Invalid Long File Name Information Invalid Group Information Profile Save Completed File Exists Overwrite Profile Save Was Hot Completed Hemory Resources Are Very Low Please Exit The DRS Software And Reboot The Computer Continue With Delete File
169. erly positioned in the defined fecum columns Tabs should be used to i EMEND Message Test separate the data fields Vidal Title Device Height 1 000 B Vision System Automatic Profile Build Search List Device Board Thickness The correct Board Thickness must be entered as automatic alignment and placement positions are based using this dimension gt 3 Manually enter value Board Thickness 00 062 gt 4 Press the Thumbs Up icon to save data exit screen and generate the complete production motion and thermal data profile DRS24C Series Manual Page 113 COMPLETE PROFILE SAVE FINAL PROFILE THERMAL AND MOTION SEQUENCE The standard profile save screen has the additional ability to attach a thermal sequence T pese c Name and Link Contre A Short Name is automatically created Shon Nase TIS n Les 1 A Long Name must be Uskhams Desnldnrieg given Cinaninn For example 256BGA Tene Replacement 062 thick board N27EZ27 Customer lr Esc Engine Company gt 2 Select Group Control Groups Greege Litany Dei Gregg Leaded sa Therma Sequence Contral wame L Reference The Thermal Sequence attachment will automatically be inserted Short Mame
170. es 127 and 128 did problem Replace problem Heater fixed no Call Air Vac no replace solid problem es state relay fixed D24DHFLO flo 1 29 98 2 DRS24C Series Manual Page 3 Section 12 Troubleshooting 12 1 3 Communications Problems If the temp communications link alarm is persistent 122 Insure that the communication cables relating to the temperature control are connected properly see schematic or block diagram in the schematics section of this manual Reboot computer to unlock COM port Verify the setup parameters Verify that the athena temperature controller has received the send temperature The green SV number should change to the temperature commanded by the process No or Low Flow Condition Verify that the incoming air line 1s still connected Look for problems with the lines Verify that the incoming pressure 15 set for 80 PSI Check fuse F6 should be O S A Slo Blo fuse Nozzle Does Not Pick Up Component Check nozzle vacuum filter Clean and replace element Check nozzle vacuum cup Replace if worn or missing No Motion Check motor driver connections right side box Reboot computer to unlock COM port 12 5 Motor Driver Communication Problems If the Motion communications link alarm appears Verify communications to the driver Check the motor driver RS232 connections both driver and computer side of the cable Verify the setup pa
171. es Manual Page 8 Section 7 Operator Training 7 5 7 Align Device Use X Y table to align the pads of the board to the leads of the Each lead should be centered on each pad e Align the top row of leads and then the left row B of leads e Once the top and left side has been aligned examine the opposite sides bottom C and right D If sides C and D are mis aligned theta adjustment 15 required A B Fig 1 D I H H H 17311 C In figure 1 sides A and B are aligned but sides C and D are not This is an indication of theta error e Use the Theta Adjustment knob to make a 50 correction then finalize the alignment with the X Y table Note Do not make 100 correction of sides C and D with theta as this will simply transfer the theta error to sides A and D lt All four sides are now aligned m e Once all four sides are aligned as shown in figure 2 increase the zoom lens magnification to check your work Viewing a few leads under high magnification may reveal minor errors not seen while aligning the entire device Lock X Y table once the alignment is complete Depress the footswitch until the yellow footswitch indicator goes off DRS24C Series Manual Page 9 Section 7 Operator Training 7 5 8 Check Alignment at Board Level e The vision system will retract and the component will be lowered until it is approximately 025 above the pads
172. es or areas Attach more than one thermocouple between bga and pcb or on top of package 4 Note The actual joint temperature recorded will be approximately 5 c below the true value or drilled pad method Installing the assembly gt 1 Insertthe board into the carrier centered over the diffuser gt 2 Insert the nozzle part number should correspond to bga physical size and lower to just touching bga 3 Based on nozzle technology raise nozzle approximately 050 for EZ style design or keep nozzle in contact with board for X style design DRS24C Series Manual Page 86 Option Preparing and Installing the Assembly Destructive Drilled Pads Method BGA Removal gt 1 Power on machine Pass operator registration and password log in screens gt 2 Select Options Then New In the Teach Screen set the following parameters e Under Event Control select Foot Depower z axis Z Power box should not be checked Visinn aed Nazzke System Tenet iHe dus 000 00 T renew eene e Under Vision and Nozzle System select MAmgea C inch Rate 6 to 50 Esant Events Nomen PE ANM Pr M I Lights Naz Vac Probe Temp C to 300 check rna eme P Wao
173. es the device joint average temperature that will allow the board to be safely removed from the machine e Cycle progress LED s and status messages DRS24C Series Manual Page 95 ACTIVATING THE THERMAL SMART TRACK CYCLE STAGE LL Reference The Preheat stage is the time until the board reaches the Board Control Target temperature gt 1 The cycle will re start when the Board Control T C 1 Start PAE is below 60 Board Control T C 1 Target C Start Board 2 he diffuser will heat 060 19 the assembly until the target temperature 90 c default or a different program target setting is reached Note The Max C is the maximum vermal Profile Graph temperature setting for the pcb during the Preen Note The Preheat entire process Diffuser will maintain indicator be illuminated setting throughout the process if reached BEEN Note Message will state Preheating Lui on Tu hi Og II ib iid QOO Boc 20 5 lage Has Been AC tiva te d Note The Upper Heater will be activated Nozzle Control at the default temperature of 125 c ora Flow 94 Preheat different program target setting is reached The flow rate will be based on the Nozzle 000 125 Search screen or override setting
174. eseat the device and reactivate the vacuum DRS24C Series Manual Page 7 Section 7 Operator Training 7 5 5 Press Microscope Slide Lock and Push Scope to top of Track Purpose To train the operator in the use of the microscope The nozzle and component will move automatically to the vision position e Press microscope Slide Lock e Push microscope along track to the top highest position This step ensures that the microscope is in the proper highest position for vision alignment Note Lowering the microscope for alignment will result in placement error due to incorrect viewing angle during alignment When this task is complete depress footswitch until yellow footswitch indicator goes off B D A C E 7 5 6 Event 4 Viewing the Component and Pads in the Beam Splitter Turn the Zoom Lens B to 63 its lowest setting Use X Y table to move the test board so that both the leads and pads are in the field of view Note Tilt the microscope as required to see the images e Turn the zoom lens to approximately 1 25 to optimize the magnification of this device e Adjust the focus using the Black Focusing Ring Additional focal adjustment can be done by turning the adjustable Eye Pieces D e Rotate the Polarizing Filter E to change the lead to pad contrast e After this task is complete depress the footswitch until the yellow footswitch indicator goes off DRS24C Seri
175. ess without a vacuum cup Change cups after long exposure to heat and flux e Transport the unit holding the base Do not lift unit by the board carrier or microscope DRS24C Series Manual Page 10 Section 11 Maintenance 11 1 Nozzle Clamp Repair e Disconnect power e Remove nozzle assembly heat shield and heater head cap Check for keyway in heating element and heater cap gasket e Two spanner wrenches with 2 5mm pins are necessary to unscrew heater tube from nozzle cone 9 Hold one wrench in heater cap to keep from twisting place second wrench in top of tube and unscrew when reassembling do not overtighten snug is best Pull tube completely out and set aside Runa 2mm allen wrench down the vacuum tube 5 and carefully straighten Nozzle clamp assembly should slide down do not use too much force vacuum tube can be stripped out easily rotate tube to help removal Lift heat shield off 2 if hand ring 4 has slipped down not seated at base press together to seat e Remove spring clip 8 and fingers 7 and inspect for twisting or wear replace if necessary e To lubricate use Never Seez or other high temperature grease Lubrication points are Top of brass ring 1 Inside brass ring on compression screws Top of fingers spring clip groove on fingers sides of fingers above bottom plate Inside threads of heater tube Reassemble in reverse order carefully bending vacuum tube to clear heater tube e Cl
176. et of Z and Vision coordinates This position will be graphically displayed using green button background The vision fiber optic lights will be automatically turned ON after all the axis motion has been completed This general motion utility can not be programmed as a complete function however the results of this motion can be saved to an event Typically this general position is adjusted to exactly match the specific vision alignment requirements This button can also be used to close and home the Z and Vision axis 6 2 1 1 13 Live Video The Live Video button will activate the camera system and generate a live video image on the computer monitor DRS24C Series Manual Page 29 Section 6 Software 6 2 1 2 Motion Control Not available on the DRS24R Teach Build Photo Links Vision and Nozzle System Events have three basic elements of Post Rate p9 tl Dest 00 000 Dest operation rH rr 62 ABS Air Z Move REL Not Move Nitrogen inch 1 Motion 2 Device 3 Time Probe Noz Site Cleani Event Control Site Cleaning Time sec Motion Power Events Foot Time 1 j 9 Vision Lights Video _ Device Nozzle Separation BIB raet Al BI Alert Events are processed using the following c
177. ew and verify any iterative cycle process optimization e Nozzle lookup tables quickly direct the operator to the correct nozzle device flow rate DRS24C Series Manual Page 84 PREPARING AND INSTALLING THE ASSEMBLY Hardware 1 K style thermocouples 1 Channel 1 for pcb top side temperature or Non contact Temperature Sensor option 2 Channel 2 for top of package 3 Channel 3 for joints Option Channel 4 8 2 Kapton Tape and high temperature epoxy such as Locktite weld gt The user has the option to use two methods to prepare the assembly 1 Non destructive Insert thermocouple under device 2 Destructive Remove bga Remove residual solder Drill pads Install thermocouples Reattach bga DRS24C Series Manual Page 85 PREPARING AND INSTALLING THE ASSEMBLY NON DESTRUCTIVE THERMOCOUPLE UNDER BGA METHOD Preparing the assembly 1 Kapton tape thermocouple to pcb One is required for channel 1 Connect thermocouple to channel 1 Or connect Non contact Temperature Sensor option to channel 1 and position over assembly 2 Kapton tape or epoxy thermocouple to the top of the package One is required for channel 2 Connect thermocouple to channel 2 3 Insert thermocouple s between the bga and pcb One is required for channel 3 Connect thermocouple to channel 3 More than one thermocouple may be used to provide more sampling Option Attach thermocouples to adjacent heat sensitive devic
178. ference Component Removal Template sf Note Thermocouple channel 1 must be connected and used to measure board temperature gt Note Both Diffusers are activated 2 Note Board and nozzle must be installed Upper Heater Diffuser Event Temperature Flow Time Temperature Flow Notes 1 off off 07 250 low Message Stabilizing heaters 2 off off 0 250 low Z 3 527 Message Nozzle to above board position 3 off off Foot 250 low depowered Message Position nozzle over device Vacuum tube should lightly contact top of device 4 off off 5 250 low do not move Message Lock table Position temperature sensor approximately 3 inches from B G A 5 off off O 250 low relative move 0 6 off off 0 420 high skip Message Preheating board 7 off off 0 420 high maintain pcb temp maintain Message Replay thermal reflow sequence 8 off off 02 420 low relative move 0 maintain pcb temp 9 off off 0 420 low nozzle vacuum pcb temp 10 off off 0 420 low relative move O nozzle vacuum on maintain Message Removing device pcb temp 11 off off 0 200 low z 0 upward movement nozzle vacuum on 12 off off 0 200 low 2 525 component drop off 13 off off 0 200 low vacuum off puff off 14 off off 5 200 low 2 0 Message Remove A 15 off off 2 200 low home position Message Process complete Select Load Process Link File for site cleaning Program is set to use the following setting based on se
179. g Name Short Name Group cross reference This index file is automatically updated each time you select the Open option File C WINDOWS drs24 Profiles Ele Edit View Help Ly Profiles X 00000004 00000005 00000007 00000008 1011006 1011013 1011 1011037 a 1011066 1011067 1067013 1067014 PII Es E ce ce ce ce pem ce ce If the Profiles folder in the pull down list 00007001 00000002 Box is not visible the Toolbar option must be selected 9 9 amp 9 amp e e e 4 e co M 9 amp 9 9 9 9 To activate this tool bar click on the View menu followed by the Toolbar option Ex mi e n3 ga e i e n3 e l e e 2 e e ce Ex amp 9 99 9 9 9 co 4 m 4 e e e h 9 aj 9 Toolbar 1067009 1067010 1067012 1067015 1067016 1067017 Status Bar a a Large Icons 1067018 1067019 10
180. g on the side of the B amp B Verify programming on the temperature controllers Check under Setup General System that the single double or no diffuser matches the configuration of the DRS Call Air Vac Technical Support 12 6 5 Cycle Counter You have reached the maximum number of process cycles that has been pre set Reset cycle counter Change the Max Process Cycle under set up process counters Call Air Vac Technical Support 12 6 6 Low Memory This alarm occurs when Windows95 can no longer manage your DRS24 s 32MB of RAM e Shut down Windows95 and re boot the DRS24 Call Air Vac Technical Support to re configure Screen Displays By doing this you will change the look of your run screen but this will save on memory DRS24C Series Manual Page 6 Section 12 Troubleshooting 12 6 7 Process Thermocouple The process you are running requires one or more thermocouples to continue Install thermocouples in the appropriate channels Verify that the thermocouple is good Plug into a handheld meter to test Make sure the thin wires on the end of the thermocouples are twisted or shorted together Call Air Vac Technical Support 12 6 8 Component Removal The machine has tried a pre determined number of component removal attempts and failed Modify removal profile Call Air Vac Technical Support 12 6 9 Site Cleaning Vacuum Your site cleaning tool requires clean
181. gh Replace ubtra C If ERROR Stop Process Iv Average L R Temperature Single DRS24C Series Manual Page 42 Section 6 Software 6 2 1 5 9 Site Cleaning Check Box The Site Cleaning check box A allows the operator to program a special vacuum port used for site cleaning The site cleaning tool requires a vacuum source to remove the molten solder from the site Programming this check box checked will activate the vacuum for the current event Run screen A clear check box will deactivate the vacuum for the current event Run screen 6 2 1 5 10 Speech Check Box The Speech check box B allows the operator to program the text to speech synthesizer for event messages Alert Message edit boxes Programming this check box checked will activate the speech system for the current event A clear check box will deactivate the speech system for the current event There are 4 languages available English Spanish German and French 6 2 1 5 11 Alert Check Box The Alert check box C allows the operator to program an audible tone 5 seconds before the end of a time based event Programming this check box checked will activate the audible tone An active audible tone will be automatically deactivated during an event change 225 256 Removal 068 thick board 1081 1081 1011030 drs Build Photo Links Vision and Nozzle System Options ut Pos Rate 24 Temp C I Sec
182. h temperature solder Set tool to temperature not to melt dissolve high temperature solder The tool will vacuum remove the high temperature balls through the large hole tip diameter Removal of all high temperature balls and contaminates is required Reference Major Issues e Damage to board is most likely to occur during this phase If the solder mask is damaged either an insufficient joint will result as solder moves from pad site to via starving the solder joint or bridging will occur e Must provide uniform level pads e Must provide correct amount of flux Z Note Braid posses a high potential damage to pads and mask from overheating Excessive tip temperatures or gauging staying on the pads too long and or excessive pressure scraping due to operator dependent skills While pad damage is easy to see mask damage is almost impossible DRS24C Series Manual Page 88 Option Preparing and Installing the Assembly Destructive Drilled Pads Method Drilling Pads 1 Aclean bare site is required to start the process The bga and residue solder must be removed see previous pages gt 2 Choose 5 or 6 pads with a good mix of potential thermal differences i e two diagonal corners center or inner row gt 3 The identified pads must then be drilled We recommend using 80 drill 0135 as it accommodates a 005 inch thermocouple wire which has a typical head diameter of 012 inches T
