Air-Vac DRS25, User Manual

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Page 3: ..._ has installed the above machine and that all items have been received or are noted below The machine is in good working order and initial training was provided Customer Signature Date Air Vac Representative Signature Date Issues Items Missing Please fax this completed document to Air Vac Engineering 203 888 1145 Attn Brian Czaplicki AIR VAC ENGINEERING COMPANY INC INSTALLATION AND TRAINING ...

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Page 5: ...0025 00 902 Rev 06 00 March 2021 Chapter 1 Getting Started Chapter 2 Installation Chapter 3 Machine Function Verifications Chapter 4 Process Development for Engineers Chapter 5 Operator Training Chapter 6 Software Overview Chapter 7 Troubleshooting Chapter 8 Schematics Chapter 9 Maintenance Diagrams ...

Page 6: ...DRS25 User s Manual Table of Contents 0025 00 902 ...

Page 7: ...ter 1 Introduction Getting Started 0025 00 902 1 1 1 Introduction Getting Started 1 Introduction Getting Started 3 1 0 Warranty General 4 1 1 Heater Limited Life Warranty 4 1 2 Material Check List 5 1 3 Options 6 1 4 Safety 9 ...

Page 8: ...DRS25 User s Guide Chapter 1 Introduction Getting Started 0025 00 902 1 2 ...

Page 9: ...r customers with any technical or operating questions If you have any questions on machine parameters correct nozzle requirements options procedures or mainte nance please do not hesitate to call Air Vac Engineering Company Inc 30 Progress Avenue Seymour CT 06483 Tel 203 888 9900 Fax 203 888 1145 http www air vac eng com airvac air vac eng com ...

Page 10: ...Reason for Warranty Products cannot be returned to Air Vac without authorization please call for an RMA 1 1 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 with out expense excluding shipping to th...

Page 11: ...couples 2 9002 12 047 Operator Components Part Number Use Nozzle Handling Tool 1022 02 040 Nozzle load unload Nozzle Stand GNS1 Holds nozzles O Ring Assortment Silicone ORASST Nozzle o rings Board Support Set 0025 01 010 Supports flexible boards 2 12 2 6 4 9 2 standalone Grounding Clip 9002 01 065 Grounding Vacuum Probe Tubing 6 9001 15 018 Parts handling By Pass Probe 3CP100 Parts handling Probe ...

Page 12: ...posite vacuum tip to provide non contact site cleaning Notes Of Interest Non contact site cleaning is critical for lead free re work due to the significantly higher temperature re quired to reflow the residual site solder Small medium and large composite vacuum tips provided Custom designs available for hard to access areas 1 3 2 Pivoting IR Probe with Laser Pointer 1012 02 017 Objective Provides ...

Page 13: ... stencil adapter which is used in conjunction with the compo nent shuttle to pick the pasted device Notes Of Interest Air Vac does not supply the component specific micro stencils Recommended supplier is Mini Micro Stencil 760 591 3804 Micro stencil installed into adapter for direct pick from shuttle 1 3 5 Flux Dip Pedestals FASET1 Stainless steel fluxing pedestals with precision machined depth pr...

Page 14: ... x 36 D ultra sturdy construction with anti static laminate surface Workstation includes CPU Holder Options Monitor Stand 1003 05 005 Nozzle Stand 1003 05 006 Locking Drawer 1003 05 007 1 3 7 Direct View HD Camera with HD Monitor 0025 03 016 Objective Provides operator viewing of the site cleaning process and placement reflow How it works Video is activated by operator Focus zoom lighting adjustme...

Page 15: ...ithout proper training from qualified per sonnel Machine Operation Both the top and bottom heating elements can be programmed to reach high temperatures Use caution near heated surfaces including the nozzle and the bottom heater Always use the gas nozzle handling tool when installing or removing nozzles The nozzle and vision systems are powered by stepper motors and are programmed to move dur ing ...

Page 16: ...y the solder or flux products with the DRS25 system The end user of the DRS25 system should follow proper handling and disposal instructions for the materials as supplied by their vendors Nozzle Changeover Safety Equipment Requirements When changing out the part specific gas nozzle use the special nozzle removal tools 1022 02 040 that are supplied in the tool kit of the system whenever handling a ...

Page 17: ...nd users of the DRS25 system Warning HOT the upper heater and diffuser plates of the system are required to reach temperatures well above 100 C Labels are found on the covers of each heated surface High power and static sensitive warning labels advise personnel of potential issues when the machine covers are opened AIR VAC ENGINEERING COMPANY INC SEYMOUR CONNECTICUT 06483 U S A DRS25 Serial Number...

Page 18: ...Comm_Restart DeviceIO_Communication_Restart Low_Pressure_Air_Regulator Low_Pressure_N2_Regulator Process Alarms Nozzle_Temperature_Limit Nozzle_TC_Error Left_Preheater_Temperature_Limit Left_Preheater_TC_Error Right_Preheater_Temperature_Limit Right_Preheater_TC_Error Center_Preheater_Temperature_Limit Center_Preheater_TC_Error Below_Minimum_Nozzle_Flow_Rate Nozzle_Flow_Sensor_In_Position_Failed E...

Page 19: ...ation 3 2 0 Unpacking 3 2 1 Facility Requirements 4 2 2 Pneumatic Connections Top and Bottom Heater 5 2 3 Electrical Connections 6 2 4 Powering Up the Machine PC and Login 8 2 5 Voltage Verification 10 2 6 Pressure Verification 13 2 7 Direct View Camera Mount Assembly Installation option 14 2 8 IR Sensor Installation option 15 2 9 Site Solder Removal System Installation 16 2 10 Workstation Assembl...

Page 20: ...DRS25 User s Guide Chapter 2 Installation 0025 00 902 2 2 ...

Page 21: ...nd take out boards 2 2 Break down crate sides top 3 Lift by openings in casting A on both sides 4 Position module on a level surface which can provide adequate support for weight 5 Remove any strapping and or packing securing board carrier and vision systems Shipping Weight 515 lbs Shipping Dimensions 48L x 48W x 37H Shipping Cartons The system is shipped in a wooden crate Accessories are individu...

Page 22: ...ing If 208 VAC is not met a buck up transformer or another line must be connected Under general conditions expect incoming line voltage to drop approximately 3 10 volts Under no load conditions power must not exceed 240 VAC No load is defined as DRS25 off and all other equipment down the line turned off Removing supplied plug will invalidate machine warranty UL approval In areas susceptible to fre...

Page 23: ...he DRS25 Upper Heater Pneumatics Connection A 1 8 27 NPT male fitting x 6 ft hose 1 4 diameter blk yellow Pressure Setting B 80 psi adjust as required C Air Nitrogen Consumption 3 cfm Other Pneumatics nozzle vacuum site cleaning vacuum board cooling option Connection D 1 4 18 NPT male fitting x 6 ft hose 3 8 diameter blue Pressure Setting E 80 psi adjust as required F Air Consumption 18 cfm B 80 p...

Page 24: ...Installation 0025 00 902 2 6 2 3 Electrical Connections Machine Power A Machine to PC Power B Machine to Monitor Power C Machine Footswitch D Machine to Optional Direct View Camera E Machine to PC Communication Cable F B A C F E D ...

Page 25: ...DRS25 User s Guide Chapter 2 Installation 0025 00 902 2 7 Machine to PC Power B Machine to PC Communication Cable F HDMI Monitor USB Keyboard and Mouse F B ...

Page 26: ...C and Login Turn on machine power by releasing the Emergency Stop if depressed and turning the key to the right The green machine power indicator light A will illuminate Turn on the PC and Monitor The PC will boot to the Administrator screen as shown below The password is airvac A airvac ...

Page 27: ... DRS25 exe icon to start the software Type in DRS25 at the Operator Login screen then click Thumbs Up The default password is left blank Click Thumbs Up Machine will perform a home operation Click on OK button DRS25 Machine Will Perform A Home Operation Please Proceed With Caution ...

Page 28: ...right side mouse button click over the Air Vac logo on the screen main menu background color will change to red You are now in the Hidden setup win dow 3 Select Options from the menu bar 4 Select Open 5 The file group should default to System System System 6 Select the Post Power Up Voltage Verification profile Click on the thumbs up icon Click on the thumbs up icon to advance to the run screen ...

Page 29: ...25 User s Guide Chapter 2 Installation 0025 00 902 2 11 7 Click on the cycle start icon A to begin the process 8 Verify that the machine voltage is between 208 and 240 volts while the process is running A ...

Page 30: ... be approximately 120 volt 10 Voltage should not be below 208 volts See facility sheet regarding buck up transformer if the voltage drops below 208 volts 11 Close the machine cover and re install the hold down screw 12 Stop the process Click on Thumbs Up icon to exit the screen ...

Page 31: ...tant THE AIR REQUIREMENT FOR THE ACCESSORY PORT IS 18 CFM THE AIR REQUIREMENT FOR THE UPPER HEATER IS 3 CFM IF AIR LINE IS COMBINED 21 CFM MUST BE MAINTAINED AT 80 PSI INSUFFICIENT AIR SUPPLY LOW VOLUME DUE TO QUICK DISCONNECTS SMALL DIAMETER LINES OR ANY LINE RESTRICTION WILL CAUSE A PRESSURE DROP INSUFFICIENT AIR WILL RESULT IN PREMATURE HEATER DAMAGE AND OR PROCESS REPEATA BILITY ISSUES IN ADDI...

Page 32: ...ion site view ing including the ability to verify compo nent reflow has occurred How It Works Operator is instructed to position the DV camera on the site Focus zoom and lighting adjustments are made to optimize clarity Notes Of Interest The DV camera is a valuable process development aid especially for difficult to see tiny devices Photos Camera mount assembly Close up view of BGA spheres ...

Page 33: ...5 2 8 IR Sensor Installation option The IR Sensor option is installed by Air Vac prior to shipment No installation is required Install the Thermocouple Plug on the IR Sensor into thermocouple channel 1 Light Pointer to indicate area being monitored by Sensor ...

Page 34: ...der Removal System Installation The Vacuum Jar Assembly is mounted on the side of the module Installation Steps The Site Cleaning Nozzle installs in the Locking Jaws A as a regular nozzle The vacuum cup on the Site Cleaning Nozzle must mate with the vacuum interface B A B ...

Page 35: ...rque to 10 foot lbs maximum at aluminum attachment points and 15 foot lbs maximum for all other attachment points Unpack your order and separate like parts into separate areas Be careful not to damage parts as they are being moved around and put into position Also be sure all parts are removed from the packing materials before these materials are thrown away Locate the Hardware Kits and keep them ...

