OPERATOR MANUAL Desk Top Series Model: DT-150 / 250 / 260 / 270 / 350 / 360 / 440 / 450-PH
Manufacturer:
UNITEK EAPRO Schootense Dreef 21 P.O. box 164 NL-5700 AD HELMOND The Netherlands Phone: +31 (0) 492 54 22 25 Fax: +31 (0) 492 53 62 22 www.unitekeapro.com
User manual specifications:
Date: 2003 Version: 1.1
The following documents are related to this manual:
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Register of changes Table 1: Register of changes
Page
Version
Date
Status
Remarks
All
1.0
Aug 2003
Release
User Manual Desktop system 69Z9998
22-23
1.1
Okt 2003
Update
Failure messages
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Preface This user manual describes the Desktop system. The information provided is very important for safe and correct functioning of the Desktop system. If you are not familiar with operating, maintenance etc. of the Desktop system, this manual should be studied well. In case the Desktop system is well known, this manual could be used as a reference. The easiest way to find the needed information quickly is to use the list of contents. In case of questions, remarks, suggestions etc. you can always contact us. To underline certain subjects or actions the following markings are used in the text.
INDICATION: Provides information to facilitate the execution of certain tasks.
NOTE: Provides advanced information with regard to possible problems
CAUTION: The system could be damaged if procedures are not followed carefully.
WARNING: You could hurt yourself or the system could be damaged if procedures are not followed carefully.
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© Copyright 2003 All rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without written consent of UNITEK EAPRO. This restriction also applies to the corresponding drawings and diagrams. UNITEK EAPRO has the right to change parts of the machine at any time without prior or direct notice to the client. The contents of this publication are subject to change without notice. For extra information as to adjustments, maintenance and repair, contact the technical department of your supplier. This user manual has been composed with great care. UNITEK EAPRO cannot be held responsible for possible shortcomings in this user manual or the consequences with regard to the shortcomings.
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Warnings on the Desktop system: To warn the user/owner of the Desktop system for certain dangers/risks several warning pictograms have been mounted on the Desktop system.
NOTE: Regularly check if all pictograms are still in place on the unit. If they are not, replace them as quick as possible.
Table 2: Pictograms on the Desktop system
Pictogram
Description
Position on the unit
Warning: Danger of short circuit as a result of simultaneously touching the two terminal clamps with electrically conductive material
On the transparent screening cap which is mounted over the terminal clamps of the power source
Warning: There is a risk at direct or indirect contact to live parts Access only for technically qualified persons
On the outside of the control cabinet. On the inside of control cabinet and connection boxes near by live parts
On the machine frame near by hot surfaces (thermode etc.)
Warning: There is a risk of burning by touching hot parts
Warning: There is a risk of getting clamp between moving parts
On the machine frame near by moving parts (thermode head etc.)
CE-mark:
Integrated on the machine type label, which is mounted on the frame (option)
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Contents 1
GENERAL SAFETY PRECAUTIONS
8
2
INTRODUCTION
9
2.1 2.2
9 11
3
4
5
6
7
8
GENERAL SPECIFICATIONS
SYSTEM CONSTRUCTION
12
3.1 3.2
12 14
GENERAL SAFETY MEASURES/DEVICES
INSTALLATION
16
4.1 4.1
16 16
TRANSPORTATION INSTALLATION
OPERATING THE DESKTOPSYSTEM
19
5.1 5.2 5.3 5.4 5.5
19 20 21 21 22
CONTROL PANELS PNEUMATIC CONTROL STARTING UP ENDING THE PRODUCTION CYCLE FAILURE MESSAGES
SYSTEM OPTIONS PER CATALOG
23
6.1 6.2 6.3 6.4 6.5 6.5
23 23 24 24 25 26
UNIBASE SYSTEMS UNISLIDE SYSTEMS WITH FRONT-REAR SLIDE UNISLIDE SYSTEMS WITH LEFT-RIGHT SLIDE UNI-SLIDE SYSTEMS WITH AUTOMATIC FRONT-REAR SLIDE UNI-TURN SYSTEMS WITH MANUAL ROTARY UNI-TURN SYSTEMS WITH AUTOMATIC ROTARY
MODULE OPTIONS PER CATALOG
27
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8
27 28 38 38 39 40 43 44
UNIFLOW POWER SOURCE BONDING HEAD THERMO-PLANE THERMODE QUICK CONNECT BLOCK OPTICAL ALIGNMENT MODULE INTERPOSER MODULE KAPTON FEEDER MODULE WATER COOLING MODULE
MAINTENANCE AND REPAIR
46
8.1 8.2 8.3
46 49 50
PREVENTIVE MAINTENANCE TECHNICAL MAINTENANCE SPARE PART LIST
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Tables: Table 1: Register of changes ........................................................................................................2 Table 2: Pictograms on the Desktop system ................................................................................5 Table 3: Technical specifications Desktop system .....................................................................11 Table 4: Uniflow settings control sheet .......................................................................................27 Table 5: Technical specifications bonding head .........................................................................28 Table 6: Maintenance daily .........................................................................................................47 Table 7: Maintenance weekly .....................................................................................................48 Table 8: Maintenance monthly....................................................................................................48 Table 9: Spare part list................................................................................................................50