183. he DRS24R The Jog check box B controls the maximum axis Z and Vision velocity that is used when the jog buttons C are pressed The following three velocity set points can be selected Slow Velocity Clear Medium Velocity Black Check Fast Velocity Blue Check v Ie DRS24C Series Manual Page 34 Section 6 Software 6 2 1 4 Force System Not available on the DRS24R The force system when combined with Z axis motion can be used to develop a close loop component placement removal event PBGA 225 256 Removal 068 thick board N1081X1081 1011030 drs Build Photo Links Vision and Nozzle System 03 696 Sl EE Z ZMove ABS Air C Z Move REL Do Not Move Nitrogen inch Site Cleaning Noz Vac Probe A Time v Motion v Power Events Vision Lights Video Foot Time Cool Air Injection H Alert Speech Device Nozzle Separatio B Alert Pulses Message nozzle to above board position R sensor 24 Force Systegn gt Units Actual Dest Range s Zero Force El El D Placement Removal Auto Adjust WM Display Only F Temp Low Low DID c nig DID Iv Average L R Temperatur Single palan C Disable Standard Replace C Add Subtract Data If ERROR
184. he Load Process Link File menu allows the operator to toggle between Load Pr Link File soldering desoldering and site cleaning profiles This allows a related profiles to be cycled without leaving the Run screen This menu option is only available when the process is not cycling Site Lleaning DRS24C Series Manual Page 73 Section 6 Software 6 2 2 12 4 View Photo Links Menu Option The View Photo Links menu allows the operator to access any photo images that may have been linked to the profile These captured View Photo Link video images are only 225 balls bga225 component available when process is not cycling Selecting double click a photo image will use Windows95 Paint tool to display the video snapshot To exit Paint and return to the DRS24 FZ BGA225_ SITE Paint software click on the File CQ MC ECC CC CA CM CD IEEE menu and select Exit cll option m M ETETEN E EEE Help cick Help Topics on thie Help Menu 25 DRS24C Series Manual Page 74 Section 6 Software 6 2 2 12 5 Export History Menu Option Graph data can be manually save by selecting the Export History menu Selecting this option will copy the current data set to the Export directory Help Message The Graph Data Has Been Sa
185. he blade and the top of glass Raise the nozzle 1 inch off of the glass Go to the outside edge of the carrier assembly to make adjustments Loosen the two 5432 allen screws that hold the carrier arms to the carrier rail Tighten 3332 allen screws 118 of a turn to adjust Tighten the two 5332 allen screws that hold the carrier arms Repeat steps 5 8 until no more adjustment is needed Turn the nozzle 90 degrees and repeat steps 5 9 for adjustment of carrier front to back DRS24C Series Manual Page 24 Section 11 Maintenance 11 10 Diffuser Leveling TOOLS e Free Standing Board Support 14 Inch Plate Glass 8x10 Inch Square 5 22 Inch Allen 3 32 Inch Allen Note All screws are referred to as wrench size needed for procedure Useaboard support to set height and levelness of the diffuser plate Place IM plate glass in carrier Center the glass over diffuser and lock in place e Place board support on the front left of the diffuser e Slide the support under the glass The diffuser plate should be adjusted so the support contacts the glass consistently four corners of glass Note The support should just touch the glass and still be free to move Remove the board support e To adjust loosen the four 5 32 allen screws on both left and right side of diffuser Tighten or loosen the four 3 32 allen screws to adjust height of the board support to the glass Note Adjust up only until four corners are
186. he drill hole must be centered on the pad in order to effectively solder the T C into the pad Z Note A larger drill size will typically destroy the integrity of the pad thereby preventing the T C from being soldered into the pad If the pad integrity is compromised the T C readings typically are inaccurate 2 Note A fully populated board is preferable to a bare board due to the thermal impact of other components Please recognize that the board will not be functional after drilling gt 4 005 inch T C s are then inserted into the arilled pads insulation near the head must be removed approximately 1 2 inch so that the wire can fit through the drilled hole The insulated wire will not fit One third of the head of the T C should protrude above the pad see attachment drawing 5 The T C should be hand held in position from beneath the board Apply a small amount of flux to the pad and T C head and then solder the T C into the pad Drop a bead of solder on the T C so the pad or T C is not damaged from direct contact with the soldering iron 6 Apply high temperature epoxy or Kapton tape to the bottom side drill hole to prevent the T C from slipping down during reflow THEHRMOCOUPLE ATTACHMENT FOR PROFILING REYYORK PROCESS 4f Note Do not use epoxy with a melting temperature below 210 c gt Note WARNING If the T C moves down into the drilled hole during reflow you will be monitoring inner board tem
187. he upper heating element nozzle If this option 15 installed air can be routed around the heating element producing cool air through the nozzle Component cool down 15 an example of the potential usage Note This is an optional feature PBGA 225 256 Removal 068 thick board N1081X1081 1011030 drs Build Photo Links Vision and Nozzle System paa Rate 29 Temp C Sec 62 8 Air mm C Z Move REL C Do Not Move Nitrogen ipe Site Cleaning Vac Probe B Events Groot 2 020 Speech Vision Lights Video Jog Cool Air Injection C Device Nozzle Separation Pulses ini D Message nozzle to above board position R sensor Force System Actual Dest Range fs 0000 00 Zero Force Eat El E Placement Removal Auto Adjust W Display Only Diffuser System R Temp Low Low ID c nien Average L R Temperature Single C Disable Standard Replace C Add Subtract Data If ERROR Stop Process DRS24C Series Manual Page 41 Section 6 Software 6 2 1 5 8 Vision Lights and Video Check Box The Vision Lights check box A allows the operator to activate the vision system s fiber optic lighting These lights are required for the component alignment procedure P
188. henever handling a hot nozzle Removing a nozzle Hold the hot nozzle with the nozzle removal tool e Turn the nozzle locking jaws counter clockwise and the nozzle fingers will open to free the nozzle With the hot nozzle held firmly in the removal tool place the nozzle in a container that can handle the heat of the nozzle To install a nozzle reverse the above procedure DRS24C Series Manual Page 4 Section 9 Safety 9 3 Label Description and Placement The following metal placards are affixed to the DRS24 system This label describes the electrical and air requirements for the system The overall system requirements can be found in the facilities section of this manual AIR VAC ENGINEERING COMPANY INC AlR VAC SEYMOUR CONNECTICUT 06483 U S A DRS24C Serial Number Voltage 220 VAC 15A 20A 50 60Hz Air Pressure 80 100 PSI Nitrogen Pressure 80 100 PSI 9 3 1 Warning Label Description and Placement The warning and hot surface labels found on the DRS24 system are intended to prevent injury to the operators and users of the DRS24 systen Warning HOT the upper heater and diffuser plates of the system are required to reach temperatures well above 100 C Labels are found on the covers of each heated surface CAUTION HOT SURFACE AVOID CONTACT WITH DIFFUSER PLATE High power and static sensitive warning labels advise personnel of potential issues when the machine covers are opened CAUTION
189. higher than standard temperature may required The solder melt trend occurs from the corners of the gas nozzle to the center joints except for extreme heat sink joints e Operator observation of the transition of solder reflow 15 a good means to monitor the process Clear inspection optics allows quality observation which may contribute to enhancing overall assembly quality 7 6 6 Microscope Vision System Always use the microscope whenever possible for process work including the application of flux site preparation soldering solder removal viewing nozzle correctly positioned to device nozzle at correct board height manual inspecting overall site and assembly alignment in vision system etc e Correct eyecup focus eyepiece width opening and tilt to individual requirements Keep all optics clean for crisp clean viewing e Use polarizing filter to change contrast e Always use maximum magnification to maximize accuracy If necessary tilt microscope in vision system DRS24C Series Manual Page 13 Section 7 Operator Training 77 Operator Issues 7 7 1 Alarm Screen When the system senses an undesirable condition an alarm screen will appear The alarm screen will indicate the nature of the problem The light tower will illuminate a red light and an audible tone will activate Press the enter key of the keyboard to stop the tone Consult a supervisor if the alarm persists after you correct the problem
190. ide of the solid state relay 15 connected back to the Athena controller which switches the negative to control temp Troubleshooting 15 com3 locked up Reboot computer Does 5232 485 have 12volt DC power In upper left hand cover check power plug tip is positive Are Athena controllers taking commands SV value changing to set temp Check Athena programming Does Athena controller see reasonable process temp PV for room temp 20 30degrees celcius Bad connection or thermocouple in heater Is air coming are hoses connected to create proper backpressure to trip air flow switch Check air supply 80psi static 70psi min with air flowing e 15 there DC voltage across input of solid state relay DRS24C Series Manual Page 12 Section 11 Maintenance 11 3 Upper Heater Assembly and Element Replacement e Heater Shield e Height Adjustment Knob 4 11 3 1 Replacement of the Heating Element e Disconnect machine main power e Lower the heat shield to expose the element D e Using the height adjustment knob lower the assembly to the bottom most position Remove the allen head screws from the heater element cap carefully separate e After noting the position of the Key Way C for reinstallation of the element carefully hold the connector and remove the element from the heater housing e Place the new element in the housing making sure the Tapered End D seats fu
191. ies Manual Page 4 Section 3 Installation 3 0 4 Electrical Connections Power After all Pneumatic connections have been made and all external and internal connections have been checked connect power to the machine as shown below DO NOT POWER ON THE MACHINE AT THIS TIME Power Connections IMPORTANT REFER TO SECTION 2 FOR FACILITY REQUIREMENTS OF DRS24 Machine Power e Monitor Power B Camera optional Power C Black Camera cable Negative to video port B C A DRS24C Series Manual Page 5 Section 3 Installation 3 0 5 Pre Power Up Voltage Check CAUTION The right side box with the Air Vac logo contains high voltage The machine should not be powered on during the pre power up voltage check Remove the rear locking screw and open the right white box with the Air Vac logo Check all of the Z Axis and Vision Motor Connections Check the voltage of Main Fuse Holders The minimum acceptable voltage in the non operational state is 208 volts IMPORTANT REFER TO SECTION 2 FOR FACILITY REQUIREMENTS OF DRS24 DRS24C Series Manual Page 6 Section 3 Installation 3 0 6 Re Installation of Main Fuses e The two 2 20 amp main fuses are removed by Air Vac prior to shipment e Remove the orange caution label covering the Main Fuse Holders A and insert the Two Main Fuses B from accessories kit into the main fuse holders e C
192. ig Set Point Set Point et Point N2 Foot Sw ER Pee m m Set Point Actual Idle ER EE Graph Process Information Date 04 02 98 09 22 Temperature vs Time 500 0 450 0 400 0 350 0 300 0 T C Control 250 0 200 0 150 0 100 0 50 0 Temperature 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 03 36 10 24 11 12 12 00 Time Event Time Profile Time Power DRS24C Series Manual Page 69 Section 6 Software 6 2 2 12 Menu Functions This section of the Run screen displays the function menus that are available to the operator PBGA 225 256 Soldering 068 thick board N1081X1081 1011003 drs Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Numerical Process Information J Nozzle System Diffuser System Thermocouple System Force System System Status 50 60 Memory 40 70 Grams Set Point Foot Sw Air Actual Actual Actual Idle EX UN Click On The Cycle Start Button To Begin Process ER HE Graph Process Information Date 04 02 98 09 22 Temperature vs Time 500 0 450 0 400 0 350 0 300 0 T C Control 250 0 200 0 150 0 100 0 50 0 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 03 36 10 24 11 12 12 00 Event Time Profile Time Power Board NENNEN
193. igits identifies the machine serial number listed on the Customer and Network setup page and the second four digits relate the a numeric identifier that becomes part to the short file name Item 6 IR Probe Calibration Range Enhancement This feature has been added to increase the usable temperature range for the IR probe The original IR probe was calibrated at 60 and 105 deg C This enhancement permits calibration to a higher temperature by adding a third temperature range The original offsets may not be correct due to changes in the software three set points must be recalibrates to Mid Range C Offset C insure the accuracy of the IR Probe Thermocouple Communication Min Range Offset 8 4 Section 6 Software DRS24 Main Screen v DRS Software Application Opticns Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator 5 DRS24C Series Manual Page 3 Section 6 Software 6 0 Summary Windows Tools 6 0 1 Buttons Icon buttons are generally used to activate a procedure or function Moving the cursor over the top of the icon and clicking on the left mouse button will initiate the button s functionality Button icons have a popup message that tell the operator what the purpose of the button 1s this automatically occurs when the cursor is placed over the top of the icon Note Ifa button is completely gray the
194. ile they are running in this case the engineering training profile Click in the Message box C and add your name at the end then click on the Teach icon D to save the changed message 8 2 2 Z Axis Positioning Click on the Up Arrow Key E in the event counter to advance to event 2 The event message should read Z Axis Test Position During this event the Z Axis head will automatically move to coordinate 2 500 e The training objective for this event is to change the Z Axis position to 3 250 Jog box H provides three speeds for moving the Z Axis and vision system Select normal speed Jog Very Slow V Jog Normal N Jog Very Fast e Click on Z Axis Down Arrow F Hold down until you approach the 3 250 coordinate as displayed in box AC then toggle to very slow to dial in the exact coordinate e Please note that by removing the check in the Power box G you can also move the Z Axis manually to the desired position Once the new Z Axis coordinate 3 250 is displayed click the Teach icon to update event 2 8 2 3 Nozzle Vacuum Advance the event counter to event 3 The event message should read Nozzle Vacuum Test No movement will occur during this event as the Do Not Move radio button AA 1s toggled on e Click in Noz Vac box I to turn on the nozzle vacuum during this event Click on the Teach icon to save the change DRS24C Series Manual Page 5 Section 8 Engineering
195. ility for the machine to return to the same spot 2 5 Force Measurement System Component Placement Force Up to 2000 grams in increments of 1 gram Target point and range adjustment throughout process Auto Adjustment Capability In process adjustment of force value range DRS24C Series Manual Page 3 Section 2 Facility Requirements Technical Specifications 2 0 Embedded Computer System Processor Hard Drive Floppy Drive Network Card Option Bar Code Scanner Option Multi Media Option Operating System Other Features 27 Voice Commands Verbal Instructions to Operator 2 8 Thermal Profiling Thermocouple Channels Thermal SMART TRACK Software Management IR Temperature Probe 2 9 Heating Systems Top Heater Bottom Heaters Heater Controllers 166 Mhz Pentium 32 MB RAM 2 5 Gigabyte 3 5 YES YES YES Supports 8 16 and 24 bit Up to 1600 x 1200 resolution Windows Windows NT 4 0 17 Multisync Monitor keyboard and trackball Standard PCI Sound Blaster compatible audio card English German Spanish and French 6 high speed K type thermocouple channels for profiling and process analysis Self calibrating Resolution of 0 15 degrees C res bit Automatic thermal profiling software with profile optimization build function Optional feature for monitoring top side board temperature Non contact articulating arm 3 degrees Patented 1000 watt triple pass prehe
196. imit Control This screen allows the engineer to program application process limits Each profile can have a unique set of process control parameters These limits are continuously monitored during the entire profile If a limit error occurs after the first 30 seconds of an event the process is immediately stopped and an alarm history entry is written Nozzle Range This parameter controls the acceptable profile temperature range target actual for the nozzle temperature controller L Diffuser This parameter controls the acceptable profile temperature range target actual for the left diffuser temperature controller R Diffuser This parameter controls the acceptable profile temperature range target actual for the right diffuser temperature controller Nozzle Flow Sensor This parameter controls the acceptable profile flow rate range target actual for the nozzle flow controller Maximum Force This parameter controls the maximum force actual that 15 allowed during a force event Limit Control Process Limits Nozzle C Nozzle Flow Sensor 26 Range 7 Range Diffuser C H Diffuser C Range Range Maximum Force GLEN DRS24C Series Manual Page 53 Section 6 Software 6 2 2 Screen The Run screen allows the operator to cycle a process profile A profile must first be opened using the Open option or created using the Teach option During each event of the cycle the system cont
197. indows E VERSES UE sau A Wi us 8 s 95 shut down Ey mananasnanaanannanannanasnannananaaaasnannanasnannanannanaana Restart the computer Restart the computer in 5 008 mode Close all programs and log on as a different user DRS24C Series Manual Page 24 Section 6 Software Safe Shutdown Screen Message This 15 the message that will be displayed on the screen when Windows 95 has been shut down properly At this point it is now safe to press the E Stop button and de power the DRS24 machine It s now safe to turn off your computer E Stop Button The E Stop button will de power the DRS24 machine It should only be used in the case of an emergency or after Windows 95 has been properly shut down Warning File Damage occur when pressing the e stop button if Windows 95 has not been shut down properly E Stop Button DRS24C Series Manual Page 25 Section 6 Software 6 2 Control View of the Control Menu DRS Software Application pticns History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Teach Process Events Run Process Import Graph Data 6 v o Ip 9 staan ttt 777 222022224 IIT DRS24C Series Manual Page 26 Section 6 Software 6 2 1 Teach Process Events Contral History Selecting the Teach Process Events option from the Controls menu will Sesen