Page 36: ...DRS25 User s Guide Chapter 2 Installation 0025 00 902 2 18 ...

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Page 38: ...pre pay and add Contact IAC Industries at 800 989 1422 if parts are missing 1 4 20x 75 Hex Head Bolt 1 4 Flat Washer 5 16 18x 75 Hex Head Bolt Beam Connector Plate Description Qty Worksurface 1 Pedestal Leg 2 Support Beam 2 Support Beam 2 Leg Extender 4 HARDWARE KIT HWR001 Description Qty 1 4 20 x 75 Hex Head Bolt 16 1 4 Flat Washer 24 Floor Glide 5 16 18 5 16 18 x 75 Hex Head Bolt 8 Beam Connecto...

Page 39: ...ont or rear beam location Step 2 Place worksurface topside down on smooth flat surface being sure to protect it from damage by foreign objects IAC recommends the use of packing type blankets or clean cardboard Place the support beams on the worksurface with the open side toward the center of the worksurface and align the slots of the support beams over the threaded inserts in the worksurface as sh...

Page 40: ...ksurface as this could cause the inserts to pull out of the worksurface Step 4 Slide the workbench leg extender into the pedestal tube making sure the plastic insert in the end of the leg extender is exposed Align the threads of the leg extender with the holes in the pedestal tube and select the desired height of the bench Thread the 1 4 20 x 75 hex head bolts with the 1 4 flat washers into the th...

Page 41: ... F Screw 14 X 1 00 PPH SMS Black 4 Ratchet Plug Cap Black HARDWARE KIT HWR021 G Ratchet Plug Cap Black 12 Step 1 To assemble the beams and pedestal to the worksurface follow the instructions on pages 5 and 6 Do not tighten hardware until the pedestal cabinet is in place and is aligned properly Be sure to set the height of the leg extenders to match the height of the pedestal cabinet Step 2 Remove ...

Page 42: ...ighten all hardware at this time being sure not to over tighten the bolts going in the inserts in the worksurface If you have purchased items such as footrests lower metal shelves or CPU holders please see pages 17 26 for assembly instructions Step 4 Install floor glides into pedestal cabinet base With the help of at least another person carefully roll the workbench right side up Install the drawe...

Page 43: ...s Step 1 Install the modesty panel to the back of the pedestal legs of the bench by using four 1 4 20 x 75 hex head bolts item C and four 1 4 flat washers item B Install plastic caps as needed Please Note To retrofit a modesty panel to an existing workbench place the modesty panel against the rear of the pedestal legs and using the slots in the modesty panel as a template drill four 7 32 diameter ...

Page 44: ...allation has been completed correctly and that the ESD material is working properly Cleaning ESD Materials ESD laminates are designed to resist abrasion scuffing scorching and most solvents Intense exposure to any of these conditions can damage the ESD properties of the laminate and will require the replacement of the worksurface or instrument shelf ESD laminate worksurfaces and instrument shelves...

Page 45: ...rifications 0025 00 902 3 1 3 Machine Function Verifications 3 Machine Function Verifications 3 3 0 Verification Overview 3 3 1 Flow Rate Verification and Adjustment 4 3 2 Temperature Verification 9 3 3 Vision Alignment Verification and Adjustment 17 ...

Page 46: ...DRS25 User s Guide Chapter 3 Machine Function Verifications 0025 00 902 3 2 ...

Page 47: ...t 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 At regularly scheduled intervals such as every six 6 months Verification processes are stored in a hidden menu to enter the hidden menu please do the following Right click on the Air Vac logo ...

Page 48: ... rates and the Nozzle Flow Sensor which controls the Computer Digital Flow Display Nozzle flow verification is required for initial installation or any time the machine is disconnected and or moved 3 1 1 Nozzle Flow Controller Verification and Adjustment Materials required Scribed reference flow meter supplied with the machine Initial conditions Pressure to upper heater must be set precisely to 80...

Page 49: ...creen 1 Log on as DRS25 or any high level security operator and select the Thumbs Up icon 2 Using right side mouse button click the Air Vac logo the toolbar will turn red You are now in the Hidden Setup window 3 Select Setup Adjustments Nozzle Flow The Nozzle Flow Adjustment screen will appear as shown below ...

Page 50: ...on the flow meter The bottom of the float should be at the scribe line If the flow meter reads too high or too low adjustments can be made immediately by dragging or click ing on the track bar within the Nozzle Flow Controller group box B The airflow should not be interrupted The adjustments will be automatically applied and stable within 3 5 seconds The track bar is always connected to the active...

Page 51: ...he left side of the track bar B 5 If the flow meter reads too low increase by the right side of the track bar B Once the 100 Flow Controller value has been set check flow controller verifications for 30 90 settings A With the nozzle flow system activated for the various settings check the flow using the meter Adjust the nozzle flow controller computer value B as required until the float correspond...

Page 52: ...d exit the Flow Adjustment screen IMPORTANT DISCONNECT THE BLUE FLOW METER HOSE FROM THE FLOW CALIBRATION FIT TING AND RECONNECT THE BLUE UPPER HEATER HOSE FAILURE TO RECON NECT THE UPPER HEATER HOSE PRIOR TO RUNNING THE TOP HEATER WILL CAUSE THE TOP HEATER ELEMENT TO FAIL Software Screen Flow Meter Target Value 30 30 scribe 82 scfm 40 40 scribe 1 10 scfm 50 50 scribe 1 37 scfm 60 60 scribe 1 65 s...

Page 53: ...E FLOW METER HOSE FROM THE FLOW CALIBRATION FIT TING AND RECONNECT THE BLUE UPPER HEATER HOSE FAILURE TO RECON NECT THE UPPER HEATER HOSE PRIOR TO RUNNING THE TOP HEATER WILL CAUSE THE TOP HEATER ELEMENT TO FAIL 3 2 1 Upper Heater Verification 1 Perform Temperature Scale Test select Options Open from the red hidden menu bar 2 Select File Group System System System 3 Select the Temperature Scale Te...

Page 54: ...tion Verifications 0025 00 902 3 10 4 Click Thumbs Up again The Run screen for the Temperature Scale Testing profile will appear 5 Install the NCAL 1 Temperature Calibration Nozzle into the machine 6 Plug the nozzle thermocouple into channel 1 ...

Page 55: ...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 8 Allow profile to run when complete click on the Save Data button B small blue this saves the graph and data points ...

Page 56: ...le Analysis Scroll through files in directory folder located the correct file be date time stamp file name will have temperature scale test label Double click on this file so graph is displayed 10 To verify go to Control Thermal Profile Analysis Printing 11 Click on Program Files Air Vac Engineering DRS25 Export Run 12 Click on the Temperature Scale Testing Profile A with the current date A ...

Page 57: ...le Analysis screen will appear 14 Move the cursor to the end of the 4 events to compare the nozzle temperature to TC 1 15 Verify that the nozzle heater and NCAL 1 thermocouple channel 1 chart lines match within a 7 degree range for the last 4 events of the process profile If they match you are done ...

Page 58: ...n be performed using the automatic calibra tion utility available from the menu Setup Adjustments Nozzle Heater The user does not need to be involved in the calculation of these offset parameters the software will automatically determine the necessary adjustments during the process cycle 17 Click on the Start Calibration Cycle icon A A ...

Page 59: ...DRS25 User s Guide Chapter 3 Machine Function Verifications 0025 00 902 3 15 18 Run the program to insert the new temperature offset 19 Click on the Save icon A to save A ...

Page 60: ...16 20 Go back and run Temp Scale Testing again and verify the difference between set heater tempera ture and actual nozzle temperature only for the last 4 events of the process profile If temperatures are within 7C you are finished Nozzle Heater red NCAL 1 Nozzle Output green ...

Page 61: ...t accuracy 1 Log on as DRS25 or any high level operator 2 Select Set Up Main menu then Vision System from Main menu The Vision Adjustment screen will appear as shown below 3 Install the Vision Alignment Board supplied with system with the QFP160 site into the carrier 4 Click on the Enable disable button A to de power the z axis red background 5 Unlock clamping fingers and install the N27EZ27 nozzl...

Page 62: ...cally move to the vision position 11 Press microscope Slide Lock D 12 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 IN CORRECT VIEWING ANGLE DURING ALIGNMENT 13 Adjust the Zoom Lens E as required 14 Refocus until pad...

Page 63: ... not remove the two 1 5mm set screws E which hold the two Vision Adjustment Disks F in place 17 Rotate the two disks slightly until component part is aligned 18 Increase the zoom lens magnification to check your work Increase magnification to maximum 19 Tilt field of view up and down to insure leads are 100 in center of pad Viewing a few leads under high magnification may reveal minor errors not s...

Page 64: ...unction Verifications 0025 00 902 3 20 22 Click on the Z Axis Power button A It will turn red 23 Manually lower the nozzle to check at board level Put the QFP160 holder under the component and click on the Vacuum button B to stop the vacuum ...

Page 65: ...ent for Engineers 3 4 0 Profile Tutor Software 3 4 0 1 Overview 4 4 0 2 Physical Setup 4 4 0 3 Profile Tutor 6 4 0 4 Thermal Profile Analysis 16 4 0 5 Required Changes Prior to Running a Second Thermal Cycle if Necessary 17 4 0 6 Optional On The Fly Adjustments of Temperature 18 4 0 7 Auto Profile Build 20 4 0 8 Program Execution 23 ...

Page 66: ...DRS25 User s Guide Chapter 4 Process Development for Engineers 0025 00 902 4 2 ...

Page 67: ...DRS25 User s Guide Chapter 4 Process Development for Engineers 0025 00 902 4 3 4 Process Development for Engineers 4 0 Profile Tutor Software ...

Page 68: ... OMEGA Part 5 SRTC TT K 40 36 TC 2 Slide at least one TC two or more recommended underneath the BGA as far into the BGA as possible Plug the TC into channel 2 3 etc Apply Kapton tape to hold the TC in place If desired x ray will show the exact positioning of the TC head however this is not critical Studies have shown that TC s underneath the BGA that are not in direct contact with a solder joint a...

Page 69: ...ent for Engineers 0025 00 902 4 5 Board device with two 003 gauge thermocouple s slid underneath BGA One TC attached to top of device with copper tape then covered with Kapton tape TC 1 IR Sensor Board TC 2 Top of Device TC 3 Joint 1 TC 4 Joint 2 ...

Page 70: ...902 4 6 4 0 3 Profile Tutor Profile Tutor is the process whereby a thermal profile for a new application is created From the menu bar select Control Profile Tutor Select double click one of the Thermal Profile Master Templates that most closely matches the new application ...