198. ing A in rear of module Connect other end of silicone tubing to Site Cleaning Nozzle The Site Cleaning Nozzle installs in the Locking Jaws C in the same fashion as a regular nozzle C E rues bali MR OZZLE FILTER SHE 4 y p 4 DRS24C Series Manual Page 26 Section 4 Verification Table Of Contents 4 Verification f M 2 4l Pressure uliie io M 3 42 Post Power Up Voltage amp Pressure Verification 4 4 3 Temperature Verification LN MEME VI T2 siti Emo T 5 6 0022 VOR CU 6 44 Flow Rate Verification amp Adjustment Zo I dNozderllowComrvrolerPtl0006 aiecssseeesivstckeuseseereius es eekxesevecivite Nvevesceventus eut evesGevesUs 7 9 4 4 2 Flow Controller 20 90 10 4 4 3 Flow Sensor 100 10 444 Nozzle Flow Sensor 20 90 005000000000000000000000000000000000000000000 11 45 Vision Alignment amp VerIicatiol unie iier te
199. ing below 20m ohm is a heater shorted to ground Any out of spec heater should be considered defective and replaced Connect power set meter to AC volts low scale 2volt range place meter leads across heater terminals to be tested Release emergency stop press start button voltage will go up to line level momentarily then should drop to below 0 5volts AC If voltage is above 0 5volts AC the solid state relay is leaking and will burn out heater very quickly Disconnect power and replace relay If fuses resistance and solid state relay leakage check out the heaters must be tested as a system Commands for the heaters are sent out through com3 to the rs232 485 translator out to the Athena controllers The command format includes I D number and temperature Nozzle has I D 01 left diffuser I D 02 right diffuser has I D 03 Temperature commands are displayed in lower read out on Athena SV set value When controller calls for heat display light 01 comes on full heat or flashes maintaining temperature The upper display 15 the control thermocouple PV process value From output 1 on the Athena controller positive goes to flow switch on top of air manifold for diffusers and at the output of the mass flow controller for the nozzle This prevents heaters from switching on without airflow by sensing back pressure from heater and connections When switch sees back pressure it closes sending voltage to the solid state relay The negative s
200. ing or is clogged e See instructions for cleaning the tool Check vacuum filters if clogged then replace Check profile Teach Screen for Clogged Call Air Vac Technical Support 12 6 10 Graph History This alarm occurs when there is an error when the software attempts to read or write to the graph history file e Check that the directory you are trying to read or write to exists or if on a network is accessible look under Set up Customer amp Network for the default directory Call Air Vac Technical Support 12 6 11 Run Export History This alarm occurs when there is an error when the software attempts to read or write to the export history file e Check that the directory you are trying to read or write to exists or if on a network is accessible look under Set up Customer amp Network for the default directory Call Air Vac Technical Support 12 6 12Process Cycle History This alarm occurs when there is an error when the software tries to read or write to the cycle history file e Check that the directory you are trying to read or write to exists or if on a network is accessible look under Set up Customer amp Network for the default directory Call Air Vac Technical Support 12 6 13Temperature Limits This alarm occurs when a pre determined temp window default to 100 degrees C on either side of setpoint is not reached by one or more of the DRS24 heaters after 30 seco
201. inuously monitors and reports the following control information e Heater and thermocouple temperatures Nozzle and diffuser flow rates Force placement removal procedures Foot switch control Alarm conditions Event messages and temperature plotting graphically show the progress of a cycle PEGA 225 256 Soldering 058 thick board HT1081xX1081 1011003 drs Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Functions Numerical Process Information Nozzle System Diffuser System Thermocouple System Force System 50 60 40 10 Low orr Grams Set Point Set Point Set Point NR EX Ed EH EH Set Point Actual Idle EX Graph Process Information Date 04 02 98 09 22 emnperatfure vs Time 500 0 450 0 400 0 350 0 300 0 Control 250 0 200 0 150 0 100 0 50 0 Temperature 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 24 07 12 08 00 na 48 09 36 10 24 12 00 Event Time Profile Time Power Board i When entering Run screen software will perform two automatic initialization routines system will display the following messages Opening Motion And Temperature Comm Link Opening Thermocouple Comm Link DRS24C Series Manual Page 54 Section 6 Software a green background when the cycle is active or a gray background when the cycle is not act
202. ion device under the bga Option If desired this BGA removal profile may be saved for later use DRS24C Series Manual Page 87 Option Preparing and Installing the Assembly Destructive Drilled Pads Method Use Site Solder Removal System to Hemove the Hesidual Solder 1 Select any Site Solder Removal Profile in the Air Vac Profile Library Area Arrays file The device is removed from the printed circuit board The BGA nozzle is removed and replaced by the site cleaning nozzle The nozzle is preheated typically at 360 C 4096 flow for 100 seconds The bottom diffuser is also on typically set at 350 C high flow to keep the assembly hot The nozzle settings are automatically changed during the operating period 310 C 40 flow for the large tip 325 C 20 flow for the small tip Tacky no clean paste flux is applied to the site The site cleaning nozzle is lowered until the vacuum tip is approximately 0 20 above the pads Proper tip height above the pads is critical While viewing through the microscope use the X Y table to move the vacuum tip over the entire site The site cleaning nozzle is removed and the BGA nozzle is replaced he site is cleaned with alcohol to remove residual flux and is inspected with the microscope O1 CO N 4f Note For non eutectic solder balls the heat should be sufficient to melt the eutectic solder pads but the melt the hig
203. iption and Placement 5 93 4 Warning Label Description and Placem elitissesseveseekaeevesvesseek Su EX SE QUERI NE PR ME EE 5 94d DRAS OM ALAS u G FONS EU RP OI PI POTE PER PONS Ua OUS OV UM 6 DRS24C Series Manual Page 1 Section 9 Safety 9 Safety The DRS24 system was designed with safety of the operator in mind The operation and maintenance of the system must be performed cautiously due to the nature of the hot surfaces and the hazardous chemicals involved in the assembly and rework of printed circuit cards NOTE When operating the AIR VAC DRS24 system follow all local codes for safe operation of the machine Disposal of materials used in the processing of Printed circuit boards must be done in compliance with each Manufacturers recommendation in accordance with local codes 9 0 Safety System Overview The DRS24C machine employs a mother board and control PCB s for the control system While the system is in operation the embedded computer will provide the first level of operator safety The controller will not allow the system to operate unless all air and electrical input requirements are connected and working System alarms are employed by the controller to minimize dangerous or non compliant operation of the machine Other safety mechanisms include A latching E stop e A separate start button next to
204. ir respective home locations This button executes a general motion utility This general motion utility can not be directly programmed as a complete function however the results of this motion can be saved to an event gt ON 2 1 1 10 Nozzle Load Not available on the DRS24R The Nozzle Load button will activate a series of predefined motion events This will allow the operator to semi automatically load the nozzle Initially the Z and Vision axis will be moved to their respective home locations Next the system will ask the operator to perform the following manual tasks 1 Open nozzle clamps 2 Load nozzle 3 Close nozzle clamps This button executes a general motion utility This general motion utility can not be directly programmed as a complete function Ex ON 2 1 1 11 Component Pickup Not available on the DRS24R The Component Pickup button will position the nozzle to a predefined set of Z and Vision coordinates This button executes a general motion utility This general motion utility can not be directly programmed as a complete function however the results of this motion can be saved to an event Typically this general position 15 adjusted to exactly match the specific component pickup requirements DRS24C Series Manual Page 28 Section 6 Software 6 2 1 1 12 Vision Alignment Not available on the DRS24R The Vision Alignment button will position the component to a predefined s
205. isplayed on the monitor It moves as you move the trackball The cursor is used to select and activate items displayed on the monitor Selecting and Activating Move the cursor over the desired item point and click push left mouse button The operator will only click once over the picture or word box to activate The OK Exit Thumbs Up icon is used a great deal to move on to the next operation 7 1 Power Up Power the module by deactivating Red Emergency Stop A pull out and turn clockwise e Press Green Power Button Power on monitor Turn on Lights C A C DRS24C Series Manual Page 2 Section 7 Operator Training 7 23 Operator Registration The computer will automatically show the Operator Registration screen as shown below Log on as DRS24 and select the Thumbs Up icon The module is shipped with DRS24 as the default Operator Note If access is denied consult supervisor Operator must be a registered name stored in program y DRS Software Application Opticns Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Thermal SMART Track Svstem Operator Registration C U 5 M H M 73 Password The password screen shown below will automatically appear after the operator registration screen Click on the Thumbs Up icon The module is shipped with no password Note If access is denied consu
206. itch A provides electrical power to the module and computer On Only Emergency Stop B stops electrical power to all systems Light Switch C turns External Lights D on and off Green Power Light E indicates computer electrical power Hard Drive Active Light indicates computer hard drive Light Tower if so equipped Red light indicates systems are inactive Green light indicates systems are active G B D E F S C A DRS24C Series Manual Page 2 Section 5 Hardware Overview 51 Board Carrier System Board Edge Supports hold and support PC boards level adjustable PCB Lock B secures PC board in carrier system e Carrier Lock C adjusts arms board edge supports to width of PC board X Adjustment D rotates to obtain precise board positioning in the X direction side to side Y Adjustment rotates to obtain precise board positioning in the Y direction front to back e Table Lock secures X and Y position e Board Support Rods provide PC board support Grounding Jacks H provide ESD ground for operator Bottom Heater Diffuser I provides hot air heating to bottom side of PC board o gt Q e H G H DRS24C Series Manual Page 3 Section 5 Hardware Overview 5 2 Viewing Alignment Syste
207. ive Clicking on this button when the background 15 green will terminate the cycle l The Cycle Start Stop button 15 used to activate or terminate the process cycle This button will display Note During the cycle the operator may be required prompted to press the foot switch before any processing continue Some events are designed to allow the operator to perform a manual task final component alignment 6 2 2 1 Alarm Screen Control The DRS24 constantly monitors the controlling sub systems If any sub system fails due to a process or hardware issue the system will respond with the following Alarm screen This screen displays the last process hardware failure that occurred Alarm Control 1 Maximum Time Process Cycle History Motion Communication Link Hun Graph History Force Communication Link Hun Export History Temp Communication Link Temperature Limits Flow Sensor Cycle Counter 1 Low Memory Low Pressure 1 Process Thermocouple 1 No Activity Time Out ri Force Removal 3 Force Placement Press ENTER key to stop audible alarm This screen is not real time correcting the problem will not reset the alarm LED red yellow Selecting the Up Thumb will close the Alarm and Run screens and return the operator to the Main screen Assuming the alarm condition has been corrected the operator can attempt to re run the cycle DRS24C Series Manual Page 55 Section 6 Software 6 2 2 2
208. le at the default alignment position G e Cycle Start Stop This button will display a green background when the motion cycle is active or a gray background when the motion cycle is not active Clicking on the button when the background is green will terminate the motion cycle C D Jog Functions Vision Axis peer 8 DRS24C Series Manual Page 76 Section 6 Software 6 2 3 Import Graph Data The Import menu allows the operator to reload and analyze historical graph data Graph data is organized and stored using an 8 digit file sequence number These sequenced files are stored in the C WINDOWS DRS24 EXPORT directory Import Graph Data The largest sequence number represents the last recorded data set Teach Process Events Hun Process The Long Name and the board serial number if available are also displayed to help the operator select the correct historical graph data set Note Import Graph Data Files x Graph Data NotePad Print Options 00000205 dat PBGA 225 Soldering Air Vac demo board N1081X1081 00000206 dat QFP 160 Removal Air Vac demo board 00000204 dat PBGA 225 Soldering Air Vac demo board N1081X1081 Lines Page Temperature vs Time san d Description 15 24 03 05 98 DRS24 PBGA 225 Soldering Air Mac demo board N1081X1081 1011134 DRS 450 0 400 0 350 0 300 0 250 0 Temperature 200 0 150 0 100
209. le by pressing and holding the button until the value is displayed Call Air Vac Technical Support 12 6 14Flow Sensor This alarm occurs when the DRS24 nozzle flows are out of the pre set range of the set point default 1s 596 e Check air pressure e Calibrate nozzle flows e Modify the Default Flow Rate Limits in the Set up Limits and Defaults screen The factory default for the Nozzle Flow Sensor is 005 e Call Air Vac Technical Support 12 6 15Low Pressure This alarm occurs when the DRS24 senses low pressure on either the air or inputs e Check pressure gauges on the rear of the DRS24 They must be set with no air flowing to the proper specs in your manual e Check to see if your air pressure drops significantly below 65psi when nozzle diffuser and vacuums are all turned on high flow e Call Air Vac Technical Support 12 6 16No Activity Time Out This error occurs when you have the Run screen up and after a pre determined length of time with no activity the screen times out e When not running a profile exit out of the Run screen and keep on the Main Drs24 screen Enter Set up General System and modify the Screen Time Out number factory set to 20 000 e Call Air Vac Technical Support 12 6 17Force Placement This alarm occurs when the force applied to a part 15 out of the specified range that was set in the profile Make sure that no one touches DRS24
210. le clearance to the glass plate 15 005 or less Check at center left and right sides Adjust as necessary 10 Turn nozzle 90 and repeat steps 7 9 for adjustment of carrier front to back Diffuser C D D N Cal4 Nozzle L Glass Plate DRS24C Series Manual Page 17 Section 4 Verification 4 7 Diffuser Leveling TOOLS Free Standing Board Support IM Inch Plate Glass 8x10 Inch Square 5 32 Inch Allen Wrench 3 32 Inch Allen Wrench Feeler Gauge e Place 1 4 plate glass in carrier Move glass over left side diffuser and lock in place e Place board support one not installed on the front left of the diffuser Note If board supports have been installed remove them so that there is no contact with the installed glass e Slide the support under the glass at points C Slide glass over right side diffuser slide support under glass at points D The diffuser plate should be adjusted so the support contacts the glass consistently at these four corners e Use feeler gauge as reference Note The support should just touch the glass and still be free to move e Remove the board support To adjust loosen the four 5 32 allen screws A on both left and right side of diffuser e Tighten or loosen the four 3 32 allen screws B to adjust height of the board support to the glass Note Adjust up only until four corners are touching then back off Raising front lowers back e Tighten the 2 1 8 all
211. le control system for a specific profile all events Standard This button allows the operator to enable the thermocouple control system Specific thermocouple control actions will be processed e Disable This button allows the operator to disable the thermocouple control system Specific thermocouple control actions will not be processed Note Profiles are typically developed using several control thermocouples In many cases these control thermocouples are not required during the production Run cycle This button allows the thermocouple system to be quickly disabled without making any adjustments to the individual event control parameters e If ERROR Stop Process This button will terminate the Run cycle if a thermocouple control condition Skip or Stop fails A typical example might be the failure of the board to reach a target temperature Note If the process is terminated an alarm history entry is written DRS24C Series Manual Page 46 Section 6 Software 6 2 1 7 Duration Time or Foot Switch After programming any motion and device control for a specific event the operator has the ability to add a time delay duration This delay can be Time fixed seconds or Foot switch based A Time based event can be programmed from 0 600 seconds A Foot switch based event is only limited by the maximum profile time 45 minutes Delays typically allow activities such as heating cycles or operator interaction component