Page 71: ...DRS25 User s Guide Chapter 4 Process Development for Engineers 0025 00 902 4 7 The Profile Tutor screen will appear The master profile name will be displayed at the top of the page ...

Page 72: ...Events Preheat Presoak Soak Ramp Reflow 1 Reflow 2 and Cool Under Options click to depower Z Axis A button box turns red Position nozzle over component Lightly touch component with nozzle o ring then retract approximately 080 2mm use Z position value B at bottom of screen as reference Click to repower Z Axis A box turns green A B ...

Page 73: ...idus until the heaters are shut off 6 REFLOW 2 Time until the joints fall back below liquidus NOTE Total time over reflow equals the total of Reflow 1 and 2 stages 7 COOL Cools the component and board down to a temperature that allows the reworked assembly to be safely handled The following are typical time temperature targets for each stage Event Tin Lead Lead Free PREHEAT Topside Board Temp C 90...

Page 74: ...w Less than 10mm 30 10 15mm 40 16 26mm 50 27 30mm 55 31 34mm 65 35 40mm 75 40 mm 85 NMX Nozzles 60 Be sure to change the flow in all events except Preheat click on each event radio button to access the event flow rate 3 Click on the Cycle Start icon A to start the Thermal Profiling process If any of the T C s are above 60C the board cooling system and nozzle cool down will come on automatically an...

Page 75: ...neers 0025 00 902 4 11 The Preheat Event will continue until T C 1 IR probe reaches the target board temperature 140 C in this example The Presoak Event will continue until T C 2 reaches 165 C Lead Free profile Time in Presoak stage is automatically recorded ...

Page 76: ...neers 0025 00 902 4 12 The Soak Event will continue until T C 2 reaches 200 C Lead Free profile Time in Soak stage is automatically recorded The Ramp Event will continue until T C 2 reaches 216 C Lead Free profile Time in Ramp stage is automatically recorded ...

Page 77: ...ll continue until T C 2 reaches 240 C Lead Free profile Time in Reflow 1 stage is automatically recorded The Reflow 2 Event will continue until T C 2 drops down below 217 C Lead Free profile NOTE Total time over reflow is the sum of Reflow 1 and Reflow 2 Time in Reflow 2 stage is automatically recorded ...

Page 78: ...DRS25 User s Guide Chapter 4 Process Development for Engineers 0025 00 902 4 14 The Cool Down Event 45 seconds ...

Page 79: ... Engineers 0025 00 902 4 15 Automatic prompt to name and save new thermal profile Click on the red green icon to save the thermal profile Confirmation of save IMPORTANT NOTE If you exit Tutor without saving the graph the process information will be lost ...

Page 80: ...Events to the Target Reflow time of 45 75 seconds 60 sec is ideal If the actual Soak and Reflow times fall within the targeted time ranges you have created a good thermal profile Proceed to the Profile Build section If the Soak and or Reflow stage s are less than the minimum target of 45 seconds the profile has run too fast If the Soak and or Reflow stage s are greater than the maximum target of 7...

Page 81: ...d increase the time in each event Increase the Nozzle temperature by in the Presoak Soak Ramp Reflow 1 stages Increasing the Nozzle temperature will speed up the profile and reduce the time in each event Click on the Cycle Start icon to begin the second cycle Cooldown of all thermocouples to 60 C will occur at the beginning of the second cycle Run the second thermal cycle exactly the same way as t...

Page 82: ...cle except during preheat To increase or decrease the nozzle temperature use the slide bar to adjust If an on the fly adjustment was made during the first cycle two events with the same name but different temperatures and time will be shown If you wish to run a second thermal cycle Click on the second of the two events and a red arrow will appear A Right click on the event and a delete event messa...

Page 83: ...xit Screen B Nozzle Vacuum C Vacuum Probe D Nozzle Blow Off Air E Nozzle By Pass Air F Board Cooling G Toggle Z Motor Enable H Direct View Camera Lights I Start Process Cycle J Toggle Tutor Analysis Display K Update TC for all Events L Update Air Flow Rate for all Events M Enable Manual Flow Control A B C D E F G H I J K M L ...

Page 84: ...uto Profile Build Now that a good thermal profile has been created and saved for the new application the Automatic Profile Build function is used to integrate the new thermal profile into a complete rework process that enables the user to remove site clean and replace the new application ...

Page 85: ...ll be shown in the Tutor Results box B Click on the Site Cleaning radio button C Select the appropriate site clean profile It will be displayed in the Site Clean box D Select create the Profile Groups E where you want the profile to be saved to or create new groups by typing in the name in the Group box Name the new profile F Click the Process Notes screen button G F E C A B D G ...

Page 86: ... The Process Notes screen H displays and allows information prior to running the program Insert notes such as nozzle size flux type etc that is important for setup Select Thumbs Up icon I to save and exit Click OK J to continue file save Click Thumbs Up K to save and exit K H J I ...

Page 87: ... 4 0 8 Program Execution Three new profiles should now be available under Options Open and the appropriate Customer Board Device Group Desoldering Site Cleaning and Soldering is automatically appended to the file name you created Double click on the Desoldering profile to open it ...

Page 88: ...r s Guide Chapter 4 Process Development for Engineers 0025 00 902 4 24 The Application Notes page is then displayed for the operator Click Thumbs Up to continue to the Run screen after reviewing the setup notes ...

Page 89: ...name A will be displayed at the top of the page Select the Cycle Start button B to start the profile Follow all prompts After the component is removed select Load Process Link File C for Site Cleaning Execute and reiterate for Soldering Desoldering Reduce the temperature for demo boards A B C ...

Page 90: ...26 Adding Photos to the Profile Take the photo you wish to attach to the profile store on a memory stick and copy to a photo directory on the computer Go to the photo file on the memory stick and copy and past into the directory OS C Program Files Air Vac Engineering DRS25 Photo ...

Page 91: ...DRS25 User s Guide Chapter 4 Process Development for Engineers 0025 00 902 4 27 Go to the Teach Screen of the profile and click on the Image box A Click on the photo B to be attached A B ...

Page 92: ...DRS25 User s Guide Chapter 4 Process Development for Engineers 0025 00 902 4 28 The image C will be attached to the program C ...

Page 93: ...DRS25 User s Guide Chapter 4 Process Development for Engineers 0025 00 902 4 29 To open the image on the run screen go to Image Link File Show Image The image will appear ...

Page 94: ...DRS25 User s Guide Chapter 4 Process Development for Engineers 0025 00 902 4 30 ...

Page 95: ...p and Log In 3 5 1 Main Screen Overview 5 5 2 Open A Typical Program 7 5 3 Running A Typical Removal Program 13 5 4 Running A Typical Site Cleaning Program 20 5 5 Running A Typical Soldering Program 28 5 6 Reference Run Screen Operator Controls 38 5 7 Process Tips 42 5 8 Preventative Maintenance Schedule Procedure 43 ...

Page 96: ...DRS25 User s Guide Chapter 5 Operator Training 0025 00 902 5 2 ...

Page 97: ...urn on machine power by releasing the Emergency Stop if depressed and turning the key to the right The green machine power indicator light will illuminate Turn on the PC and Monitor The PC will boot to the Administrator screen as shown below Click on the black Air Vac Administrator icon The password is airvac ...

Page 98: ...een will automatically appear after the Operator Registration screen Enter a password and click on the Up Thumb icon to continue If access is denied consult supervisor Passwords are installed and must be correct to access software Low priority will only allow access to minimal screens The machine is shipped with operator and no password blank under low priority limited access The machine will perf...

Page 99: ... 902 5 5 5 1 Main Screen Overview Note USING THE LOW PRIORITY PASSWORD LIMITS THE OPERATOR ACCESS TO CERTAIN COMPUTER SCREENS AND RESTRICTS PARAMETERS FROM BEING CHANGED THIS ALLOWS ALL PROFILES TO BE RUN AS PROGRAMMED AND MINIMIZES OPERATOR RESPONSIBILITY ...

Page 100: ... vac eng com 5 1 3 Exit Closes the software prior to shutting the machine down Note DO NOT TURN OFF MACHINE PRIOR BEFORE CLOSING THE SOFTWARE 5 1 4 Run Process Activates screen to run the program This screen is automatically displayed after a program is opened and the Open Profile screen is presented 5 1 5 Reset Operator Allows a new operator to log on Note IT IS GOOD PROCEDURE TO PRESS RESET OPER...

Page 101: ...pen will present the Open Profile All Listings Screen 1 Select Group The operator must select the correct Customer Board and Device Group directory Using the Up Down Arrows at the right side of the each group box to select a BGA removal file 2 Select Program Under files highlight a BGA removal program file i e BGA 27mm Removal 3 Click on Thumbs Up icon ...

Page 102: ...orked For example BGA225 Location Describes position on the board For example U43 Flux Type Describes the flux to be used For example manufacturers name and flux type Nozzle The nozzle used For example N27EZ27 Notes Saves helpful information about the assembly Provides operator tasks and checks prior to running the program Prior to going to the Run Screen INSTALL NOZZLE INSTALL BOARD INTO CARRIER ...

Page 103: ... part number is engraved on the side of the nozzle For BGA s the nozzle part number will have EZ on it Install the nozzle relatively square in the nozzle fingers Rotate the nozzle ring clockwise to close the nozzle fingers Note The nozzle fingers may be hot during operation Do not touch nozzle fingers Note The nozzle may be hot during operation Use the nozzle pliers supplied to install and remove ...

Page 104: ...r the Temperature Sensor IR probe to be positioned without interference from the vision system extended Loosen the Carrier Lock Knobs B left and right to allow the carrier arms to adjust to the board width Tighten the carrier lock knobs to secure the board Hint Tighten on carrier board rail lock knob to secure one side while placing board in Board Edge Supports C Hint Locking the carrier with the ...

Page 105: ...e side supports Note The bottom heater will be hot during operation DO NOT TOUCH THE BOTTOM HEATER DURING OPERATION Move the board supports in a 3 4 inch square pattern under the BGA against the board material Note Do not place the board supports against any device The board will bend when placed against the preheater Note During actual operation the board may flatten by the bottom heat The board ...

Page 106: ... following the board preheat event It must be plugged in for this program Note Failure to have a thermocouple or temperature sensor plugged into channel 1 will result in an alarm and will stop in running the program in the Run next screen Note The thermocouple or temperature sensor may not be used for certain programs For those programs an alarm will not occur Note The programmer has the ability t...

Page 107: ... or events The Message Box will change for each event to provide instructions The information on the screen is only for recording to a history file The operator is not responsible for process development Temperatures times and air flow settings cannot be changed on this screen Click on the Cycle Start Stop icon The Cycle Start Stop Button is located at the bottom right side of the screen Move the ...