212. lease refer to Section 6 10 Software Release Notes Summary for up to date information 6 Software 60 Summary Windows sees YSE EFE SE NN DEEE YA SR eH YEN 3 8 a M M N 9 25 62 26 Q21 eH Hu au 27 53 DM MEME UU RII 54 76 NS Dro 7 82 63 Thermal SMART Track SOIUWSEG uu Po ab EH vae a 83 QUII E 83 84 Preparing amp Installing the Assembly 85 91 SO 92 94 E EE E 95 102 AO ST en 103 106 Applying the Best Fit Thermal Seguence 107 109 D TT ONGC FPO ERR 110 121 FTO 122 Final Tesine VQ 600 a 123 Saved Back Up Restore Thermal SeQHuenees emet ddr ess kE E Sabena sue dU 124 125 LST Pro hine Sree QVCIVIOW vies vacrscisncoubw s aden EDS e QUE 126 127 Jl ii 3
213. lection Application Definitions Nozzle Definitions Reflow Position Component Removal Removal Retry Raised Contact off c 125 125 off 96 35 35 E 0 seconds 60 60 5 relative move 9 0 200 0 off 125 109c 20sec 0 seconds 15 skip Thermocouple 90 90 maintain Thermocouple 125 125 DRS24C Series Manual Page 120 Reference Nozzle Definitions English or Metric Units The Automatic Profile Build screen is defaulted to the English inches system Er Option Unit Conversion Automatic Profile Build Search Lists If desired metric mm units may be selected DAS Setup General System Options Millimeters Open I Graph Export I Thermocouple s I Vacuum Sensor Inches I Notes History Nozzle Definitions sf Note The Nozzle Definitions on the Automatic Temperature inch Profiling screen inch mm will indicator the English or Metric System C mm The Nozzle Length is converted to English or metric system units Inch Dimensions mm Dimensions Harrie Seach Pan amp Fims Rale R ABSWHEHZEEEGSEERER lt Setup Reset Operator Diffuser Idle Menu Option Automatic Profile Build Search Lists Process Counters The user can manually enter nozzle or device lengths for non Customer and Netw
214. lly e Replace the cap with the key way properly aligned to the element Be sure the gasket is installed and seated properly e Screw down the cap evenly so the fit is snug Be careful not to over tighten the element the element can be crushed Also insure that an air tight seal has been created DRS24C Series Manual Page 13 Section 11 Maintenance 11 3 2 Heating Element Checkout 0024 22 042 To check the condition of the heating element use a digital ohm meter and measure the resistance between pins 2 6 The reading should be 52 5 1 ohm on a good element Also read between pins 3 and 4 process thermocouple for continuity Thermocouple Safety Thermocouple Element 11 4 Diffuser Heater Replacement Disconnect 220vac power Open right hand side box Locate terminal strip inside lower casting e diffuser is connected to terminals 22 and 19 right terminals 21 and 18 Disconnect wires to heater to be replaced Thermocouple for the heater must be disconnected and male plug removed The left heater thermocouple is connected to wire 127 right 128 Wires must be pulled out the back of power module by loosening the strain relief right side heater wires are on right side left wires on left Remove panel above strain relief to cut tye wraps holding wires when installing new heater route wires around ring transformer they should not touch e Carefully loosen all nine flat head screws that hold heate
215. lose the right white box but do not install the locking screw at this time B A DRS24C Series Manual Page 7 Section 3 Installation 3 0 7 Power Up Sequence Turn the Emergency Stop Button A clockwise to deactivate e Press the Green Power Button e Power on the monitor C D A B The Green Internal Computer Power Indicator C will illuminate and remain on The Yellow Hard Drive Indicator D will illuminate momentarily and then will go off The computer monitor will display the Operator Registration screen as shown below DRS24 and select the Thumbs Up icon the system is shipped with DRS24 as the default Operator Select Thumbs Up again when prompted for the password the system is shipped with no password y DRS Software Application Opticns Control History Video Screen Utilities Reset Cycle Counter Setup Thermal SMART Track System C U S T R N A M E DRS24C Series Manual Page 8 Section 3 Installation 3 0 8 Microscope Installation Remove protective cap from Microscope Zoom Lens e Position Microscope Eyepiece Housing B parallel to Microscope Trolley C and install e Tighten Lock Screw D A B C DRS24C Series Manual Page 9 Section 3 Installation 3 0 9 Board Support Installation Lock carrier using Table Lock A Unlock two 2 Carrie
216. lt supervisor Password must be correct to access software system 3 ecurity r m m m m s f f lt zx DRS24C Series Manual Page 3 Section 7 Operator Training 7 4 Main Screen Options Open Directory Files Main Screen select Options then Open The screen below will appear e Select the following directory paths Customer Group Air Vac Engineering Company Board Group Profile Library Device Group Leaded Devices e Double click on Operator Training OFP160 Align and Place to open the profile Profile HotePad Files Operator Training GFP 160 Align and Place PLCC 68 Removal 068 thick board N354E954 PLCC 68 Soldering 068 thick board 954 9541 QFP 160 or 208 Removal 066 thick board HOT NOZZLE 160 208 Removal 068 thick board M1103B1103 HOT GAS NOZZLE 160 208 Soldering 066 thick board BAR NOZZLE 160 of 208 Soldering 068 thick board M1103B1103 HOT GAS NOZZLE SOCKET 44 Removal 066 thick board 5 SOCKET 44 Soldering 068 thick board N654J654 SOIC 20 Removal 060 thick board N3DA51 SOIC 20 Soldering 068 thick board 51 warm up Customer Group Air Vac Engineering Company Board Group Profile Library Device Group Lea
217. ly generated and is composed of two separate elements The first four characters of the Short Name are taken from the DRS24 machine serial number The remaining numbers represent a sequence number This sequence number changes as new profiles are saved The file extension for all short file names must DRS 6 1 3 2 Link Name Soldering Desoldering A soldering desoldering link 5 allows the operator to quickly open a related profile soldering or desoldering without leaving the Run screen The Link Name is not automatically generated The operator must enter this information The Link Name identifies points to to a previously created profile with process related functionality Typically a soldering profile has the desoldering Short Name entered as the Link Name 6 1 3 3 Link Name Site Cleaning After the component has been removed a Site Cleaning profile C 15 generally cycled to remove the excess solder from the site The Link Name is not automatically generated The operator must enter this information The Link Name identifies points to to a previously created profile with process related functionality Typically a desoldering profile has the site cleaning Short Name entered as the Link Name 6 1 3 4 Long Name The Long Name D is used to describe the overall function purpose of the profile Long names are used by the Open option to help the operator accurately select a profile The Long Name can be up to 60 characters l
218. m Vision System A superimposes component leads to PC board pads e Stereo Microscope B allows operator to view removal alignment and reflow processes e Camera C optional allows operator to view removal alignment and reflow processes on computer monitor e Trolley Adjustment D sets the viewing angle for microscope camera between 45 60 axially Top position is used for vision based alignment Bottom position is used for direct viewing at board level e Theta Adjust E rotates to obtain precise theta component position Nozzle Vacuum Switch On Off vacuum to hold component Manual Z Height Adjustment G adjusts nozzle height to PCB Software must disable motor power C B E F A D DRS24C Series Manual Page 4 Section 5 Hardware Overview 5 3 Computer System e Monitor A provides viewing of profiles and camera image option Monitor Power Switch B On Off electrical power to monitor Keyboard C Trackball D provides point and click activation of computer functions e Floppy Drive E allows backup and restore installation of programs or profiles Thermocouples provide feedback of temperature to computer A B OOOOOOOOOO OOOOOOOOOO OOOOOOOOOO m D E DRS24C Series Manual Page 5 Section 6 Software Table Of Contents NOTE If the software screens shots in this manual appear different than on the machine p
219. m Thermocouple System Force System System Status 50 60 Memory 40 70 Grams Foot Sw Air Cycle Busy Alarm Set Point EX EX EN Actual Actual Set Point Actual Ramp Idle Idle ER ER ER EZ EE Graph Process Information B Date 04 02 98 03 22 Temperature vs Time 500 0 450 0 400 0 350 0 300 0 T C Control 250 0 200 0 150 0 100 0 50 0 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 09 36 10 24 11 12 12 00 Event Time was Profile Time Power U zi Ei m a Temperature Note Messages may be programmed to use the text to speech synthesizer The languages which are available include English Spanish German and French DRS24C Series Manual Page 63 Section 6 Software 6 2 2 6 Graph Process Information C This section of the Run screen displays the Temperature vs Time graph This window only displays a 12 minute view of the process cycle To display the entire graph after the cycle is complete the operator can select the Auto Scale Graph menu option see Menu section for more information C PBGA 225 256 Soldering 068 thick board N1081X1081 1011003 drs Ea Graph Data Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Numerical Process Information I i xi Nozzle System Diffuser System Thermocouple System Force System System Statu
220. me Component Removal Corresponding Profiles Mame and Link Control short Name 011001 085 Link Mame Soldering Desoldering f ink Clesning Name gt 7 Goto Options Then Open Call up Component Removal profile Provide the Short Name for the Site Dress and Component Replacement Corresponding Profiles DRS24C Series Manual Page 122 FINAL TEST SOLDEH OR REMOVE ACTUAL DEVICES oolder quality should be verified using x ray and or functional testing gt Profile development should always include a production process verification step repeatability and accuracy using production parts and the standard run utility e For component replacement Soldering quality e Motion accuracy e Component pickup e Nozzle position for vision alignment Starting force placement position 0 050 above board automatic 0 100 manual e For component removal e Removal efficiency Motion accuracy Component drop off Sub System Alarm Control The system protects against the following standard alarm conditions e Flow and temperature limits ow pressure Thermocouple system e Force e Maximum cycle counter DRS24C Series Manual Page 123 Reference Open Thermal Sequence Screen All Thermal Sequences are stored e o access click on Control then Automatic Profile Build
221. mer Group Air Vac Engineering Company Board Group Profile Library Device Group Leaded Devices Ei DRS24C Series Manual Page 3 Section 8 Engineering Training 82 Teach Screen Overview The Teach screen contains a wealth of information as it 1s the control mechanism for virtually every process parameter in the profile Engineering personnel must become intimately familiar with the Teach screen functions in order to create modify and save process profiles Now that you have reviewed the Teach screen information in the software section of this manual section 6 page we are ready to proceed with some engineering specific training Open the Engineering Training profile in the Air Vac Engineering Profile Library Leaded Devices directory Follow the instructions on the notes page prior to proceeding At the bottom of the notes page click in the Continue To Run Screen box to delete the check mark then select the Thumbs Up icon Select Control then Teach from the main menu You should now be in the teach screen for this profile as shown below B G AB X S 7 Engineering Training Profile 1054002 drs i Vision and Nozzle System AA Options Rate Temp C Sec 2 D 000 D m 080 i 9004 D BE 1 Z Move RE G Z Move ABS Aj Cmm C Do Not Move Nitrogen Event ControIW
222. munication Expansion Board D A D Card E Thermocouple Card F SS D C B A Page 2 DRS24C Series Manual Section 10 Schematics 10 1 Computer Connection Locations DRS24C Series Manual Page 3 Section 10 Schematics 10 2 System Block Diagrams 10 2 1 Wiring Control Block camera mother board inputs Printer DB9 port Multimedia LPT4 PCI bus PCI bus Network Keyboard E coax RJ45 Force Meaurement 1 AD101 BOARD COM1 HD15 PCI bus monitor ue Thermcouple RTD ADA1110 module 16 ANALOG INPUTS Digital x16 thermocouple connectors k type PCI bus 2 free slots Athena Athena IDE controller controller ISA bus iGA RS232 COM3 rs232 485 FDD DUAL COM translator BOARD 4 2400 Athena Hard controller 19 2 Baud Sneaker Plug RC systems V8601 AMI speech module DM225l d24cpuwi flo 3 20 98 DRS24C Series Manual Page 4 Section 10 Schematics 10 2 2 Power Wiring Block Single Diffuser 220 VAC CH1 15 Amps DRS24 Power Wiring block single diffuser 5 Amps Jl F8 220V ac O O Top heater controller Diff B right controller 4 Amps Pe 220V ac Top heater O
223. n W The event counter will show that you are still on event 7 however the total number of events has increased to nine originally 8 Events 7 and 8 are exact duplicates e Advance the event counter to 8 Change the event message to Cool Down Change the upper heater temperature and flow rate to zero e Change the left and right diffuser temperatures to zero e Click on the Teach icon to save the new event 8 8 2 9 Acceleration and Velocity Advance the Event Counter to Event 9 The event message will read Process Complete During this event the nozzle will raise up Make the following changes Change the value in the Accel box X from 50 to 10 This change will cause the initial and final movements to accelerate decelerate slowly Using a slow acceleration percentage is a good practice anytime you need precision or caution ie moving close to the board picking up or dropping off a component etc Click on the Teach icon to save the changes for event 9 DRS24C Series Manual Page 7 Section 8 Engineering Training 8 3 Process Notes e Click on the Process Notes icon Y to access the Process Notes page Add the following text to the nozzle line 1103 1103 e Click on the Thumbs Up icon to return to the Teach screen 8 4 Saving Changes Permanently The process of clicking on the Teach icon saves any changes as long as the profile is in current memory e To permanently
224. n this control option requires a target temperature A to be programmed This target temperature is used to trigger an event change Target temperatures can be defined as increasing heating cycle or decreasing cool down cycle e Stop D This control option monitors a thermocouple channel during the process cycle In addition this control option requires a target temperature A to be programmed This target temperature is used to stop the process cycle Target temperatures can be defined as increasing heating cycle or decreasing cool down cycle Maintain This control option monitors a thermocouple channel during the process cycle and is connected to the control logic for the diffuser heating system If the actual board temperature measured by a thermocouple is above the target temperature A then the diffuser system heat air is turned OFF If the actual board temperature measured by a thermocouple is below the target temperature A then the diffuser system heat air is turned ON E D C B PBGA 225 256 Removal 068 thick board N1081X1081 1011030 4 Build Photo Links Vision and Nozzle System Pos 00 000 Rate Temp C C Bo 6 Z Move ABS Air Z Move REL Do Not Move Nitrogen inch Site Cleaning Noz JT Probe Motion Power Events Vision Lights Video Iv
225. n 6 Software 6 2 1 2 4 Power Check Box The Power check box A helps to provide maximum Z axis flexibility to the operator during the Teach and Run procedures This check box can be used to program the state powered de powered of the Z axis motor after completing any required event motion Run screen In addition this check box can be used to immediately adjust the state of the Z axis motor power during the development process Teach screen When the Z axis motor is de powered adjustments can be made by manually rotating the Z axis knob C PBGA 225 256 Removal 068 thick board N1081X1081 1011030 drs Build Photo Links Vision and Nozzle System Temp Dest tS 7 ABS Air C mm Z Move REL Not Move Nitrogen inch Site Cleaning NozVac J Probe Events Vision Lights Video Jog em Speech Bei Cool Air Injection B Device Nozzle Separation Pulses Message nozzle to above board position R sensor Force System Units Actual Dest Range 0 Fumar Zero Force u g ga gi Placement Removal J Auto Adjust W Display Only Diffuser System L Temp C R Temp C High High Iv Average L R Temperature Single Arlan Disable Standard Replace C Add Subtract Data If ERROR Stop Process 6 2 1 3 Jog Check Box Not available on t
226. n screen Individual profiles may be programmed to Low Low deactivate the Diffuser Idle feature during the Run screen DR524 Diffuser Idle Control High High 6 7 2 DRS Maintenance Process Counters Selecting the Process Counter option from the Setup menu will present the DRS Maintenance Process Counter screen This screen displays the Current Process Cycles and Max Process Cycles parameters The operator can change these counters by deleting the old value and retyping the new value DAS Maintenance Process Counters The Machine Cycles counter is not an adjustable number This represents the total number of Current Process Cycles Max Process Cycles Machine Cycles machine cycles that this machine has e 730 processed Ur DRS24C Series Manual Page 135 Section 6 Software 6 7 3 Customer and Network Setup Screen The Customer and Network setup screen allows operator to adjust several customer specific parameters The Customer Name field will be displayed on the Main screen The numeric field to the right of the Customer Name is used to position the text on the Main screen The Serial field is used as part of the profile name that is saved to the hard disk drive This number should exactly match the serial number of the machine This value is setup at the factory and should not be changed The following edit boxes control the critical system directories Open Export History Phot