Page 108: ...n Screen Press the footswitch to continue Note The operator has as much time as needed as this is a footswitch not a time controlled step Event 2 Move carrier to center BGA under nozzle Using the z axis knob lower the nozzle using it slightly touches the top of the BGA Press footswitch to continue Position Nozzle Over Device O Ring Should Touch Top Of Device Press Footswitch to Continue Install No...

Page 109: ...ure sensor thermocouple away from the nozzle and not on or over another device or at the edge of the board Press the footswitch to continue Event 4 There is no operator involvement during this event The nozzle automatically moves up 075 of an inch from the BGA Note A relative move will move the programmed distance from where the operator last leaves the nozzle z axis It is important that the nozzl...

Page 110: ...ed Note Board preheating does time will vary depending on the initial temperature of the bottom heater board and machine Note Board preheating temperature may be programmed differently for various assemblies Event 6 9 There is no operator involvement during this event The programmed heating of the BGA is automatic and is based on the thermal profile developed by the engineer in Profile Tutor This ...

Page 111: ...the Z motion and automatically go to the next event Event 12 There is no operator involvement during this event The nozzle vacuum will be on to the hold the component The nozzle automatically move up to approximately 3 16 of an inch from the board Event 13 There is no operator involvement during this event The nozzle vacuum will be on the hold the component The nozzle will automatically move up to...

Page 112: ... should NOT be in the unload tray Event 15 There is no operator involvement during this event The nozzle vacuum will be turned off and low pressure air will be applied to insure the component drops Event 16 This is a timed event 5 seconds The operator is to remove the BGA Note The event may be changed to allow more time for the operator to remove the part Or this event may be changed to footswitch...

Page 113: ...erator involvement during this event At the end of the removal process the operator has three options Select the Load Process Link File for the Site Cleaning Program Press the Start Stop Cycle icon to start another Removal cycle Press the Thumbs Up icon to exit the screen process complete ...

Page 114: ...e Site Cleaning Program select the Application Notes icon The Open Profile Note screen will appear It provides information prior to running the program It is important that the site cleaning nozzle be clean See Maintenance Section Select the Cycle Start Stop icon to begin the site cleaning program Process Hints Running the site cleaning program immediately after the removal program will take advan...

Page 115: ...aning nozzle in the same manner Be sure that the Site Cleaning vacuum cup interfaces properly with the vacuum stalk as shown Rotate the nozzle ring clockwise to close the nozzle fingers Event 2 Using the z axis knob lower the nozzle until the tip is just above the solder at the rear left corner of the site Remove Nozzle Caution Hot Install Site Cleaning Nozzle Unlock table Press Footswitch to Cont...

Page 116: ...r of the microscope viewing Adjust oculars to operator Lower rotate microscope to the lowest position to allow a better viewing angle Focus microscope using the focus ring and adjustable eyepieces Adjust the zoom lens to the maximum setting for magnification of the site cleaning operation Refocus as needed Use the x and y thumb wheels of the carrier to move to the left corner of the site under the...

Page 117: ...ased event The IR Sensor will monitor the board temperature It is displayed under Thermocouple System TC 1 The bottom heater is displayed and will heat the board until the programmed board temperature is reached The next event will occur automatically when the preheat temperature is reached Note Board preheating time will vary depending on the initial temperature of the bottom heater board and mac...

Page 118: ...g height auto adjust mode of the site clean nozzle can be adjusted during a process cycle The site clean slide bar can be used to raise or lower the auto height position If the nozzle is moving to close to the board move the slide bar slowly upwards until the overall position is optimized If the nozzle is moving to far from the board not collecting enough solder move the slide bar slowly downwards...

Page 119: ...nt The site cleaning nozzle moves up Event 9 After raising the nozzle moves the operator can clean the site with additional flux and a brush The nozzle can be manually lowered to touch up areas of not completely removed solder The pads should be flat The pads and via s must not have the solder mask removed before the soldering process Note There are various tip sizes and fittings to allow site cle...

Page 120: ...eplacement soldering process Event 12 Caution The Nozzle is Hot Use the Nozzle Pliers to remove nozzle Note It is important to place the Site Cleaning Nozzle in the Site Cleaning Holder If the site cleaning nozzle is left on its side after a site cleaning process solder may clog the tool Reference Maintenance Section Remove Site Clean Nozzle and Reinstall Nozzle Press Footswitch to Continue Clean ...

Page 121: ...0 902 5 27 Event 13 After the site cleaning process is complete select the Load Process Link File for the Soldering Program or Removal Program Click on the Start Stop Cycle icon to start another Removal cycle Click on the Thumbs Up icon to exit the screen ...

Page 122: ...t the top of the Run Screen will change to the Site Cleaning Program To review the Application Notes for the Soldering Program select the Application Notes icon The Open Profile Note screen will appear It provides information prior to running the program Click on the Thumbs Up icon to proceed to the Run screen Select the Cycle Start Stop icon to begin the replacement ...

Page 123: ... is used use Kapton tape to attach it to the board material Note The IR sensor is meant to read the board temperature It is important to position the sensor thermocouple 2 3 inches away from the nozzle on an open area of the board Note If the starting board temperature is too high the operator can activate the board cooling option prior to starting the process Check Board Temp If Above 70 TL 100 L...

Page 124: ...tors handle components with their fingers theparts handling vacuum probe can be used Note If component tray is not purchased this event should be changed To allow operator to insert component manually under nozzle Note If component tray is not purchased event should be changed to no nozzle movement and time to allow operator to move hand Event 4 The nozzle will automatically move to the component ...

Page 125: ...ighest position Press the microscope slide lock Push the microscope along the track to the highest position Note Lowering the microscope for alignment will result in placement error due to incorrect viewing angle during alignment 2 Use the x y adjustment wheels of the table to move the board so that the leads and pads are in the field of view 3 Tilt the microscope as required to see the site and B...

Page 126: ...e as the pads The operator has the ability to adjust the BGA height position Click and toggle the Z axis enable button to red The z axis is now de powered and free to move Using the z axis knob slowly raise or lower the nozzle until the component leads are in focus The leads balls will appear to be at the same height as the pads of the board If the nozzle is too high or low they will appear to be ...

Page 127: ...ction until leads are in a horizontal row Balls must be parallel to pads Finalize the alignment by readjusting with the x and y fine adjustment wheels Check alignment of top row and bottom row to insure correct theta x and y position Option Use zoom lens at maximum setting to increase operator alignment accuracy Viewing under high magnification may reveal minor errors not seen while aligning the e...

Page 128: ...nsor option over the board If a thermocouple is used use Kapton tape to attach it to the board material This must be done prior to this event Note The IR sensor is meant to read the board temperature It is important to position the sensor thermocouple 2 3 inches away from the nozzle on an open area of the board Event 8 BGA will automatically be lowered to board until the programmed force is reache...

Page 129: ...A Event 11 There is no operator involvement during this event This is a temperature based event The thermocouple or temperature sensor will monitor the board temperature It is displayed under Thermocouple System TC1 The bottom heater is displayed and will heat the board until the set programmed temperature is reached The next event will occur automatically when the preheat temperature is reached n...

Page 130: ...uring this event The heating events are finished Cool air will be controlled through the nozzle and the board cooling system This is a timed event based on the programmer Event 17 There is no operator involvement during this event This is a timed event for 45 seconds The board cooling system air flow is set to high flow Event 18 There is no operator involvement during this event This is a timed ev...

Page 131: ... next cycle The nozzle heater is set to 50 air flow at 100C and the board cooling system air flow is set to low air flow At the end of the process the operator has three options Select the Load Process Link File for the Removal Program OR Press the Start Stop Cycle icon to start another Removal cycle OR Press the Thumbs Up icon to exit the screen process complete heater cooldown ...

Page 132: ... Reference Run Screen Operator Controls Common Icon Controls Cycle Start Stop Starts the program Repressing the Start Stop icon will stop the program The program will default back to the start of the program Click on the stop sign symbol will stop all process activity ...

Page 133: ...m It may be useful to open when a linked profile is opened Z Power Enable Disable Allows the operator to de power or re power z axis LED Adjustment Allows operator to change the lighting of the component leads and or board pads Is shown in the soldering program during the alignment event when it is programmed Adjust Top LED to control component lead contrast Adjust Bottom LED to control board cont...

Page 134: ...art away from the nozzle Site Cleaning Vacuum On off vacuum for the site solder removal system Camera Live Video May turn on video lights for the direct view camera option Machine Cooling Allows upper heater and bottom heater to perform rapid cool down The nozzle cool down involves a bypass operation to delivery cool air directly into the nozzle chamber does not cool down the heating element Home ...

Page 135: ...g display blue Idle Temperature setting when machine is not used yellow Thermocouple System Top Box Set point temperature This is the target temperature for that event Bottom Box Actual temperature Note The system has a maximum of 8 thermocouple channels Only pre programmed active channels will be displayed Each channel has an identification number When a thermocouple channel is controlling the pr...

Page 136: ...ss Please note the correct removal and site preparation process must occur for the correct soldering process It is advised to use the DRS programs for removal and site preparation for all applications Open the appropriate software profile and be sure to follow all set up notes Footswitch must be held until yellow radio button goes out Microscope Vision System Always use the microscope whenever pos...

Page 137: ...ystem optics with lens cleaner kit Clean site cleaning tool Quarterly Wipe flux from table carrier arms and overall machine Clean nozzles with flux remover and soft brush Advise maintenance to perform preventative maintenance procedures Check and clean site cleaning tool system Clean as required Clean microscope and vision system optics with lens cleaner kit or alcohol Wipe eyepieces mirror top an...

Page 138: ...muffler and recheck to determine if muffler must be replaced Disassemble Vacuum pump clean and recheck to determine if vacuum pump must be cleaned or replaced Vacuum gage must read at least 18 Hg with system closed Close end of hose with your finger and turn on site cleaning vacuum If vacuum gage reads under 18 Hg system has vacuum leakage or vacuum pump is clogged Tighten Filter jar Tighten all c...

Page 139: ...iew 0025 00 902 6 1 6 Software Overview 6 Software Overview 3 6 0 Windows Tools Overview 3 6 1 Options Menu Functions 7 6 2 Control Menu Functions 18 6 3 History Menu 58 6 4 Setup 60 6 5 Reset Operator 65 6 6 Protected System Security Access 66 ...

Page 140: ...DRS25 User s Guide Chapter 6 Software Overview 0025 00 902 6 2 ...

Page 141: ...ocedure or function Moving the cursor over the top of the icon and clicking on the left mouse button will initiate the button s functionality Button icons have a popup message that tell the operator what the purpose of the button is this automatically occurs when the cursor is placed over the top of the icon Note IF A BUTTON IS COMPLETELY GRAY THE FUNCTIONS ASSOCIATED WITH THAT BUTTON ARE DIS ABLE...

Page 142: ...ram a DRS25 function or activity Inactive Clear state A blank check box indicates the Off or the inactive state Active Black state A black check mark indicates the On condition or the active state For Example The nozzle vacuum is off and the live video camera system is programmed to be active 6 0 5 Radio Buttons Similarly radio buttons allow a functions or activities to be programmed Typically rad...

Page 143: ...gh 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 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 Full List Box ...

Page 144: ... to display several lines of information on the screen After making a selection the list box collapses back down to one line For Example By clicking left button on the down arrow the board group list box will expand to show more of the possible choices The operator can select any line within the list box by simply clicking left mouse on that line The edit box will return to its original state with...

Page 145: ...DRS25 User s Guide Chapter 6 Software Overview 0025 00 902 6 7 6 1 Options Menu Functions View of the Options Menu ...

Page 146: ...apter 6 Software Overview 0025 00 902 6 8 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 ...

Page 147: ...rofile list can be adjusted by changing the group selection combination Clicking on the down arrow of a group list box will display a window with all the available options for that group Use the scroll bar to view any additional entries beyond those that are currently displayed Customer Groups Air Vac Engineering Company Board Groups Demo Board Profile Library Device Groups Area Arrays Demo Board ...

Page 148: ... 902 6 10 After selecting a file the system will automatically take the operator to the Open Profile Notes screen 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 ...

Page 149: ...is 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 ...

Page 150: ...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 oper ator 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 Link Name Site ...

Page 151: ... and Device Group These groups E allow profiles to be organized using a combination of customer board and device name New groups can be easily created see Setup Group Categorizing profiles by group can sig nificantly improve the operator s ability to find the correct application profile File Search These controls allow the user to interactively search for the necessary file links The group drop do...

Page 152: ...tionality of the profile The operator has the option to move the new profile to a different group New link names can be added at any time Note THE ORIGINAL PROFILE REMAINS UNCHANGED AND COMPLETELY INTACT THE OPERATOR SHOULD BE CAREFUL NOT TO ALLOW EXACTLY A LONG NAME THAT ALREADY EXISTS THE SYSTEM WILL ALLOW IDENTICAL LONG NAMES TO EXIST IN THE PROFILE LIBRARY The Short Name will auto matically be...

Page 153: ...Overview 0025 00 902 6 15 6 1 5 Delete Profiles The Delete Profile screen allows the operator to delete files based on the Long Name similar to the Open option The operator will be prompted before any files are removed Delete Profile Screen ...

Page 154: ...DRS25 User s Guide Chapter 6 Software Overview 0025 00 902 6 16 6 1 6 About DRS The About screen contains general information about Air Vac Engineering and the current software ver sion ...

Page 155: ...n any active devices vacuum air flow etc The Windows Desktop screen will be displayed DRS25 Machine E Stop Button The E Stop button will de power the DRS25 machine It should only be used in the case of an emergency or after Windows has been properly shut down Warning FILE DAMAGE MAY OCCUR WHEN PRESSING THE E STOP BUTTON IF WINDOWS HAS NOT BEEN SHUT DOWN PROPERLY Click on the Start menu lo cated in...

Page 156: ...DRS25 User s Guide Chapter 6 Software Overview 0025 00 902 6 18 6 2 Control Menu Functions View of the Control Menu ...

Page 157: ...ator with the Teach screen The Teach screen allows profile control parameters to be quickly and easily adjusted A control profile is developed by combining together simple events to create a complex motion and control sequence Events can have any combination of 1 motion 2 device control or 3 time Events can be added or deleted based on the application s processing requirements ...

Page 158: ...le 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 Start Stop The Cycle Start Stop button is used to activate or terminate the process cycle This button will display a stop sign symbol when the cyc...

Page 159: ...tion 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...

Page 160: ...leted This general motion utility can t be programmed as a complete function however the results of this motion can be saved to an event Typically this general position is adjusted to exactly match the specific vision alignment require ments This button can also be used to close and home the Z and Vision axis Live Video The Live Video button will activate the camera system and generate a live vide...

Page 161: ...moval 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 ev...

Page 162: ...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 machine motion may occur and des tination motor positions will be used as the target motor positions New or adj...

Page 163: ...ision axis This coordinate is taught during the profile motion development phase The Vision Up button C will close the Vision axis toward back of machine The Vision Down button D will open the Vision axis toward front of machine Note The Jog check box controls the axis velocity Note If the Motion check box is selected checked the Z and Vision axis coordinates will be saved each time the Teach func...

Page 164: ...y controls the maximum speed that the axis will reach To achieve a maximum velocity set the axis parameter to 100 Acceleration controls the length of time the axis will need to reach the maximum speed The Z and Vision axis share a single event acceleration parameter To achieve a maximum acceleration shortest time set the event parameter to 100 Note The default values for velocity and acceleration ...

Page 165: ...tate powered de powered of the Z axis motor after completing any required event motion Run screen In addition this Enable Disable buttons B can be used to immediately adjust the state of the Z Vision axis motor power during the development process Teach screen When the Z Vision axis motor is de powered manual adjustments can be made Jog Check Box The Jog trackbar C controls the maximum axis Z and ...

Page 166: ...tions associated with this option Display Only Check Box The force Destination B value allows the operator to fine tune the applied placement removal force Force is measured in grams or newtons 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 c...

Page 167: ... Force Placement 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 force value Step 3 All events beyond the actual force placement event steps 1 2 must be designed to eliminate any Z axis motion This is accomplished by checking the Do Not Move radio bu...

Page 168: ...mocouples These event elements are activated after all the required motion has been completed Z Vision and Force placement Note IT IS IMPORTANT TO REMEMBER THE PRIORITY OF EVENT PROCESSING SOME DEVICE CONTROL ELEMENTS SHOULD BE ACTIVATED BEFORE THE CURRENT EVENT IS PROCESSED FOR EXAM PLE IT IS IMPORTANT TO ACTIVATE NOZZLE VACUUM IN THE EVENT PRIOR TO THE COMPONENT REMOVAL MOTION EVENT ...

Page 169: ...ain air source large blue hose The main air source is also used by the vacuum and cooling systems Selecting the Nitrogen option automatically connects the upper heater to the secondary pressure connection smaller blue hose or yellow black hose This secondary pressure source is generally connected to nitrogen If nitrogen is not available this required connection must be made to air Note The seconda...

Page 170: ...ng desolder ing a component and the right side can be used for board cooling or solder pasting The lower heating system temperature TempºC can be programmed from 50ºC to 350ºC Note During the process cycle Run screen the panel event controls will override any global diffuser idle that may have been activated Board Cooling B controls the air for the board cooling system Unchecked means the system i...

Page 171: ...from the nozzle Pro gramming this check box checked will activate the air flow for the current event Run screen A clear check box will deactivate the air flow for the current event Run screen Nozzle Vacuum Check Box The Nozzle Vacuum check box A allows the operator to program nozzle vacuum The operator can use this device control to pick up or release the component at the appropriate process time ...

Page 172: ...ll 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 e...

Page 173: ...or to program a special vacuum port used for site clean ing The site cleaning tool requires a vacuum source to remove the molten solder from the site Program ming 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 A ...

Page 174: ... a thermocouple channel during the process cycle Skip C This control option monitors a thermocouple channel during the process cycle In addition this control option requires a target temperature A to be programmed This target temperature is used to trigger an event change Target temperatures can be defined as increasing heating cycle or decreasing cool down cycle Stop D This control option monitor...

Page 175: ...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 maxi mum profile time 45 minutes Delays typically allow activities such as heating cycles or operator inter action component alignment to be time tracked and graphically plotted ...

Page 176: ...5 User s Guide Chapter 6 Software Overview 0025 00 902 6 38 Application Notes This screen allows application specific notes to be entered These notes are made available to the oper ator during the Run cycle ...

Page 177: ...39 Table Event Editor The Table Event Editor allows the operator to adjust all profile control parameters using a tabular form The Table Event Editor provides the operator with the ability to quickly adjust any information contained in the parameter control table ...

Page 178: ...pen option or created using the Tutor Teach options During each event of the cycle the system continuously monitors and reports the following control information 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 ...

Page 179: ...en background when the cycle is active or a gray background when the cycle is not active Clicking on this button when the background is green will terminate the cycle Note DURING THE CYCLE THE OPERATOR MAY BE PROMPTED TO PRESS THE FOOT SWITCH BEFORE ANY PROCESSING CAN CONTINUE SOME EVENTS ARE DESIGNED TO ALLOW THE OPERATOR TO PERFORM A MANUAL TASK FINAL COMPONENT ALIGNMENT ...

Page 180: ...tware alarms 1 Machine Hardware Alarms 2 Process Alarms Machine Hardware Alarms This alarm type occurs when one of the following conditions is detected SerialPort_Failure Z_Axis_Motor_Comm_Restart Vision_Axis_Motor_Comm_Restart Nozzle_TempControl_Comm_Restart Left_Preheat_TempControl_Comm_Restart Right_Preheat_TempControl_Comm_Restart Center_Preheat_TempControl_Comm_Restart DeviceIO_Communication_...

Page 181: ...eheater_TC_Error Right_Preheater_Temperature_Limit Right_Preheater_TC_Error Center_Preheater_Temperature_Limit Center_Preheater_TC_Error Below_Minimum_Nozzle_Flow_Rate Nozzle_Flow_Sensor_In_Position_Failed Exceeded_Max_FootSwitch_Delay Exceeded_Max_TC_Control_Delay TC1_Not_Connected TC2_Not_Connected TC3_Not_Connected TC4_Not_Connected TC5_Not_Connected TC6_Not_Connected TC7_Not_Connected TC8_Not_...

Page 182: ...erview 0025 00 902 6 44 Profile Notes Page The Profile Notes button allows the operator to refer to any application related notes that may have been setup by the process engineer The operator cannot access these notes while a cycle is active ...

Page 183: ...screen is organized into the following sections Numeric Process Information Profile Event Alert Foot Switch Messages Graph Process Information Event Time Event Counter Process Time Button Functions Software Hardware Communication Link Error Status Bar Code Board Serial Number Tracking Menu Functions ...