227. nds e Check incoming AC voltage and air pressure flow rates and make sure that they per spec s in DRS24 manual sec 2 2 2 p 6 Make sure all DRS24 heaters are functioning Open and run the Heater Burn In profile in the hidden screen Make sure the heaters are coming up to the temp setpoints and are tracking properly graph lines are smooth with no large spikes or oscillations Re calibrate upper heater and flows if you determined that the alarm is coming from the upper heater If the Heater Burn In profile runs properly with no alarms check and modify your particular profile DRS24C Series Manual Page 7 Section 12 Troubleshooting Ifthe Heater Burn In profile does not run properly determine which heater upper left diffuser right diffuser 15 causing the alarm If no heat at all 15 being generated check the fuse for that heater and replace if necessary nozzle F3 left diffuser F4 right diffuser F5 If fuses are not blown measure heater resistance to determine if the heater element is good See DRS24 manual sec 11 2 p 6 for this procedure If you determine the element is bad replace e If heaters checkout o k see if the temperature controller is receiving its set point Open the right box to expose your controllers Re run the Heater Burn In profile and view set points On Athena controllers the set point 15 the lower green value on the display On the Cal 9300 the set point is viewab
228. ng 7 Menu Functions 225 256 Soldering 068 thick board 1081 1081 1011003 drs Ea Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Numerical Process Information J Nozzle System Diffuser System Thermocouple System Force System System Status a ECIAM crams EN EX 20 Set Point Set Point et Point FootSw m mm A Nozzle E m e e 9 Set Point Actual Ramp Idle Idle Range EE ER ERED EX Graph Process Information b Date 04 02 98 09 22 Temperature vs Time 500 0 450 0 400 0 350 0 T C Control Temperature Ch e zn 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 TA 59 07 12 08 00 08 48 03 36 10 24 11 12 12 00 Profile Time lt F Power JI D i y F G H I E DRS24C Series Manual Page 57 Section 6 Software 6 2 2 4 Numeric Process Information A This section of the Run screen displays numeric information associated with process temperature flow rate force and thermocouples PBGA 225 256 Soldering 068 thick board 1081 1081 1011003 drs Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Process Information Nozzle System 40 50 60 70 Diffuser System Thermocouple System 1 EX
229. nnel the static protected laminate should not be directly connected to ground at any point Recommended grounding procedures suggest installing an in line 1 MEG OHM current limiting resistor between the static protected laminate and the ground Electrical Hydro grounding circuits may not be at actual ground potential It is recommended that a separate ground circuit be installed for the static protected work surface Mounting Detail 13 32 Dia 13 16 Dia 82 Countersink Brass ground lug Work surface Ground lead with 1 resistor 3 8 16 Nut DRS24C Series Manual Page 16 Section 3 Installation 110V Electrical Panel Installation Step 5 e Electrical Panel Caps fit into Left amp Right Table Supports slots as shown Slots End Caps DRS24C Series Manual Page 17 Section 3 Installation Nozzle Rack Installation Step 6 e Assemble Bracket Arm and Rack using two King Pins as shown e Attach assembly to Table Support slots and secure using Locking Pin King Pin Universal Bracket King Pin Nozzle Rack Nozzle Rack Swing Arm Locking Pin location DRS24C Series Manual Page 18 Section 3 Installation Monitor Stand Installation Step 7 Assemble Bracket Arm and Stand using King Pin e Attach assembly to Table Support slots and secure using Locking Pin Locking Pin location Universal bracket King Pin w Swing Arm CRT Stand DRS24C Series Man
230. ntrols adjacent device maximum temperature Page 106 APPLYING THE BEST FIT THERMAL SEQUENCE selecting the Thermal Sequence Process Optimization Rule x Note The system does the best it can to optimize the cycle results in a progressive sequence typically cycle performs better than cycle 1 1 Click on the last data radio button filled The graph will be drawn to this thermal sequence Themal SHARAT Track Automatic Temperature pave gt 2 Click on Save _______ Device Joinijs Average Target C CoulDown The Save Thermal Sequence screen will appear 200 179 060 Naming and Saving the thermal Sequence Save Thermal Sequence Reference A short file name will be automatically generated Name Control Short Name The short file name is used in the backup restore utilities The short name file extension is THL LL Reference completed profile will have 2 events defined with replay requirements Board preheat Device reflow This event will occur after the preheat event and is comprised of the soak reflow and cool down stages These thermal sequence files will be attached to a motion sequence This task is completed during the automatic profile build session 1 Along file name similar to standard profile names must be given these control steps 2 Press the The Teach sc
231. o DAS Setup Customer and Network Customer Network Information Customer Name Name Serial 0000 Open Dir C WWINDOWSYDRS241PROFILES s Export Dir CAWINDOWSYDRS2AYEXPORT History Dir CWZINDOVZSADRS24 SY Photo Dir CAWINDOVWSYDRS241IPHOTO DRS24C Series Manual Page 136 Section 6 Software 6 7 4 Customer Board and Device Group Setup Screens The group maintenance screens allow the operator to create or delete a group To create a new group name type the desired group name into the group edit box A Click on the New Add Entry button to insert the new group into the existing list A To delete a group the operator must first highlight the group A Next the operator can click on the Delete Highlighted Entry button to remove the entry from the list To save these changes click on the Thumbs Up button To cancel any changes click on the Thumbs Down button Air Vac Engineering Company oystem Files Board Group Ea BGA Demo Board LEADED DEVICES Profile Library ze Device Group Ea Leaded Devices System Files AU 1 OK Save Changes Exit Screen Delete Highlighted Entry Cancel Do Not Save Exit Screen New Add Entry DRS24C Series Manual Page 137 Section 6 Software 6 7 5 Operator Setup Screen Operator This screen is used is used to modify regist
232. o save all event 5 changes 8 2 6 Thermocouples Skip to Next Event Advance the event counter to event 6 The message box should read Preheating Board to 60 Degrees Then Skip to Next Event Click in the Data box P in the thermocouple section and type in 1 Click on the Thumbs Up icon Using the right mouse button click in the thermocouple box under the Skip column Q The box value should change from zero to 1 This indicates the Skip function for thermocouple 1 is active for this event Replace the 17 in the data box with 60 then using the right mouse button click on the thermocouple 1 box under the Temp column R The box should now display 060 Click on the Teach icon to save the changes for event 6 DRS24C Series Manual Page 6 Section 8 Engineering Training 8 2 7 Heater Temperatures and Flow Rates Advance the event counter to event 7 The event message should read Upper Heater Ramp Up Make the following changes e Type 40 into the Rate box S for the upper heater 200 into the Temp box T for the upper heater e Type 300 into the two Diffuser Temperature boxes U amp V e Verify that both diffusers are toggled on low flow Click oon the Teach icon to save the changes for event 7 6 2 8 Insert Event Do Not Advance the Event Counter rather leave it at event 7 after saving event 7 changes Click on the Insert Event ico
233. on 4 Verification To access the Flow Adjustment Screen DRS24 or any high level security operator and select the Thumbs Up icon DRS Software Application Opticns Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator Thermal SMART Track System Operator Registration U 5 M R N A M e Using right side mouse button click on the Air Vac logo You are now in the Hidden Setup window Select Setup from the menu bar Select Nozzle Flow Meter The Nozzle Flow Adjustment screen will appear as shown below Flow Adjuchments Nozzle Flow System 0 20 30 E Ei z C 10056 Initialize Ramp Increment Nozzle Flow Sensor Nozzle Flow Controller 20 Offset 3096 Offset 2096 Offset 3096 Offset D 60 Offset 70 Offset 25 50 Offset 50 70 Offset 80 8096 Offset 90 Offset Bo Offset 25 9096 Offset Controller Idle Bir 100 100 2770 Nitrogen Ex G B DRS24C Series Manual Page 8 Section 4 Verification Making Flow Controller 100 Verifications and Adjustments Click on the 100 radio button A The air flow will activate after 1 4 seconds Walt 45 seconds before making any adjustments e Check the 100 scribe line on the flow meter If the flow meter reads too high or t
234. on is initiated Note The Motion check box protects the destination coordinates from accidental modification C If the Motion check box 15 clear the motion function buttons located in the Options section will remain gray and inactive This mode also allows the operator to use the scroll buttons to advance the event counter to a new event 3 of 2 If the Motion check box is selected checked the operator can not scroll beyond the last event DRS24C Series Manual Page 31 Section 6 Software 6 2 1 2 2 7 and Vision Axis Jog Buttons Z AXIs Display A This motor coordinate represents the actual position of the Z axis Display B This motor coordinate represents the destination event position of Z axis This coordinate 15 taught during the profile motion development phase The Z axis Up button C will raise the nozzle The Z axis Down button D will lower nozzle Vision Axis Display A This motor coordinate represents the actual position of the Vision axis Display B This motor coordinate represents the destination event position of the Vision axis This coordinate is taught during the profile motion development phase The Vision Up button C will close the Vision axis toward back of machine The Vision Down button D will open the Vision axis toward front of machine Note The Jog check box controls the axis velocity A Pns 13 595 B Des
235. ong The Long Name is not automatically generated The operator must enter this information Warning The operator should be careful not to enter exactly a long name that already exists The system will allow identical long names to exist in the profile library DRS24C Series Manual Page 14 Section 6 Software 6 1 3 5 Customer Board and Device Group These groups allow profiles to be organized using a combination of customer board and device name New groups can be easily created see Setup Group Categorizing profiles by group can significantly improve the operator s ability to find the correct application profile Warning Message When operator clicks on thumbs up button to save a profile system may e notify the operator that they are about to replace an existing file this will only occur if the profile currently exists in the library Short Name To complete the save the operator must click on the Ok button Help Message Profile Save Completed When the operator completes the save function the following confirmation message will be displayed If the operator Cancels the save function the following confirmation message will be displayed 69 Profile Save was Mat Completed DRS24C Series Manual Page 15 Section 6 Software 6 1 4 Save As Options Contral Neu The Save As option functions very similar to Save option however
236. ons 9002 10 006 24 10 5 Electrical Schematics DRS24 PONGFDUS TDUHOR HEEL ves tasa ER VESSERRESRNEERUER UE VERE VEO UI 25 2 COMO CUCU ive adn 1a E kasus 26 TOD L Eo ipi O rr 27 10 5 4 Athena Controller amp Temp 28 TOD Die Control Cir CU 29 TOD IP ANICICONNCC ON iis 30 VISION VOIR gins 31 1030 Speech Card ERE 32 OIS OPT TE pasas 33 103 40 VO Board 34 Theuma S DON COME T Ont E 35 105 1 DyOnMOMerbOdrd Mouse Cuba RESE 36 DRS24C Series Manual Page 1 Section 10 Schematics 10 Schematics 10 0 Computer Card Locations PCI Speech Card A Video Multimedia Board B Communication Expansion Port C Com
237. ontrol sequence Pulses Message Force System Units Actual Dest Range D 2 Force E El Placement Removal Auto Adjust Display Only Highest priority Motion Force place remove Diffuser System F Temp Middle priority Device control Low 6 Low DB Iv Average L R Temperature Single Lowest priority Time or foot switch Note Entering the Teach screen will display the control parameters for the first event 1f any events exist Motion control Motion control involves activities that relate to movement in the Z or Vision axis Force placement removal is also considered motion control Device control Device control involves activities that relate to the following items temperature flow rate vacuum lights video and thermocouple control Time or footswitch control Time control involves activities that require a fixed or unknown duration Fixed time is represented by standard seconds An unknown time is represented by the use of a foot switch event During a foot switch event the process will not continue change events until the operator presses the foot switch Note The Teach button must be selected to temporarily save any control parameter event adjustments DRS24C Series Manual Page 30 Section 6 Software 6 2 1 2 1 Motion Check Box The Motion check box helps to control which parameters
238. oo low adjustments be made immediately by entering a new value into 100 Nozzle Flow Controller box B The air flow should not be interrupted The adjustments will be automatically applied within 3 5 seconds Note No adjustment is necessary if the flow is off by less than the thickness of the float Flow Meter Flow Meter Value Chart 1 Software Screen Flow Meter Target Value 20 scribe 55 scfm 30 scribe 82 scfm 40 scribe 1 10 scfm 50 scribe 1 37 scfm 60 scribe 1 65 scfm 70 scribe 1 92 scfm 80 scribe 2 20 scfm 90 scribe 2 47 scfm Meter should settle at 100 Read bottom of float head largest diameter Reference 100 is equivalent to 2 75 scfm Note It is recommended that you use the tab key to enter into the adjustment box to change the setting Ifthe flow meter reads too high decrease the value by increments of 5 in the 100 Nozzle Flow Controller box B Ifthe flow meter reads too low increase the value by increments of 5 in the 100 Nozzle Flow Controller box B DRS24C Series Manual Page 9 Section 4 Verification 4 4 2 Nozzle Flow Controller Verification and Adjustment 20 90 only Making Flow Controller 20 90 Verifications and Adjustments At this point the 100 Flow Controller value has been set For each of the remaining radio buttons 20 90 location C the operator should run through the same verification and adjus
239. ork standard types A menu option has been added to access the search lists provided in the Automatic Profile Build screen Operator menu option allows entries to be added or removed Additional Password entries must be properly positioned in the defined columns Tabs stc Message Title should be used to separate the data fields see above Vision System Automatic Profile Build Search List F Mozzle Device DRS24C Series Manual Page 121 SITE CLEANING PROFILE LINK COMPLETING ALL LINKED PROFILES DAS Software Application gt 1 Select Options then Open mom Files gt 2 Select a good known Site Cleaning profile gt Click on Thumbs Up gt 3 Uncheck Continue to Run Screen at bottom of Open Profile Notes screen Click on Thumbs Up DAS Software E 4 Go to Options Then Save As 5 Rename Long Name Enter Short Name of the Component Replacement Corresponding Profiles Record Short name for the Component Link Name Site Cleaning Replacement and Component Removal Long Name ecco Corresponding Profiles Click on Thumbs Up Options Control 6 Goto Options hen Open gt Call up the Component Replacement profile Provide the Short Name for the Site Dress Provide the Short Na
240. ote Top of package thermocouple installed after BGA is soldered DRS24C Series Manual Page 91 RUNNING THE PROCESS GETTING TO THE THERMAL SMART TRACK AUTOMATIC TEMPERATURE PROFILE SCREEN 1 Power on machine Pass operator and password login screens 2 Select Control DAS Software Application Options Contro History Video Screen Utes Reset Cycle Counter Setup Reset Operator gt 3 Select Thermal Smart Track Automatic Temperature Profile The Thermal Smart Track Automatic Temperature Profiling TST run screen will appear hamal SMAAT Track H FPrefling Device Boem T C Fetlar 5 Max fC Target C Start Maxi man a m lidupundeut Sosk s am io F ars ar Bol BIG remo Combo cu E i m PS P Hazri a mm Eowd Fletbow s M di Adjust mm VHS C fumer CJ
241. otes 7 Miscellaneous Control Miscellaneous Control Removal Retry Counter 9 Temp Increment o9 Continue Diffuser Idle Mozzle Load Position 9 6 2 1 9 1 Miscellaneous Control Continue Diffuser Idle Diffuser idle is typically used to maintain a low temperature in the diffuser heating panels Diffuser idle can minimize and stabilize the warm up time required at the start of each cycle This control defines whether or not the diffuser idle will be continued when the Run screen is selected e Nozzle Load Position This parameter allows the default nozzle load position to be adjusted for a specific profile In general the standard default position 15 acceptable for most nozzle load requirements If a unique nozzle component insertion tool combination 1s designed a custom nozzle load position can be programmed A zero in this edit box will use the default position This position is measured in motor pulses Any change to this value should be based on an offset plus the default position i e new Nozzle Load Position default 1 000 motor pulses DRS24C Series Manual Page 49 Section 6 Software 6 2 1 9 2 Removal Retry An option is available to monitor the vacuum levels during the component removal process A specific event can be programmed to detect vacuum reduction nozzle component separation during Z axis upward motion Run screen If detected the event will retry the removal proces
242. penings Gas openings must be correct to transfer heat to assembly Use gas nozzle handling tools e Store nozzle in tray Do not drop nozzles Donotrun process without a vacuum cup in the nozzle Vacuum cup provides insulation to device Be sure vacuum cup is large enough to pick up device e Remove arrows from repair components Vacuum port will be closed when arrow 15 held Device will not pick up Do not clean nozzle in cleaning solution or degreaser with vacuum cup still installed not apply excessive force into nozzle nest 7 6 4 Software e Open the appropriate software profile and be sure to follow all set up notes Footswitch must held until yellow radio button goes out Not touch apply any pressure to the machine during the force placement event DRS24C Series Manual Page 12 Section 7 Operator Training 7 6 5 Thermal Conditions e Preheating of the nozzle will provide more consistent results While soldering heating of the solder leads just above the PCB pads and heating of the solder prior to placement at board level will promote better bonding between the bottom of the lead and top of the pads e Heating the pads prior to placement will diminish lead stress and possible misalignment Lowering the flow rate for soldering process relative to the desoldering process may offer better solder joint quality e For very dense assemblies a lower than standard flow rate and
243. perature as the T C is no longer in contact with Solder Paste the BGA sphere Solder Ball PYVB Attachment Pad Via Attach T C using eutectic solder One third of T C head Fihrougliceciiterar must be above the attachment pad attachment pad with 80 0135 7 drill Apply high temperature epoxy or Kapton tape keep in place after soldering T C head into pad Thermocouple K type gt 7 Attach additional T C s as follows Board 3 inches away from site or use Non Contact Temperature Sensor board or adjacent device if heat sensitive Note Be sure to account for the actual size of the device which is larger than the pad area gt 8 Neatly arrange and label all T C s This will simplify your life when you go to use it again at a later date DRS24C Series Manual Page 89 2 Option Preparing and Installing the Assembly Destructive Drilled Pads Method Attaching Instrumented BGA Eutectic Solder Balls gt 1 Apply uniform amount of tacky flux not low solids flux across the site t Option Place 012 015 shim stock on site not on pads to maintain solder height reduce gradual ball collapse during repeated heat cycles gt 2A Use soldering profile note nozzle design X or EZ style close to nozzle size Or gt 2B Use the TST system to solder down new part Non Eutectic Solder Balls Warning Board must be cool or solder will slump 1 Place stencil ver
244. perature has occurred 6 2 1 4 5 Auto Adjust During the heating process the nozzle the board or the component may experience expansion or growth The Auto Adjust F check box allows the operator to adjust control the applied force that occurs during an event Run screen The force Destination and Range values are used as a target control points for the adjustment procedure 6 2 1 4 6 Zero Force Button Actual Force Display A H The Teach screen allows the operator to manually visually test approximate target force placement removal values For Force placement testing the component can be lowered to an above board position Clicking on the Zero Force A button will clear any currently applied force that may have been generated during the X Y Z axis positioning The operator can then manually powered or de powered lower the component while watching the Actual H force display For Force removal testing the nozzle can be lowered to the component engagement position At this point the nozzle vacuum should be activated Clicking on the Zero Force A button will clear any currently applied force that may have been generated during the X Y Z axis positioning The operator can then manually powered or de powered raise the component while watching the Actual 77 force display A negative force will be displayed just before the nozzle breaks loose from the component This negative force can be used to determine the success of a removal
245. perature prediction algorithm allowing the slope curve to be adjusted any time during the process The thermal momentum will be dampened reducing any sharp thermal changes Dev Top Ramp Cs Target Actual 3 Device assemblies that retain considerable heat ceramic devices may require more significant flow adjustments to continue to track and map the targeted process Nozzle Control Adjust This parameter check box provides additional decision making power to the flow rate prediction algorithm allowing the flow rate to be adjusted any time during the process Selecting this check box checked will allow the system to reduce the nozzle flow rate whenever the device top temperature ramp projection exceeds the user defined thermal model In addition this feature allows the prediction algorithm to more frequently dynamically interact with the Nozzle Control process Adjustments can never exceed the maximum flow limit defined by the operator however these flow rates can be significantly reduced during the process Flow 26 Af Note Standard flow adjustments check box clear only occur during the reflow stage The default value of this parameter is not active clear check box This is an advanced prediction input feature and should only be used when the standard algorithm does not yield the required process results Adjust LII Reference The air flow is normally reduced by half
246. place down the length of the column Add trim wn Support Beam see NOTE2 if Table Top m M V4 x 1 Screws 8 Support Beam see NOTE 2 Add trim DRS24C Series Manual Page I4 Section 3 Installation Drawer Installation Step 3 see NOTE 1 NOTE I Two people are required to hang the Drawer NOTE 2 The Pelican Drawer should be mounted after the Workstation 15 fully built e NOTE Place the Drawer Nut Plates into the worksurface Support Beams Make sure that both Nut Plates have Threaded Inserts facing inward as shown e NOTE 4 Unlock the Drawer and extend the Slides all the way out e NOTES Place the Drawer under the Support Beams and loosely install the screws through the Drawer Slides and into the Nut Plates NOTE 6 The Drawer may now be positioned on the Support Beams and the screws tightened Support Beams Refer to NOTE 3 Nut Plate Drawer Hanger Threaded Inserts Pelican Drawer NOTE Two people are required to hang drawer Nut Plate 10 32 x 1 0 Phillips Head Screws 4 DRS24C Series Manual Page 15 Section 3 Installation Grounding Static Protected Work Surfaces Step 4 NOTE I Install the brass ground lug washer and ground lead as shown Do not over tighten the nut snug down firmly to ensure contact between the and the laminate IMPORTANT In order to prevent a possible electrical shock hazard to perso
247. played and will indicate which file is currently being copied It will also display the source location Profiles C drive and the destination A location 00000001 085 From Profiles to DRS24C Series Manual Page 20 Section 6 Software 6 1 7 2 Restore files to disk The procedure for restoring files is very similar to the procedure used in backing up files files are copied from the floppy disk and pasted to the Profiles directory C drive Selecting Files Click on the pull down list box to show all of the available choices Scroll through the entries and select the A drive To select a single file move the cursor over the desired file and click on the left mouse button This will highlight the specific file icon Multiple selections can be made by holding down the control key Ctrl while simultaneously clicking on the desired file w When all necessary files have been selected click on the Edit menu followed by the o Ease option selected files are now ready to be copied to the Profiles directory C drive Note Selected file names are temporarily copied into memory To quickly reset or return to the Profiles directory click on the File menu and select the Close option Explorer main window Close any additional Explorer windows that may still be open DRS24C Series Manual Page 21 Section 6 Software Control After re
248. quality 8 10 6 Microscope Vision System Always use the microscope whenever possible for process work including the application of flux site preparation soldering solder removal viewing nozzle correctly positioned to device nozzle at correct board height manual inspecting overall site and assembly alignment in vision system etc e Correct eyecup focus eyepiece width opening and tilt to individual requirements Keep all optics clean for crisp clean viewing e Use polarizing filter to change contrast e Always use maximum magnification to maximize accuracy If necessary tilt microscope in vision system DRS24C Series Manual Page 13 Section 9 Safety Table Of Contents PH 2 9 0 Safety System OvervIiew TEN Tee eG s FREE RE EA YR e V 2 IS IRE SIR EIS 3 VS M MOACHINC ODEON ctxctssciparetuctensiacamtechupeiaersescermmiadacteestadis sa yuacessietiacnesuecaassagiasss 3 A 3 92 Additional Safety 8 255 xoxo EOS e Eure EOS E P REOR SPERA I 4 92 1 Handling of Hazardous Solder and Flux Products eee e ecce eee ee eee eee e eee eese eee eee 4 9 2 2 Nozzle Changeover Safety Equipment Requirements 4 9 3 Label Descr
249. r workmanship Other damages if any direct or consequential are expressly excluded from this warranty Air Vac shall be liable under this warranty only if 1 Air Vac receives notice during the warranty period 2 The products are operated in accordance with the supplied documentation and 3 Such products are to Air Vac s satisfaction determined to be defective When contacting Air Vac for warranty inquiries please provide the following information Order number under which the parts were shipped Model and serial number of the product Reason for warranty Products cannot be returned to Air Vac without authorization please call for an RMA DRS24C Series Manual Page 3 Section 1 Introduction Getting Started 1 2 Unpacking Shipping Weight including monitor 425 Ibs Shipping Dimensions 47 x 37 x 56 Shipping Cartons The system 15 shipped in a wooden crate Accessories are individually packaged and secured inside the crate covering the system or in separate containers Please keep crate in upright position when moving Save crate for future shipping Removing Module Remove screws A in side of crate and take out boards 3 Break down crate sides top e Lift by openings in casting B both sides Note Module weighs 255 lbs Please provide CAUTION and adequate capability when lifting Note Weight is unbalanced Back end of unit is heaviest Please be careful of delicate electrical
250. r Lock Clamps B and lift carrier until Side Supports catch Install four 4 Board Carrier Support Rods D as shown Six support rods are provided 2 6 2 9 and 2 12 in length Push V end through center of retaining clips Support rods should hold position against PC board e Unlock side supports and lower board carrier Retaining Clip blue face V End D DRS24C Series Manual Page 10 Section 3 Installation 3 0 10 Vacuum Probe Installation e Attach silicone tubing to Fitting A provided in rear of module e Attach remaining items as shown e Attach Tool Holder B to convenient operator position ie right side of right base Vacuum Probe A B DRS24C Series Manual Page 11 Section 3 Installation 3 1 Installation of Options Note Some or all of the listed options may not be purchased with the DRS24 system 3 1 1 Workstation 1003 05 001 Assembly Tools Required Phillips screw driver 7 16 wrench or socket 15 wrench or socket Component List included with Workstation Description t Part No e Static Dissipative Laminate Top 6 gt x 36 1 SP3761 1 e Column Assembly pair SP3761 CA Worksurface Support Beam 2 SP3761 5 e Stabilizer Panel 60 1 5 3761 6 Footrest Connector 1 SP3761 8 e Workstation Hardware Kit 1 SP3761 HK 4 5 16 x1 4 Glides 6 MW x Hex Head Screws 6 MW Flat Washers 4 5 16
251. r block to diffuser plate with a 5 64 allen wrench These screws are installed with Never Seez but are still hard to remove Replace any damaged screw with 6 32 flatheads and a high temp lubricant Slide table so heater to be removed is away from machine base On the bottom of the heater block an inch in from outside edge is a cutout through the heat shield Through the cutout loosen the set screw with a 1 16 allen wrench Element can now slide out of heater block CAUTION Heater has a glass liner For warranty replacement old heater must be returned intact The two button head screws remove the cable clamp bracket Lift bracket up and slide forward It should be unnecessary to disconnect any other connections to bracket Be careful not to pull to far Cut tie wraps holding cables and pull heater wires free e Have new heater ready to go with compare cable lengths and routing to reinstall It may be necessary to use L tube from old heater Cut tubing and push tube on to new harness e Slide new heater into heater block orient same as old element retighten set screw on bottom and retighten heater block screws on top Coat exposed threads of screws with high temperature lubricant Run wires through cable clamp bracket and tie wrap in place Put cable clamp bracket back in place and screw down Check to be sure nothing interferes with vision system moving in and out Reconnect air tube carefully run wires through stain relief and up
252. r task bar Graph Data Scroll through to end of events 7 10 and look at temperature of T C 1 Subtract actual temperature of 1 from the target temperature and enter this number as the Offset for each range in the Setup Communication screen Event 7 180 T C 1 Temp Offset 001 200 C Event 8 250 1 Temp Offset 201 270 C Event 9 300 T C 1 Temp Offset 271 340 C Event 10 350 T C 1 Temp Offset 341 420 C Run cold air through the nozzle use nozzle flow meter screen Setup Nozzle Flow Meter for 15 minutes to cool nozzle assembly e Go back and run Temp Scale Testing again and check offset between set temperature and actual at end of events 7 10 If temperatures are within 6C you are finished If not calculate differences and add to offsets to pull temperatures into spec Temperature vs Time Description 08 46 06 03 98 DRS24 Temperature Scale Testing 00000004 drs I II TITI TIT a AH u a SEES E ee a MT rmm riii tar T T 0 00 00 00 51 01 42 02 33 03 24 04 15 05 06 05 57 _ 06 48 07 39 08 30 09 2 10 12 08 11 54 12 45 4 3 2 Bottom Heater Verification There is no verifi
253. rameters DRS24C Series Manual Page 4 Section 12 Troubleshooting 12 6 Machine Alarm Conditions amp Alarm Screen Alarm indication explanation e Green condition OK e Yellow warning may effect the process results process aborted process problem issue When the system senses an undesirable condition an alarm screen will appear The alarm screen will indicate the nature of the problem The light tower if your machine is equipped with will illuminate a red light next to the alarm that 15 occurring The following pages list all alarms and what causes them Alarm Control ji Maximum Time 1 Process Cycle History 1 Motion Communication Link 1 Hun Graph History 1 Force Communication Link 1 Hun Export History 1 Temp Communication Link 1 Temperature Limits 1 Cycle Counter 1 Flow Sensor 1 Low Memory 1 Low Pressure Process Thermocouple 1 1 Activity Time Out 1 Force Removal 1 Force Placement Press ENTEH key to stop audible alarm 12 6 1 Maximum Time Alarm The maximum time of the profile has expired Modify profile Work faster Call Air Vac Process Support DRS24C Series Manual Page 5 Section 12 Troubleshooting 12 6 2 Motion Com Link The communications link between your computer and your motor drivers for your vision cube and your Z axis 1s not functioning Make sure the cables are plugged into your two motor drivers Make sur
254. rature average of selected T C channels e Device joint time gt 183 e Device joint cool down temperature user defined solder joint stable e Device joint soak temp min e Device joint soak temp max e Device joint soak time e Device top temperature max e Device top temperature ramp e Board starting temp e target temp e Adjacent device max temperature e Max process nozzle flow rate e Nozzle heater preheat temperature gt Process output parameters computer managed e Device joint temperature average soak and reflow stages e Temperature ramp Device top Device joint average e Device top temperature max e Nozzle flow rate e Device joint time over reflow gt 8 process thermocouple channels e 1 Target board temp e 2 Device top max temp e 73 8 Joint or adjacent temperature monitoring and control Automated Thermal Development Strategy e Automatic iterative thermal process optimization operator free Automatic parameter adjustment based on embedded process knowledge rules implemented prior to the start of a optimize cycle e Advanced prediction algorithms are used to balance and adjust the process results in real time e Automatic profile build utilities help the operator attach the recorded thermal sequence to a motion and control template soldering desoldering e Cycle stage LED s quickly and visually communicate the process progress e A graphical analyze mode allows the operator to revi
255. reen will appear n BE Pur V mim Fw ht i DRS24C Series Manual Page 107 APPLYING THE BEST FIT THERMAL SEQUENCE The Import Graph Data Files Screen will appear Doe pari nca m EIE ERN cb PNIS PIE 2 I VRR n F TELERI Tham Fai ia a i PEPEE dek ER T a r SS gt ix Trimet r gt Click on the up thumb to activate the automatic profile build utility by passing this import thermal sequence reports screen LIT amp i a T a Hg a a j mua Time Reference Import Thermal Sequence Heports The user has the opportunity to analyze and print the results of the automatic thermal profiling session If desired the user can perform these tasks at a later time The same reports available for standard profiles are available for automatically generated thermal cycles 1 Heview process results 2 Print detail graph data Print summary or graph data Thermal sequence data is recorded each second and saved as a standard ASCII file These files are stored in the c windows drs24 thermals directory These files can be viewed using a standard tool such as notepad A thermal a