Page 184: ...low rate force and thermocouples Nozzle and Preheater System The Nozzle System upper heater graphically displays the following control parameters Nozzle flow rate percentage set point A yellow needle Nozzle flow rate actual percentage B blue needle Nozzle target temperature set point C green number Nozzle actual temperature D red number Preheater idle temperature E yellow number B A A C D E ...

Page 185: ... positioned between the set point and actual displays When a thermocouple channel is controlling the process a yellow T C Control A message will be dis played at the bottom of the screen This message will define the type of thermocouple activity and the temperature target A real time display offers the current temperature of all thermocouple channels B Note All active thermocouple channels must be...

Page 186: ...ociated with component force placement force re moval or force adjustment The Force System graphically displays the following control parameters Force target set point green Force actual applied force red Note DURING ANY FORCE CONTROLLED ACTIVITY PLACEMENT REMOVAL ADJUSTMENT THE OPER ATOR SHOULD NOT TOUCH ANY PART OF THE MACHINE ...

Page 187: ...nt and Foot Switch Messages B This section of the Run screen displays system foot switch messages or pre programmed event alert messages Messages are used to inform the operator when machine interaction is required or to com municate the general progress of the profile cycle B ...

Page 188: ...Information C This section of the Run screen displays the Temperature vs Time graph Event Time D Time remaining in the current event Event Counter E Current and maximum profile event counters Process Time F Total overall cycle time all events is plotted on the chart display D E F ...

Page 189: ... 902 6 51 Function Buttons G This section of the Run screen displays the function buttons that are available to the operator Probe Vacuum The Probe Vacuum button will activate or deactivate the special vacuum probe port used with compo nent handling tool G ...

Page 190: ...nozzle When this function is active the button back ground will be display in green Cycle Start Stop The Cycle Start Stop button is used to activate or terminate the process cycle This button will display a stop sign symbol when the cycle is active or a machine symbol when the cycle is not active Clicking on the button when the stop sign symbol is visible will terminate the cycle Thumbs Up OK Exit...

Page 191: ... provide a form to review the application process notes Home All Motors This button will home all the Z and Vision motor axis Live Video The Live Video button will activate the camera system and generate a live video image on the computer monitor In addition this button may turn on video lights for the direct view camera option additional camera used to view the active process Note THE ABOUT DRS25...

Page 192: ...ode 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 I ...

Page 193: ...s that are available to the operator Load Process Link File Menu Option The Load Process Link File menu J allows the operator to toggle between the soldering desoldering and site cleaning profiles This allows related profiles to be cycled without leaving the Run screen This menu option is only available when the process is not cycling J ...

Page 194: ...display L will toggle the display from line graphics to a to data point table Clicking on the small blue button K will export the chart data to the export folder Export directory C Program Files Air Vac Engineering DRS25 Export Run This information can be retrieved at a later time using the Thermal Profile Analysis utility A help message will inform the operator that the graph data was successfull...

Page 195: ...zed and stored using an 8 digit file sequence number Clicking on the green button will present a file browse window allowing the operator to select chart data files from one of the following folders C Program Files Air Vac Engineering DRS25 Export Run C Program Files Air Vac Engineering DRS25 Export Tutor Clicking on the red button will toggle the display from line graphics to a to data point tabl...

Page 196: ...uide Chapter 6 Software Overview 0025 00 902 6 58 6 3 History Menu The History menu has two options Cycle and Alarm 6 3 1 Cycle History A History file entry is recorded each time the operator cycles a process profile ...

Page 197: ...pter 6 Software Overview 0025 00 902 6 59 6 3 2 Alarm History The software continuously monitors the controlling sub systems If an alarm condition occurs for any process or hardware issue an Alarm file entry will be recorded ...

Page 198: ...s These options are only available to high priority operators 6 4 1 Preheater Idle Selecting the Preheater Idle from the Setup menu will present the operator with the Preheater Idle Control screen These settings are global and will control the preheater during all screens except the Run screen Individual profiles will control the preheater based on process requirements ...

Page 199: ...ame 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 B To delete a group the operator must first highlight the group Next the operator can click on the Delete Highlighted Entry button C 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 ...

Page 200: ...er 6 Software Overview 0025 00 902 6 62 6 4 3 Limits and Defaults This screen is used is primarily used to modify the default profile groups used by the Open profile option The process temperature limits are for reference only ...

Page 201: ...ocess adjustments The password edit boxes are used is used to enter modify verify the password associated with each operator priority level To add an operator click on OPERATOR under Operator Under User Name type new entry Type Password and Reenter Password for the new entry Change Group to Operator Click on the Insert icon at the bottom center of the screen To add a high priority name click on DR...

Page 202: ...apter 6 Software Overview 0025 00 902 6 64 6 4 5 Vision System This screen is used to provide access to the basic machine vision controls This screen is normally used to assist the user during a vision calibration procedure ...

Page 203: ...Overview 0025 00 902 6 65 6 5 Reset Operator Click on the Reset Operator Log Off option on the menu bar and the Operator Login screen will be displayed Log in again followed with your security access code to gain access to the DRS25 machine ...

Page 204: ...ystem Security Access To access the Protected System Menu the operator must click on the Air Vac logo with the right mouse button The menu background color will change to red The menu options will be changed to allow access to machine calibration and critical properties parameters ...

Page 205: ...lity as the standard operator idle option Selecting the Preheater Idle from the Setup menu will present the operator with the Preheater Idle Control screen These settings are global and will control the preheater during all screens except the Run screen Individual profiles will control the preheater based on process requirements ...

Page 206: ...DRS25 User s Guide Chapter 6 Software Overview 0025 00 902 6 68 6 6 2 General System The General System setup page is used to configure the software to match the type of DRS25 system hardware ...

Page 207: ...e offsets are set for each air flow percentage reference and calibrated to a certified flow meter The Flow Sensor and Flow Controller have individual dial indicators and are adjusted individually starting at 100 Slide bars make adjustments easier and only the target flow rate that is currently being change this reduces accidental adjustment to different flow rate parameters ...

Page 208: ...6 Software Overview 0025 00 902 6 70 6 6 3 2 Force Adjustment This screen is used to provide adjustment and calibration to the force system This activity is performed at the factory and normally does required customer adjustments ...

Page 209: ...individual calibration points should not be made Adjustments are available to influence the automatic adjustment decision logic contact Air Vac fac tory technicians To start the calibration sequence the operator need only plug the NCAL 1 nozzle into thermocouple channel 1 and click on the start button The cycle will run for 25 35 minutes All necessary offsets are automatically computed Click the u...

Page 210: ... 6 3 4 I R Sensor This screen is used to automatically map a non contact I R sensor to a typical contact thermocouple attached to the surface of a board This procedure allows a more precise temperature reading from the I R sensor across the entire range of the device ...

Page 211: ... Properties All machine properties control setup parameters are connected to this screen Machine properties associated with different peripherals to be quickly adjusted Click on the plus sign to expand a category Use caution before making any critical machine control properties ...

Page 212: ...r 6 Software Overview 0025 00 902 6 74 6 6 5 Machine Maintenance This screen offers access to all machine the interface control signals This screen is normally used to test individual control signals diagnose a repeatable issue ...

Page 213: ...bleshooting 0025 00 902 7 1 7 Troubleshooting 7 Troubleshooting 3 7 0 No Heat 3 7 1 No or Low Flow Condition 3 7 2 Nozzle Does Not Pick Up Component 3 7 3 No Motion 3 7 4 Machine Alarm Conditions Alarm Screen 4 7 5 Wago Modbus Flash 7 ...

Page 214: ...DRS25 User s Guide Chapter 7 Troubleshooting 0025 00 902 7 2 ...

Page 215: ...e upper heater element It should be 52 ohms See section 10 Maintenance for details on how to checkout the heating element Replace the element if required 7 0 2 Communications Problems If the temp communications link alarm is persistent Insure that the communication cables relating to the temperature control are connected properly see schematic or block diagram in the schematics section of this man...

Page 216: ...pages list all alarms and what causes them Machine Hardware Alarms This alarm type occurs when one of the following conditions is detected SerialPort_Failure Z_Axis_Motor_Comm_Restart Vision_Axis_Motor_Comm_Restart Nozzle_TempControl_Comm_Restart Left_Preheat_TempControl_Comm_Restart Right_Preheat_TempControl_Comm_Restart Center_Preheat_TempControl_Comm_Restart DeviceIO_Communication_Restart Low_P...

Page 217: ...heater_TC_Error Right_Preheater_Temperature_Limit Right_Preheater_TC_Error Center_Preheater_Temperature_Limit Center_Preheater_TC_Error Below_Minimum_Nozzle_Flow_Rate Nozzle_Flow_Sensor_In_Position_Failed Exceeded_Max_FootSwitch_Delay Exceeded_Max_TC_Control_Delay TC1_Not_Connected TC2_Not_Connected TC3_Not_Connected TC4_Not_Connected TC5_Not_Connected TC6_Not_Connected TC7_Not_Connected TC8_Not_C...

Page 218: ...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 7 4 4 Site Cleaning Vacuum Alarm Your site cleaning tool requires cleaning or is clogged See instructions for cleaning the tool Check vacuum filters if clogged then replace Check profile Teach Screen for Clogged track bar Call Air Vac Technical Support 7 4 ...

Page 219: ...roubleshooting 0025 00 902 7 7 7 5 Wago Modbus Flash 1 Open small access door on main Wago unit 2 Set small dipswitch under access door to the downward position as shown for programming 3 Set ID pots for 0 Lower ID pot Upper ID pot ...

Page 220: ...DRS25 User s Guide Chapter 7 Troubleshooting 0025 00 902 7 8 4 Install Wago I O Cable between the main Wago unit and the serial port on the back of the computer ...

Page 221: ...Troubleshooting 0025 00 902 7 9 5 Power up DRS25 6 Go to Start Programs Wago I O Pro 32 7 Go to File Open then Browse To Support Wago Sample Programs Baud Rate Setup Pro if prompted to save changes select No 8 Open Wago 10 Pro32V2 ...

Page 222: ...No Program notice appears select Yes 10 Go to online then run go to online and flash Observe brief flicker from red CRC LED on Wago Unit Exit Wago Software 11 Power down reset ID pots to 0 lower and 6 top 12 Remove Wago cable and store properly 13 Re set the dip switch on the Wago unit to the upper most position ...

Page 223: ...DRS25 User s Guide Chapter 8 Schematics 0025 00 902 8 1 8 Schematics ...

Page 224: ...DRS25 User s Guide Chapter 8 Schematics 0025 00 902 8 2 ...

Page 225: ... 175 97 174 58 Shorting bar chassis ground 84 116 Shorting bar BottomLEFTHOT 99 56 UH220V RET 83 52 B2 Breaker 2 pole UH220V HOT AC Power connector 91 TB11 72 BottomLEFTRET 54 76 93 96 BottomRIGHTHOT 61 77 CN2 86 60 Bottom center RET 82 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 J2 CON19 94 CN1 78 BottomCenterHOT 95 12 4 cable J9 76 57 J12 77 J10 INITIAL RELEASE 82 J8 59 J11 PS1 contains an i...

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Page 227: ...1 220 VAC CONPLHOT TB18 0025 00 946 CONPLNEU TB17 ELECT SCHEM DRS25 91 TB12 LFUH1 86 T C T C K type 93 94 95 87 88 5B1 5B1 bottomcenterhot 1B4 Located outside the lower box bottcenterRET Description UH220V HOT AC AC DC DC SSR4 rev date UH220V RET CH GND HEAT HEAT 22 ohms 208 VAC 1967 W 8 x16 element 0025 01 041 AC AC DC DC SSR1 DIFFLEFTHOT Bottom Left DIFFFEFTRET Bottom Right 1 2 3 4 5 6 7 8 9 10 ...

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Page 229: ...wn 0 V 3 blue Z axis Home switch 5V PROX SW A 1 1 2 2 1 1 2 2 3 3 3 3 4 4 4 4 TS2 58 59 24VD 24V RETD rev date Description 60 128 147 146 7B4 1D6 1C6 1D6 1D6 1 2 3 J15 1 2 3 J16 INITIAL RELEASE 120 121 1 2 3 4 5 6 P35 CON6 139 138 142 141 140 143 24V 24V RET DIN1 4 NOZ VAC SW Z HOME PROX 4C1 4B2 AIR VAC Engineering Inc 30 Progress Ave Seymour CT 06483 www air vac eng com ELECT SCHEM DRS25 0025 00 ...

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Page 231: ...ue green yellow orange red brown 1 2 3 4 5 6 7 8 J CON8r nc nc grey violet Blue Green Grey Violet Blue Green Grey Violet Brown Blue Brown Blue 7C3 7B3 See 0024 90 933 for Vision LED Assembly Detail VISION CUBE ASSY 1 2 3 4 5 6 7 8 10 9 J CON10R Ribbon cable Ribbon cable Red 19 46 42 167 44 ELECT SCHEM DRS25 0025 00 946 A 3 21 07 NC MOTOR SENSE A SENSE B SENSE C SENSE SENSE GND MOTOR SENSE 1 GND 24...

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Page 233: ... Output 3 Sensym ASCX15AN Ground 4 N C 5 Do Not Use 6 Site Clean 1 2 3 4 5 6 CON6 B 5 OF 8 JEFF DUHAIME AIR VAC Engineering Inc 30 Progress Ave Seymour CT 06483 www air vac eng com 1 2 262 1 pinout 15V DC 15V DC COM RETURNA 24V ret Earth Ground 24V reg LFUH1 V 260 263 261 262 264 AOUT 3 MFC INITIAL RELEASE 1 2 3 4 5 6 7 8 9 79 250 ELECT SCHEM DRS25 0025 00 946 261 5 V 260 GND 176 GND 38 GND 176 24...

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Page 235: ...RE CONTROLLER 2C4 2B2 2A2 2C4 2D2 2D2 NC NO C ALM GND N L NO C OP2 NO C OP1 TC TC PTA COM TX2 TX1 LH1 NO LH1 C R Y GN BK R LEFT PREHEAT TEMPERATURE CONTROLLER 2B2 NC NO C ALM GND N L NO C OP2 NO C OP1 TC TC PTA COM TX2 TX1 LH2 NO LH2 C R Y GN BK R RIGHT PREHEAT TEMPERATURE CONTROLLER 2B2 NC NO C ALM GND N L NO C OP2 NO C OP1 TC TC PTA COM TX2 TX1 LH3 NO LH3 C R Y GN BK R CENTER PREHEAT TEMPERATURE...

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Page 237: ...OZ VAC 5 DOUT1 7 PROBE VAC 3 DOUT1 8 AIR KNIFE HIGH 7 DOUT2 3 S2 2 DOUT2 6 S1 1 DOUT2 7 N2 AIR 8 AOUT 1 MASS FLOW CTRL 25 AOUT 3 MFC 23 AOUT 5 COOLING RING 26 AIN 1 MASS FLOW SENSE 24 AIN 3 NOZ VAC SENSE 261 AIN 5 SITE CLEAN VAC SENSE 262 DIN1 1 206 DIN1 3 ACP2 127 DIN1 4 NOZ VAC SW 128 DIN1 6 CYCLE FT SW 126 DIN1 7 TOP HTR LOW PRESS 14 DIN1 8 DIFF LOW PRESS 15 STRN1 140 STRN2 141 STRN3 139 STRN5 ...

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Page 239: ...75 97 174 58 Shorting bar chassis ground 84 116 Shorting bar BottomLEFTHOT 99 56 UH220V RET 83 52 B2 Breaker 2 pole UH220V HOT AC Power connector 91 TB11 72 BottomLEFTRET 54 76 93 96 BottomRIGHTHOT 61 77 CN2 86 60 Bottom center RET 82 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 J2 CON19 94 CN1 78 BottomCenterHOT 95 12 4 cable J9 76 57 J12 77 J10 INITIAL RELEASE 82 J8 59 J11 PS1 contains an int...

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Page 241: ...ative Maintenance Checklist Schedule 3 9 1 Nozzle Clamp Repair 11 9 2 Y Axis Bearing Adjustment 12 9 3 Carrier Leveling 13 9 4 Preheater Leveling 15 9 5 Vacuum Ports System 16 9 6 DRS Z Axis Motor Belt Adjustment 17 9 7 Replacement of the Heating Element 19 9 8 Wire Diagrams and Assembly Drawings 23 ...

Page 242: ...DRS25 User s Guide Chapter 9 Maintenance 0025 00 902 9 2 ...

Page 243: ...quired Replace nozzle vacuum filter Clean the fan cover filters on the two back fans Drain water and oil from air supply filters Check for play in carrier Y bearing Check for play in carrier X bearing Check diffuser to carrier parallelism Clean and lubricate vertical shafts Check microscope lights Check for wobble in nozzle cone Check nozzle clamp must open completely and hold and snap closed Rebu...

Page 244: ...aily Self explanatory Monthly Clean Microscope and Vision System Optics Wipe eyepieces mirror and vision system prism A with alcohol Clean bottom of vision prism Wipe flux from table arms and rails Apply a film of light oil to the X and Y rails Clean and oil rails Remove any flux build up on supports etc A A ...

Page 245: ...lux vapors in the vacuum pump will result in insufficient vacuum operation Unscrew glass jar Replace two nozzle vacuum filters A Unscrew glass jar Unscrew stem to remove and install new filters Note Filter must cover holes on stem Drain water and oil from air supply filters B Clean the fan cover filters on the rear of the upper box ...

Page 246: ...oard carrier set carrier aside Remove the four screws B left 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 Remove the four screws C holding the x bearing rail Lift and move the carrier assembly to the back of the machine A B C Adjustment screw Adj...

Page 247: ...en 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 w...

Page 248: ...vement should be firm but not stiff Check tension by twisting rail Reattach the x bearing rail Reattach the diffuser and board carrier Check perpendicularity of carrier Check diffuser to carrier parallelism Remove heater cover Remove all grease from bearings and shafts top and bottom with alcohol Brush on and wipe Apply silicon vacuum grease on shafts and bearings To correct wobble in nozzle cone ...

Page 249: ... Clean all areas of anti seize Apply pressure stand on it with your foot on nozzle ring and housing to seat Remove spring clip and fingers Clean all areas of anti sieze Inspect for wear File burrs at top of fingers if necessary Apply anti seize at the two contact points E as shown Reassemble Move assembly up and down Check if all pem nuts are in place If not plate must be replaced Clean brass ring...

Page 250: ...scfm clean dry compressed air or inert gas Change the nozzle with the GNT1 or GNT4 tools only DO NOT GRAB at the bottom of the nozzle as it will damage the gas nozzle opening Store nozzles in tray Do not drop nozzles Do not force the SMD into nozzle Damage will occur to the nozzle nest PCB or component Do not apply excessive flux Consider fume extraction system Remove the arrows from repair compon...

Page 251: ...amp assembly should slide down do not use too much force vacuum tube can be stripped out easily rotate tube to help removal Lift heat shield off 2 if hand ring 4 has slipped down not seated at base press together to seat Remove spring clip 8 and fingers 7 and inspect for twisting or wear replace if necessary To lubricate use Never Seez or other high temperature grease Lubrication points are Top of...

Page 252: ...ide bearing to the y bearing block Tighten a small amount on the 3mm allen an adjustment cam in the center of the right side bearing Retighten the two 3mm allen screws holding the right bearing Check the y bearing assembly for excessive play by twisting the bearing plate left and right There should be less than 1 16 play in the assembly Do not over tighten Table will not move with y drive or beari...

Page 253: ...Leveling TOOLS NCal4 Nozzle Glass Plate 8 x 10 x 1 4 Allen wrench set Feeler Gauge Warm Up From the Main DRS25 Screen select Setup Set both heaters to 200 C and high flow Let heaters stay on until heater is heat soaked 5 10 minutes Change heater temp to 200 C at low flow ...

Page 254: ... hits the glass plate raise the nozzle release the nozzle clamp and then re clamp the nozzle into place 6 Using the feeler gauge check level of nozzle to glass plate The left to right nozzle clearance to the glass plate must be 005 or less 7 To adjust raise the nozzle Go to the outside edge of the carrier assembly to make adjustments Loosen the four allen screws A that hold the carrier arms to the...

Page 255: ...uld be adjusted so the support contacts the glass consistently at these four corners Use feeler gauge as reference Note The support should just touch the glass and still be free to move Remove the board support To adjust loosen the four 5 32 allen screws A on both left and right side of preheater Tighten or loosen the four 3 32 allen screws B to adjust height of the board support to the glass Note...

Page 256: ...ion chamber Inspect the chamber for excessive dirt Take corrective action on the input air line if excessive dirt is found Nozzle Vacuum Filter C Keep the nozzle vacuum glass tube free of contaminants Change felt filter F1AE as needed Site Clean Vacuum Filter D Keep the site clean glass tube free of contaminants Change felt filter F1AE as needed For internal vacuum pump locations and part see the ...

Page 257: ...DRS25 User s Guide Chapter 9 Maintenance 0025 00 902 9 17 9 6 DRS Z Axis Motor Belt Adjustment Adjustment Spring Spring Bracket Adjustment Screws Pulley Z Motor Belt ...