256. remestepe Vrimeabove 183 Time Above 4 C 7 Max Temp Mintempc Wempsipe time Above 183 Time Above 08 TIC48 Max Temp C Temp siope tipe above 183 Time Above 2 C L K J F G H 1 DRS24C Series Manual Page 78 Section 6 Software The summary section of this screen provides the operator with the cycle analysis details This information is organized separately for each thermocouple channel The following categories are calculated Maximum and minimum F G temperature Max Temp C Min Temp C e Temperature slope H 5 e Time above reflow D Time Above 183 C In addition a programmable temperature analysis column Time Above C allows the operator to temporarily modify adjust the time above reflow analysis calculation Selecting the Resample Data button K will re process the cycle data using the new analysis data Selecting the Up Thumb button L will exit the Graph Data screen and return the operator to the Run screen DRS24C Series Manual Page 79 Section 6 Software 6 2 3 2 Print Options Print Options This Print Options menu allows the operator to setup or print several reports Graph Page Printer Setup based on the currently loaded graph data set Print Graph Page Hun Data Points Detail Report Hun Data Points Summary Report 6 2 3 2 1 Graph Page Printer Setup
257. ret tirer Eee a ra dan Fata 12 13 4 5 1 Precision Optical Alenment INSIVUCTIONS u aa umasa qaqsaykaadasusipsaqaswska 14 15 SCISCO 16 17 47 Ley ITS u Su 18 AS P Cool Vepification Process y u I UI qusqa 19 DRS24C Series Manual Page 1 Section 4 Verification 4 Verification 4 0 Verification Overview DRS Software Application Opticns Control History Video Screen Utilities Reset Cycle Counter Setup Reset Operator F 4524 AR VAC Thermal SMART Track System 5 T O M E R N M Once the DRS24 has been setup according to the instructions as outlined in section 3 critical machine functions including pressure gas flow rate temperature and vision must now be verified to ensure proper machine performance It is important that the verification procedures be done sequentially as outlined in this section Machine verification should be done after initial setup anytime the system is physically moved or disconnected and at regularly scheduled intervals such as every six 6 months DRS24C Series Manual Page 2 Section 4 Verification 4 1 Pressure Verification Check the pressure regulators on the back of the machine to insure they read a minimum of 70 psi while the profile is running The Pressure Gauges for the Upper Heater A and the Bottom Heater B should both read 80 psi 5 psi 70 psi minimum while post
258. ring the last process optimization Temp Communication Link 1 Temperature Limits ri Cycle Counter 1 Flow Senso gt The user may then select by clicking on a radio button any data set to initiate a graph Process Optimization j Low Memory 2 Low Pressure i Component Removal 1 Force Placement Site Cleaning Tool Clogged Ta Press ENTER key stop audible alarm Data v F DRS24C Series Manual Page 102 gt Only if standard conditions do not allow 3 target setting parameters top of package Joint temperature and time over reflow then advance features may be required 1 If the device top overshoot is unacceptable the Device Top f x parameter should be increased Device top f x This parameter scroll bar provides weighed functional influence to the overall process prediction algorithm Increasing this value improves the process sensitivity of the algorithm Decreasing this value reduces the process sensitivity of the algorithm This parameter only influences the prediction algorithm during the Device Top TAC 2 reflow stage The range for this parameter is 0 10 PCI fx as 2 gt The default value is 2 gt 2 If the device top continues to overshoot with in the Device Top f x parameters exhausted the Dev Top Ramp C should be decreased This parameter provides additional decision making power to the tem
259. rogramming this check box checked will activate the fiber optic lighting for the current event Run screen A clear check box will deactivate the fiber optic lighting for the current event Run screen The Video check box B allows the operator to activate the live video camera system This video system can be used to display images on the computer monitor Programming this check box checked will activate the video system for the current event Run screen A clear check box will deactivate the video system for the current event Run screen PBGA 225 256 Removal 068 thick board N1081X1081 1011030 drs Build Photo Links Vision and Nozzle System Pos Pos 93695 Rate J Temp C C Sec V S Z Move REL 1 Do Not Move Nitrogen inch 0 S Site Cleaning Noz J Probe Time Events Velocity Accel 6 Velocity 94 Vision Lights Video Iv Time 5 2 Speech Be o Alert A Pulses EA RAR 2 to above board position R sensor Syst prm Actual Dest Range s 30006 Zero Force El El El E Placement Removal J Auto Adjust W Display Only Cool Air Injectio Device Nozzle Separati B Diffuser System R Temp O F IMEEM Disable amp Standard High Hi
260. s New groups can not be added to the list of available groups from this screen The Default Groups can be changed in this option only To change the default groups the operator must click on the down arrow A to the right of the groups edit box This will expand the edit box B to display all of the available groups After making a selection the list box collapses back down to one line The new group will be displayed in the edit box Click on the Thumbs Up to save the changes and exit or click on the Thumbs Down D to discard changes and exit the Limits and Defaults screen DRS Setup Limits and Defaults Maximum Temperatures Nozzle C Time sec Diffuser C Default Temperature Limits Nozzle C Diffuser C R Diffuser Solder Reflow Temperature Default Groups Default Farce Limits Placement Force Force Range D Default Flow Rate Limits Nozzle Flow Sensor A B Customer Engineering Company Board Library rea Arrays Area Arrays Demo Board DRS24C Series Manual Page 144 Section 6 Software 6 9 3 Reset System Access To reset the system access to the production environment the operator must reset the operator Click on the Reset Operator option on the menu bar and the Operator Registration screen will be IA NN displayed Log in again followed with your 2 security access
261. s page break e Click on OK to save the changes DRS24C Series Manual Page 10
262. s 50 60 Memory o Grams EE Foot Sw Set Point EN Cycle Busy Alarm 90 0 0 110 Actual Actual Actual Set Point Actual Ramp Id Idle Range EX ER EXEZ EX Click On The Cycle Start Button To Begin Process Graph Process Information Date 04 02 98 09 22 Temperature vs Time 500 0 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 03 36 10 24 11 12 12 00 Event Time HERE Profile Time mug Power Board it w WS BA zi xl TC Control Temperature DRS24C Series Manual Page 64 Section 6 Software 6 2 2 7 Event Time D Time remaining in the current event 6 2 2 8 Event Counter E Current and maximum profile event counters 6 2 2 9 Process Time Total overall cycle time all events PBGA 225 256 Soldering 068 thick board N1081X1081 1011003 drs Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Numerical Process Information Nozzle System System Thermocouple System Force System System Status De EZ NJ Lo o Grams Set Point Set Set Point FootSw DH 2 Cycle Busy Alarm Actual N m m e e Set Point Actual EE EN Graph Process Information Date 04 02 98 09 22 Temperature vs Time 500 0 450 0 400 0
263. s B amp B 5232 485 ISA RS232 DUAL COM translator BOARD LPT2 Athena right diffuser 12V power controller add 03 J29 J15 I vision led J56 I q sw _ DM224 Speaker MD1 Z axis Plug HC systems Stepper n V8601 Motor e MOGGE with Encoder J16 DM224 MD2 J14 vision stepper Power d24wire5 flo 10 13 97 j 5 i Right fan DRS24C Series Manual Page 8 Section 10 Schematics 10 2 6 Main Harness Wiring Block Double Diffuser j Fob FDD mE J42 compas HOD Power m Supply 2 423 Force mother board i Strain guage Pneumatics section J21 RTD ADA1110 module halogen fan function button Toal amener Nozze add 01 ISA bus COMS B amp B rs232 485 translator ISA RS232 DUAL COM Athena left diffuser controller add 02 BOARD i COM4 LPT2 Athena right diffuser controller add 03 J29 J15 g vision led J56 prox sw Speaker Plug RC systems Stepper n V8601 Motor ceo q with Encoder vision stepper Power motor d24wire3 flo 327 10 13 97 1 Right fan DRS24C Series Manual Page 9 Section 10 Schematics 10 2 7 Pneumatics Electrical Block J3 Diffuser high left solenoid Relay Board Diffuser low left solenoid Computer JO Motherboard Nozzle vacuum Board solenoid Site clean solenoid Probe Vacuum sol
264. s is accomplished by clicking on the desired table field with the left button highlight table field The operator can then press the enter key to enable the table field edit mode At this point the operator can use the standard keyboard to adjust the table field information PBGA 225 256 Removal 068 thick board 1 081 1081 1011030 4 Build Photo Links Vision and Nozzle System Rate Temp C Sec Bo Z Move ABS Air Z Move REL Do Not Move Nitrogen inch Site Cleaning Noz J Probe Motion Power Vision Lights Video Jog Foot C Time 8 21 DIG raet mspeech Ej EJ Cool Air Injection Device Nozzle Separation Alert Pulses Message nozzle to above board position R sensor F Syst ERN gm Actual Dest Range s 00000 Zero Force El Ea Placement Removal Auto Adjust W Display Only Diffuser System R Temp Low Low Action FILE RT C Replace CAdd Subtract Data PEE C Disable amp Standard 19 ig If ERROR Stop Process Average L R Temperature Single A B C DRS24C Series Manual Page 45 Section 6 Software 6 2 1 6 2 Global Thermocouple Control The global thermocouple control radio buttons C are used to define the state of the thermocoup
265. s up to a maximum number of attempts Time and temperature adjustments can be applied to each retry attempt e Counter This parameter determines the maximum number of component removal attempts retry If component removal fails the process cycle will be terminated e Temp Increment This parameter determines the temperature increment that will be applied to each component removal attempt retry e Time This parameter determines the maximum time between retry attempts Note retry Z axis position will be automatically recorded before the initial removal motion occurs DRS24C Series Manual Page 50 Section 6 Software 6 2 1 10 Table Event Editor The Table Event Editor allows the operator to adjust all profile control parameters using a tabular form Selecting this button will present the operator with a pop up menu This menu will provide a list of parameter categories Selecting a category will quickly position the table editor to the exact column and row of the current event Nozzle System Diffuser System Vision System Force System Board Cooling Event Control Event Message Alert Message Teach Data Matrix 1 0 04457 5 l 150 1 09 000 14 040 000 04 451 5020 260 00 1 J0441 0 295 1000 4 1 295 1000 0 04231 000 0 3G jooo 000 0 02 379 _ _
266. save the changes you have made click on the Thumbs Up icon Z to exit the Teach screen At the Main screen select Options then Save As e Change the profile name to Engineering Training Profile Revised The revised profile has now been permanently saved without impacting the original profile 8 5 Testing the Revised Profile e Open the newly saved profile in the Air Vac Engineering Company Profile Library Leaded Devices directory e Install the nozzle board and thermocouple as per the notes instruction The profile name Engineering Training Profile Revised should be shown at the top of the Run screen e Click on the Cycle Start button to start the profile e Verify that the profile properly executes all of the changes made in the Teach mode DRS24C Series Manual Page 8 Section 8 Engineering Training 8 6 Table Editor The table editor is an excellent means of making changes to profile events especially when the same change needs to be made to several all events The table editor displays all of the data for all of the profile events in a data table e Go back into the Teach screen control teach Inthe Teach screen click on the Table Editor icon AB then select the data section you want to change from the table editor menu Teach Data Matrix 0 0 00 000 000 000 000 400 0 00 40 0 LL 000 04 420 joon T 420 90 9000 4 400 000 000 ooo 1000
267. station Table Dimensions W x D x H 62 x 40 x 27 e Monitor Dimension W x D x H 16 x 17 x 17 e Monttor Weight 53 Ibs e Operator Viewing Height from module base 21 24 adjustable height chair recommended DRS24C Series Manual Page 2 Section 2 Facility Requirements Technical Specifications 21 Component Requirements Beamsplitter Vision System No minimum size 2 0 square 1 0 height Direct View perimeter No minimum size 4 0 square 2 0 height Top amp Bottom Side Clearance Top 1 12 Bottom 920 NOTE Using microscope or camera to scan the perimeter of the devices for applications outside the range of the beamsplitter i e connectors and leaded devices NOTE For additional clearances please consult Air Vac Engineering directly 2 2 Component Positioning Adjustments Maximum Vertical travel 5 0 top to bottom travel Theta Adjustment 10 degrees 20 degrees total X amp Y Table Manual control Cable driven backlash free design Fine adjustment with resolution of less than 0 0005 2 3 Internal Vacuum System Nozzle Vacuum 26 Hg at pump 20 Hg minimum at cup Parts Handling Probe 25 Hg minimum Solder Removal Tool 25 Hg minimum 2 4 Accuracy and Repeatability Placement Accuracy 0 001 at 3 Sigma or a true position of 1 4 mil This is defined as the ability for the machine to hit the target Repeatability 0 0003 This 15 defined as the ab
268. ted or appended to during the automated thermal profiling session Note The last thermal sequence displayed on graph screen will used to create the thermal sequence in the automatic build program gt 6 Press the Thumbs icon to exit screen and go to profile build DRS24C Series Manual Page 109 Reference Automatic Profile Build Overview This screen performs the attachment of a thermal sequence to the user defined profile motion sequence The screen defaults to the automatic component replacement option The operator must define the following build parameters 1 Application Definitions e Component replacement e Or Component removal excludes the cool down replay sequence gt 2 Nozzle Definitions e Raised or Contact e Nozzle Length e Device Height e Board Thickness 3 Thermal Sequence Attachment Control e Select Build Profile Template Sequence Application Definitions Component Removal Component Replacement Removal Retry Automatic Pickup C Manual Pickup Auto Force Placement Manual Placement Nozzle Definitions Reflow Position Raised C Contact Nozzle Length 0 000 Device Height 0 000 Board Thickness 00 062 Thermal Sequence Attachment Control Long Name EJ short Name Reference The following list defines the data that is recorded Process stage measured
269. the setting When a temperature of 5 C lower than the setting is sensed the diffuser will reactivate DRS24C Series Manual Page 98 ACTIVATING THE THERMAL SMART TRACK CYCLE COOL DOWN STAGE Process Oplimize Soak s Hozzla NM Board Retlow s Dev TAG CoolDown 5 Reference The Cool Down Stage is defined as the time the joints go from the Target Temperature 200 c default setting of the joints Device Joint to 183 c 1 The Cool Down Stage 183 user Will start when the Joint temperatures have reached Dev Top Ramp 5 the Device Joint Target C Eu o Dev Joint Ramp Target Actual m Average Real time Temperatures value of solder joint s Note The Cool Down Stage indicator will be illuminated e f Note Message will state Device Joints Are in Reflow Cool Down Stage ss E Note Message Will state OIN pcd du EKZE COR SSE DEN Cool down above 1832 Device Joint s Average Reflow s Cooldown C Reflow s n 060 4 oolDown 183 C fuser 2 The combined Process Reflow s and Cool Down s 183 c time should
270. the system to make force corrections These corrections may be necessary due to board nozzle or component expansion and will only be applied if the actual force 15 outside the force range tolerance Force Removal Step 1 Program a Z axis nozzle position to be in contact with the component to be removed Be sure the nozzle is accurately aligned Step 2 The next event must be designed to have a negative Destination force value This negative force will be used to detect board lifting Board lifting will occur during the component removal motion if all the joints are not at the required solder reflow temperature Note This negative force value is used to determine the success of a removal process Run screen If the removal process fails Run screen the software will discontinue any motion de power the Z axis and terminate the nozzle vacuum The operator now has the control option to continue the removal process manually Note The Teach button must be selected to temporarily save any control parameter event adjustments DRS24C Series Manual Page 37 Section 6 Software 6 2 1 5 Device Control Device control includes the following programming tools flow rate temperature vacuum video lights and thermocouples These event elements are activated after all the required motion has been completed Z Vision and Force placement 2 Device 3 Time Note Itis important to rememb
271. tivated Device Joint 4 8 thermocouples Nozzle Control Flow Flow of nozzle after board preheat and before cooldown Presents automatic flow setting screen Adjust Preheat C Setting of nozzle temperature during heater stabilizing event Options Rapid Sets the speed when using the up down arrows Machine Icon otarts the cycle Thumbs Up oaves information and exits screen Thumbs Down Exits screen with no information saved Process Optimization Rule oets and displays the rule to adjust profile run criteria Data Indicates the cycle number of attempts DRS24C Series Manual Page 127 Section 6 Software 6 4 History History 1 The History menu has two options Cycle and Alarm Both options will activate the Windows 95 WordPad tool and load the appropriate file print a file select the File men and click on the Print option To return to the Run screen select the File menu and click on the Close option Cycle History Alarm History 6 4 1 Cycle History A History file entry is recorded each time the operator cycles a process profile Note To activate this data logging feature the operator must activate this option from the General Setup option This file captures the following fields Field 1 The time of day the cycle was run Field 2 The date the cycle was run Field 3 The board serial number Field 4 The operator who ran the cycle Field 5