Page 258: ...g the edge of a scale on the centerline of the pulley Note the measurement 4 Belt tension is determined by pressing on belt as shown Once the pulley starts to move from the force take a reading Deflection should be set at 3 16 5 To adjust deflection loosen adjustment screws and pull up on spring bracket Retighten and check measurement ...

Page 259: ...e system to fail NOTE To determine whether a heater is good or not check with a multi meter Terminal 2 and 6 53 0 Ω 5 0 coil Terminal 3 and 4 should have continuity thermocouple 1 Check heater for keyway and location of keyway at the connector Disconnect machine main power Remove heat shield to expose the element Using the z axis adjustment knob lower the assembly to the bottom most position Remov...

Page 260: ...zle housing 3 Place heater into nozzle housing with keyway to the right side viewed from operator position wiggle side to side to be certain heater is seated 4 Place gasket over heater Keyway right side Keyway left side No Thermocouple Thermocouple Correct Orientation Incorrect Orientation Gasket Nozzle Housing ...

Page 261: ...rness passes inspection attach to heater Snug only screws in place alternating bolt pattern Over tightening the screws will damage cap NOTE For CXX modules the stack up will be gasket spacer gasket 7 Be certain the calibration hose is securely attached in the rear of the machine before applying power to the heater If hose is not in place or secure the heater will burn out NOTE Whenever heaters are...

Page 262: ... right side of unit Temperature Box Assembly Rear left of machine 2 Located inside are the relays Replace the bad relay 3 Remove the panel from the Temp Box Assembly to expose the SS relays Reverse panel and mount as shown to make it easier for checking Nozzle Left Heater Right Heater Center Heater ...

Page 263: ...DRS25 User s Guide Chapter 9 Maintenance 0025 00 902 9 23 9 8 Wire Diagrams and Assembly Drawings ...

Page 264: ...DRS25 User s Guide Chapter 9 Maintenance 0025 00 902 9 24 ...

Page 265: ... 2 3 175 L1 L2 72 102 174 L3 73 75 103 113 24V 74 114 104 24V Ret 73 76 75 74 77 111 78 110 89 90 92 101 99 100 72 92 93 94 95 215 96 98 91 112 100 101 102 AC Contactor L3 174 169 175 170 G round 218 218 F9 99 218 97 179 218 connects to F3 F4 for 3 heater configuration 218 connects to F3 F6 for 2 heater configuration Power In BK R1 4A BK R2 20A 02 5 2007 Right Sub Plate 0025 77 075 ...

Page 266: ...5 96 98 78 91 112 Ret Pow er AC Contactor L3 174 169 175 170 G round 218 218 F9 99 218 97 179 218 Connects to F3 F4 for 3 heater configuration 218 Connects to F3 F6 for 2 heater configuration 175 Connects from 4 amp breaker to terminal 4 new longer wire 175 lt blue Move black wire 78 to fuse 9 from terminal 3 Tie off lt blue wires to keyswitch 76 and 82 also tie off 76 lt blue at contactor For Zev...

Page 267: ...calDiagrams IOmap p65 DRS25 WAGO DC Power Distribution Diagram 3 Phase Wiring 15V N G L 83 89 96 Lt Blue Green Black CTRL W C V COM V 21 Brown 11 Violet 13 Violet MASS FLOW POWER SUPPLY 02 8 2006 Right Sub Plate 0025 77 075 ...

Page 268: ...Phase Wiring Terminal Blocks 6 7 11 10 9 8 110 111 112 216 178 88 87 86 85 84 83 82 62 16 6 7 11 10 9 8 110 111 112 216 178 88 87 86 85 84 83 82 62 16 Jumper Settings 3 Heater 9 10 7 8 2 Heater 8 9 10 Wires 62 and 16 are from the DC harness 02 5 2007 Right Sub Plate 0025 77 075 3 Heater 2 Heater ...

Page 269: ... AC Power Distribution Diagram 3 Phase Wiring Terminal Blocks 6 7 11 10 9 8 110 111 112 216 88 87 86 85 84 83 82 62 16 Jumper Settings 3 Heater 8 9 10 2 Heater 8 9 10 Wires 62 and 16 are from the DC harness 06 14 2006 Right Sub Plate 0025 77 075 2 and 3 Heater ...

Page 270: ...Ground 16 2 15 11 3 15V Ground 21 4 15 13 5 12 60 6 12V Ground 61 7 24V DC 52 8 24V DC 54 9 24V DC 56 10 24V DC 58 11 24V DC 116 12 24V DC 115 13 24V Ground 53 14 24V Ground 55 15 24V Ground 57 16 24V Ground 59 17 24V Ground 27 18 24V Ground 63 19 Earth Ground 62 7 12 16 19 1 4 8 13 17 Right Sub Plate 0025 77 075 ...

Page 271: ...eft Heater 12A Right Heater 12A Center Heater 12A 12V PS 25A 15V PS 5A 24V PS 4A Return Line In 3 Bottom Heaters L2 L1 L3 L1 L3 L2 Nozzle 4A Left Heater 12A Right Heater 12A Center Heater 12V PS 25A 15V PS 5A 24V PS 4A 2 Bottom Heaters L3 L1 L3 L2 L3 L2 02 8 2006 Right Sub Plate 0025 77 075 ...

Page 272: ...Wiring FS2 1 4 3 133 Brown 202 W hite Green FS1 1 2 3 NC 133 63 Brown 126 W hite Black Back of Sockets 2 127 W hite Red 201 Yellow 12 13 15 14 177 203 199 217 198 16 17 19 18 125 196 123 20 21 197 124 91 L1 1 L3 5 L4 7 88 193 216 L2 3 A 1 A 2 AC Controller 2 T1 6 T3 8 T4 4 T2 87 194 86 196 197 198 199 AC Controller 2 ...

Page 273: ... Assembly Diagram 0025 77 046 SSR1 NOZZLE HEAT W R 250 131 Brown 93 Black 123 Black AC AC SSR2 LEFT DIFFUSER White 81 130 Brown 94 Black 124 Black AC AC SSR3 RIGHT DIFFUSER W Grn 80 129 Brown 95 Black 125 Black AC AC SSR4 CENTER DIFFUSER 205 W R 214 Brown 215 Black 217 Black AC AC ...

Page 274: ...1 LEFT PREHEATER NC NO C NO C NO C GND N L TC TC PTA COM TX2 TX1 R Y GN 158 163 BK 159 162 R 160 161 130 81 180 183 181 184 182 185 ALM OP2 OP1 CENTER PREHEATER NC NO C NO C NO C GND N L TC TC PTA COM TX2 TX1 R Y GN 166 BK 165 R 164 214 205 186 187 188 ALM OP2 OP1 RIGHT PREHEATER NC NO C NO C NO C GND N L TC TC PTA COM TX2 TX1 R Y GN 163 166 BK 162 165 R 161 164 129 80 183 186 184 187 185 188 ALM ...

Page 275: ...25 WAGO B B Left Box Sub Plate 0025 77 043 TDA TDB RDA RDB GND 155 157 Blk Blk 153 154 Red Red 151 152 Red Red 136 137 Blk Blk 191 192 Green Green B B USB Dip Switches RS485 ECHO OFF 2 WIRE 2 WIRE RS422 ECHO ON 4 WIRE 4 WIRE ALL SWITCHES SET TO ON 1 2 3 4 ON ...

Page 276: ... DO5 DO6 DO3 DO4 DO1 DO2 1 Y201 5 195R 2 202 6 1R 3 R2 7 8R 4 8 204R D OUT 530 DO7 DO8 DO5 DO6 DO3 DO4 DO1 DO2 1 W R205 5 2 6 126 3 W R127 7 14Y 4 128 8 15Y D IN 436 DI7 DI8 DI5 DI6 DI3 DI4 DI1 DI2 1 R142 5 141GY 2 W138 6 143BL 3 GN140 7 139BK 4 8 Force 491 UU UU UD UREF UD UREF 1 Y 5 Y 2 R 6 R 3 7 4 8 TC 1 2 469 TC1 TC2 TC1 TC2 1 Y 5 Y 2 R 6 R 3 7 4 8 TC 3 4 469 TC1 TC2 TC1 TC2 1 Y 5 Y 2 R 6 R 3 ...

Page 277: ...e Vac 6 5 D out 4 750 530 Site Clean 3 4 D out 5 Probe Vac 7 3 D out 6 Air Knife High 4 6 D out 7 Air Knife Low 8 7 D out 0 8 Accessory Plug 4 1 201 D out 1 9 Relay Motor Power 5 195 D out 2 10 Accessory Plug 3 2 202 D out 3 11 750 530 Diff Left High 6 1 D out 4 12 Diff Left Low 3 2 D out 5 13 N2 Air 7 8 D out 6 14 4 D out 7 15 Z Motor Stop Input 8 D in 0 Future Use 1 200 D in 1 5 D in 2 2 D in 3 ...

Page 278: ...142 Force Strain Gauge 2 138 Force Strain Gauge 3 140 Force Strain Gauge 4 Force Strain Gauge 5 141 Force Strain Gauge 6 143 Force Strain Gauge 7 139 Force Strain Gauge 8 Address Map ID 2 Nozzle Temp Controller 3 Left Temp Controller 4 Right Temp Controller 5 Center Temp Controller 6 WAGO 7 Vision Motor 8 Z Axis ...

Page 279: ...rature Control Module 0025 77 046 Assembly View 16 35 34 22 16 35 34 11 20 31 21 23 23 24 15 10 14 12 10 4 28 10 14 26 25 26 17 2 29 19 36 9 32 33 8 1 40 11 5 35 3 30 6 13 27 NOTE 1 Place wire tie mounts as required NOTE 1 35 34 16 21 24 35 34 16 23 ...

Page 280: ...5 Page 2 of 2 DRS25 Temperature Control Module 0025 77 046 Parts List 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 40 236A M3 Star Internal 4 39B 8 32 Button 2 15 1 2 2 ...

Page 281: ...25 Category Site Solder Tube 9001 15 048 Replacement Remove the nozzle heat shield screw located on the left side of the shield Do not remove the one on the right Remove the heat shield Locate the site solder tube and remove it from the bracket Install the double barb fitting into the existing site solder tube as shown ...

Page 282: ...the rear of the machine and locate the existing site solder tube Gently pull the tube until the double barb comes through the fitting as shown Remove the old tube along with the double barb from the new tube Route the new site solder tube to the barb fitting on the filter jar as shown Attach the new tube to the bracket Verify the tube routing and re attach the nozzle heat shield ...