272. tment procedure that was just completed for the 100 Nozzle Flow Controller value If the flow meter reads too high decrease the value by increments of 5 in the appropriate 20 90 Nozzle Flow Controller box location D If the flow meter reads too low increase the value by increments of 5 in the appropriate 20 90 Nozzle Flow Controller box location D 4 4 3 Nozzle Flow Sensor Verification and Adjustment 100 only Making Flow Sensor 100 Verifications and Adjustments Click on the 100 radio button A The air flow will activate after 1 4 seconds Wait 45 seconds before making any adjustments The software screen displays to the operator a Yellow Needle E flow rate set point and a Blue Needle F actual flow rate sensor reading Check the blue needle that is being displayed on the software screen This needle represents the actual flow rate sensor output from the flow controller The blue needle should bounce between 99 10190 If the blue needle is not within this range adjustments can be made to the 100 Nozzle Flow Sensor value If the blue needle 15 too high increase the value by increments of 5 in the 100 Nozzle Flow Sensor box G If the blue needle is too low decrease the value by increments of 5 in the 100 Nozzle Flow Sensor box G Note This is OPPOSITE from all other flow controller and flow sensor adjustments DRS24C Series Manual Page 10 Section 4 Verification 4 4 4 Nozzle Flow Sensor
273. to slow down the thermal momentum DRS24C Series Manual Page 103 Reference Parameters be altered to meet specific requirements rai ur dur aee E Device Average Device Tap TC 2 Control fr Target C C FEO Fee Target Stat 281 170 nna 205 msi nai 120 A BE 3 Tm Eb n Adjacent Independent Min C Max Soak a Max 140 16S or ET TM a r s Hezzh Cental ONOI Corea simak 1 Flow Preheat PC Teper vs Tine UU m Wm t oo Tr EJ Aujest OP UMME M TC AL 8 pem gt Process parameters are defaulted to the following Device Joint s Average Tolerance Target C 200 User Cool down 170 Reflow s 60 Min Soak C 140 Soak C 170 ooak s 60 Device Top T C 2 Max C 225 Adjacent Device s Independent Max C 150 Board Control T C 1 Target C 90 Start C 60 Max C 120 Nozzle Control Preheat C 125 Max Flow 96 000 DRS24C Series Manual ra
274. ttachment will be replayed second by second during the appropriate profile event determined automatically during the profile build session To review the process run The Thermal Sequence radio button must be checked The listing is in chronological order Select Profile by double clicking Select Graph Data to access thermocouple summary information DRS24C Series Manual Page 108 Heference Any or all of the Thermal Sequences be saved and analyzed The system does the best it can to optimize the cycle results in a progressive sequence typically cycle 2 performs better than cycle 1 however the operator is still responsible for selecting the best fit thermal sequence before continuing to the automatic profile build utility Optimization Rule a gt 1 Click any data button filled After the optimize cycles have completed rana p i r wd We mn i wan r vd INL ra m Fw ki I LI run re gt 2 Click on Save gt 3 long file name must be given gt 4 Press the Thumbs up icon The Teach screen will appear gt 5 the procedure for as many thermal sequence runs as you wish to save i Note At later date the user can select thermal sequence from the available database crea
275. turning to the Air Vac software reselect the Backup Restore option from the Options menu This will reopen the Explorer tool and display the contents of the Profiles New di C dr rais irectory C drive Save f f Ges dE Note At this point the selected file names Restore are temporarily saved in memory Print Profile k I Backup Restore Copying Piles Maintenance IRE View Tools IE View Tools Help About DAS Undo Delete Undo Copy Exit t Select the Edit menu followed by the Paste option This will Copy i Paste Lev Ct copy the selected files to the aste shortcut Profiles directory C drive Select All Select Invert Selection Invert Selection Copying The Copying message will be displayed and will indicate which file is currently being copied It will also display the source location and be us destination Profiles location 10000001 085 From Frafiles to 8 During the restore process Explorer may encounter duplicate files If a duplicate file is detected a window will prompt the operator whether or not to replace the existing file It is the operator s responsibility to decide which files should be replaced x Oppi I
276. u 3 Z4 Accuracy k uy u u u 3 2 9 Force Measurement SVS Ollh L u u wakaskakaaaqssasaaaaqusauaaqusskasaqasaksasaaassqas 3 2 0 Embedded Computer SySIeW u 4 u uuu 4 2 0 Jhernial PEODDBIPE sesso E E E 4 a E E E E 4 210 Automatic Flow Adjustment 4 IL az au si usss UT 5 2212 M minin RET T T Mm 5 EMD c 5 DMA Microscope OPCS cs RR 5 DRS24C Series Manual Page 1 Section 2 Facility Requirements Technical Specifications 2 Facility Requirements Technical Specifications 2 0 Electrical Pneumatic Physical DRS24C 2D amp DRS24C 1D Electrical also see Operating Notes Machine Power 220 VAC 5 50 60 Hz single phase 4 4K 30A Nema L6 30P 250V plug 30 amps 2 pole 3 wire supplied e Monitor Power 120VAC 50 60Hz 2 amps e Camera Power 120V AC power cube 60 Hz 125 ma e Speaker Power 120V AC power cube 60 Hz 125 ma Air Nitrogen also see Operating Notes e Bottom Heaters 90 130 psi 25 scfm DRS24C 2D 20 scfm DRS24C 1D clean dry air non condensing source
277. ual Page 19 Section 3 Installation 3 1 2 Multimedia Package Installation CAUTION The machine should be powered off prior to installing this option Installation Steps e Install Camera Camera Bracket to Mount on side of microscope camera trolley with Screw C provided Scribed lines on bracket and mount must align D Install Camera Cable E to the Video Adaptor Plug The adaptor plug connects to the video port at the rear of the machine Multimedia card 15 factory installed Tighten screws Cable should be tie wrapped to top of module e Connect red wire to positive terminal and black wire to negative terminal e Provide electrical power 110V to the Camera Plug G A DRS24C Series Manual Page 20 Section 3 Installation 3 1 3 IR Sensor Installation The IR Sensor option A 15 installed by Air Vac prior to shipment No installation is required Install the Thermocouple Plug B on the IR Sensor into thermocouple channel 1 as shown A Page 21 DRS24C Series Manual Section 3 Installation 3 1 4 Fume Extraction Manifold Installation Installation Steps Remove tape from Hook amp Loop Velcro on underside of Fume Extractor Box Set Fume Extractor Box A on top of the DRS24 at location B Press firmly in place e Connect a hose to the rear of the Fume Manifold C e Connect other end of the hose to central exhaust or other collection system
278. ual Page 9 Section 12 Troubleshooting 12 7 Force Measurement Problems If the force measurement system does not reach the specified force value Verify in the Teach screen for that event that proper force values are entered properly Make sure the nozzle 15 approximately 50 thousandths of an inch above the PC board prior to beginning force placement Note If the nozzle is too high above the board there will not be enough pulses to properly perform the placement e Check that the number of adjustment pulses in the Motion Setup screen has not been altered The number should be 25 Communications verification can be performed outside of the Air Vac software Consult the factory technical support group 12 8 Printer and Voice Card Checkout Verify that the printer port for the speech option in WIN95 is setup properly e Get to this via control panel Select the printer s icon e Select generic text e Select file Select properties In the details section make sure the following is selected e Print to the following LPT2 printer Driver selection Text generic e Spool settings e Select spool print jobs Select start print after 1515 page is spooled Spool data RAW e Port setting e Select spool MS DOS e Select check port state In the paper section make sure the following is selected e Paper source continuou
279. ulti Media button activates Live Video option The live video window will be positioned in the upper left hand corner of screen 09524 Live Video Close About DRS24 Note The About DRS24 menu option will display the software version number for the Live Video program DRS 24 Live Video Close About DR524 About DRS24 Engineering Company Inc 30 Progress amp venue Seymour CT 06483 USA Version 1 60 Phone 203 888 9900 Fax 203 888 1145 egin Process ial x TiC Control 0 00 00 00 48 01 36 02 24 03 12 04 00 04 48 05 36 06 24 07 12 08 00 08 48 03 36 10 24 11 12 12 00 Profile Time 1 Power fo O O Event of E DRS24C Series Manual Page 68 Section 6 Software 6 2 2 11 Bar Code Board Serial Number Tracking I This section of the Run screen allows a board serial number to be tracked and recorded in the cycle history file The operator has the option to enter this information using the standard keyboard or to use the optional bar code scanner PBGA 225 256 Soldering 068 thick board N1081X1081 1011003 drs Graph Data Auto Scale Graph Load Process Link File View Photo Links Export History Load Function Jog Functions Numerical Process Information lel Nozzle System System Thermocouple System Force System System Status 80 19 n
280. ved Export File This information can be retrieved at a later time using the Import option A help message will inform the operator that the graph data was successfully saved Clicking on the OK button will return the operator to the Run screen 6 2 2 12 6 Load Nozzle Function Menu Option Not available on the DRS24R The Nozzle Load menu allows the operator to activate a general motion utility to semi automatically load remove a nozzle This utility can be activated by selecting the Nozzle Load button 5 The Z axis can be de powered by clearing the Power check box A This allows the operator to manually reposition the nozzle during the load procedure if necessary The Cycle Stop C button allows the operator to terminate the load procedure if necessary The Up Thumb button D will return the operator to the Run screen Nozzle Load Function 0 0 x D C A B DRS24C Series Manual Page 75 Section 6 Software 6 2 2 12 7 Jog Function Menu Option Not available on the DRS24R This menu option allows the operator to access a motion jog screen This screen provides the following motion tools Z and Vision axis jog controls Power check box power de power 4 axis D Home Z Vision axis return each axis to an initialization position Vision Alignment Position this button will open the vision cube activate the fiber optic lights and position the nozz
281. w event in between two existing events The inserted event will be an exact copy of the current event The inserted event will be added ahead of the current event 6 2 1 1 3 Delete Event The Delete event button is used to temporarily remove the current event DRS24C Series Manual Page 27 Section 6 Software Table Editor The Table Editor button allows the operator to adjust all control parameters using a tabular form This button will present the operator with a popup menu This menu will allow the operator to quickly position the table editor to the correct control column Cycle Stop Not available on the DRS24R The Cycle button is used to stop any motion that may occur during the teaching process Motion will be graphically displayed using a green button background 6 2 1 1 6 Thumbs Up The OK Thumbs Up button will exit the Teach screen and return to the Main screen 6 2 1 1 7 Profile Notes The Profile Notes button will display the application notes page This page is used to add any instructions that may be required to correctly process the application 6 2 1 1 8 Limit Control The Limits button will display the profile limits page This page is used to control the maximum or minimum process limits related to flow rate temperature and force 6 2 1 1 9 Home Z Vision Axis Not available on the DRS24R The Home Z Vision Axis button will reposition Z and Vision axis to the
282. w rate will increase every 20 f Coma seconds 3 times os gmE LEX F xx E 3 Complete Nozzle wama Definitions information required Thama Sequesece Conr Lagi Ez 4 Press the Thumbs Up icon MUT LL Reference The Thermal Sequence attachment Control Long and short name should appear and match the corresponding profile The Save As screen will appear 5 Provide the Long Name Reference The Short Name will appear Mame and Link Control Z Note The correct Group Control will appear if done in sequence to the original short Name fi 11001 DR5 B thermal sequence save Link Mame Soldering Desoldering 6 Provide the short name Link Name Site Cleaning of the corresponding TTE 4 Component Replacement thermal profile Control gt 7 Press Thumbs Up icon to save DRS24C Series Manual Page 115 Reference Any Profile Can Be Modified Using The Standard Teach Utility After creation of a thermal sequence modifications can be made to suit unusual requirements No modifications can be made to the replay sequence event Vision and System ms Rate Temp ib lt 990 gag Replay Thermal Sequence
283. x soak setting Thermocouple for joint temperature T C 4 8 Option thermocouples for joint temperature DRS24C Series Manual Page 126 Device Top 2 C Setting for maximum top of package temperature in reflow event Adjustment for process sensitivity of temperature reflow event Board Control T C 1 Target Setting for maximum board temperature in preheat event Start C Setting for minimum board temperature prior to preheat event Max C Setting for maximum board temperature throughout process maintain mode Adjacent Device s Independent C Setting for maximum joint temperature throughout process T C 3 8 Option thermocouples for adjacent device temperatures Process Soak s Actual time joint is between min Soak and max Soak settings Reflow s Actual total time joint is between Target C setting and 183 C initial 183 C to Target plus 183 C values Cool Down s 183 C Actual time joint is from Target C setting to 183 C user C Actual time joint is from Target C setting to Cool Down C Dev Top Ramp 2 5 Target Setting of temperature time slope of Device Top T C 2 Actual Actual temperature time slope of Device Top 2 Dev Joint Ramp 2 6 Average Setting of average temperature of T C 3 and activated Device Joint T C 4 8 thermocouples Actual Actual average temperature of T C 3 and ac
284. y accurately over site 4f Note Stencil must be very flat All holes must clean All pads must be flat to allow stencil to seal to pads and not bend Solder will smear if allowed to go under stencil Care must be taken to accurately position stencil 2 Kapton tape edge of stencil Do not move position 3 Apply solder paste with blade 4f Note Solder paste must be properly prepared stirred and at room temperature Care must be taken to fill all holes Do not hit edge of stencil which will cs gt lt 2 cause solder to smear Do not allow solder to SS yt MIS reach adjacent areas bs E o gt 4 stencil gt 5 Carefully remove tape Clean stencil and blade gt 6 Use a soldering profile note nozzle design X or EZ style close to nozzle size Warning Solder profile may need to be adjusted for all steps prior to bga placement to insure solder paste does not slump DRS24C Series Manual Page 90 Option Preparing and Installing the Assembly Destructive Drilled Pads Method Installing Assembly 1 Insert the board into the carrier centered over the diffuser 2 Insert the nozzle part number should correspond to bga physical size and lower to just touching bga gt 3 Based on nozzle technology raise nozzle approximately 050 for X style design or keep nozzle in contact with board for EZ style design N
285. ystem lock table Vision system is presented Event 5 Loosen vision system adjustment wheels lock screw Make correction to vision system optics Retighten wheels Event 6 Manually adjust z if necessary Note Move vision system optics in the opposite direction from the center of the target Move the same distance the dot is from the center of the target Glass Reticle Component is positioned near Glass Reticle Board Event 7 Do Touch the Machine or Table Glass Reticle Component is placed using force placement system Event 8 Unlock Carrier and slide forward place 100X Portable Microscope carefully over reticle and check placement Placement Nozzle retracts Event 9 I adjustment is required repeat procedure Event 10 DRS24C Series Manual Page 15 Section 4 Verification 4 6 Carrier Leveling TOOLS N Cal4 Nozzle Glass Plate 8 x 10 x 1 4 5 32 Allen wrench 3 32 Allen wrench Feeler Gauge Diffuser Warm Up From Main DRS24 Screen select Setup Diffuser e Set both diffusers to 200 C and high flow Let diffuser stay on until diffuser is heat soaked 5 10 minutes Change diffuser idle to 200 C at low flow Check carrier arm movement The carrier arms should move freely to the fully open and fully closed positions ty DRS Software Application Opticns Control History Video Screen Utilities Reset Cycle Counter Setup Reset perator E x Ve c
286. zle vacuum will shut off and the nozzle will raise up The parts handling probe vacuum will activate Use the probe to return the device to its shipping container Use care to avoid damaging the leads e This completes the initial operator training overview Additional operator training by a trained individual 15 required prior to running actual process profiles Thermocouple System Force System ER M2 Feel es 006 Dry Alarm o 6 6 Cooling Ring EE Even M or DRS24C Series Manual Page 11 Section 7 Operator Training 7 6 Process Tips 7 6 1 General Use proper height adjustable chair to allow comfortable viewing of microscope at top and bottom position e Nitrogen will improve solder joint appearance and quality particularly with no clean flux In addition nitrogen can reduce or eliminate the need for pad preparation after a leaded device has been removed e Use same flux type as in production in paste form for rework Do not mix flux or solder types not open electrical compartments 7 6 2 X Y Table Do not lean on or apply excessive force on carrier Carrier coplanarity to nozzle is critical e Use board supports where possible Hold assembly gently with board clamps and side arm locks 7 6 3 Gas Nozzles Select the proper gas nozzle Usethe GNT handling tools to hold Hot nozzles not grab nozzle at bottom Damage may occur at gas o

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