Figures: Figure 1: Main components system front....................................................................................12 Figure 2: Main components system back ...................................................................................13 Figure 3: Warning pictograms packing material..........................................................................16 Figure 4: Thermode power cables ..............................................................................................17 Figure 5: Uniflow cables..............................................................................................................17 Figure 6: Main control panel .......................................................................................................19 Figure 7: Uniflow control panel ...................................................................................................19 Figure 8: Pneumatic speed controllers .......................................................................................20 Figure 9: Pneumatic handcontrol valves.....................................................................................20 Figure 10: Uniflow power source ................................................................................................27 Figure 11: Uniflow dipswitches ...................................................................................................27 Figure 12: Pneumatic bonding head 500 N ................................................................................28 Figure 13: Pneumatic bonding head 500 N details .....................................................................31 Figure 14: Pressure paper ..........................................................................................................32 Figure 15: Pneumatic bonding head 80 N details .......................................................................33 Figure 16: Force adjustment 80N head ......................................................................................34 Figure 17: Firing switch 80N head ..............................................................................................35 Figure 18: QCB & Thermode ......................................................................................................38 Figure 19: Main components QCB & Thermode .........................................................................38 Figure 20: Optical alignment module ..........................................................................................39 Figure 21: Manual Interposer module .........................................................................................40 Figure 22: Automatic Interposer module .....................................................................................41 Figure 23: Main components Interposer / Kapton module ..........................................................42 Figure 24: Water Cooling module ...............................................................................................44 Figure 25: Liquid specifications Water Cooling...........................................................................45
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1 GENERAL SAFETY PRECAUTIONS
WARNING: Read this manual carefully before taking any action with regard to the Desktop system. Your supplier has got no liability for injuries, damage and/or excessive wear, due to incorrect maintenance, unintended use, modifications or deactivation of safety devices.
WARNING: The Desktop system and its safety devices may not be extended, modified or changed without written permission from your supplier.
WARNING: It is forbidden to place the Desktop system in an explosive area.
NOTE: If the Desktop system is being used by a third party, you are responsible (being the owner/user) unless agreed otherwise.
WARNING: Disconnect the system from power supply before repair or maintenance of electrical circuit or its components. Do not remove covers yourself but contact a technical qualified person.
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2 INTRODUCTION 2.1GENERAL
Target The target group whom the system and this manual are applicable are competent persons and technical qualified persons, according to the definition below: Competent persons are persons who: • Have an adequate level of knowledge gained by training/education; • Have adequate skills necessary to operate the Desktop system. Technical qualified persons are persons who: • Are competent; • Have an adequate level of technical knowledge gained by training/education; • Are familiar with techniques in the unit; • Are aware of the possible risks (trained by "UNITEK EAPRO" personnel).
WARNING: Installation, technical maintenance, repair and (de)mounting may only be done by technical qualified persons, unless specified otherwise.
Operating the Desktop system contains: • Controlling the machine • Cleaning the unit • Simple maintenance operations Purpose of this user manual is to create a safe and an efficient interaction between man and system.
Intended use The Desktop system is a desk top system for manual (un-)loading of the parts with a fully automatic process control. The system can be used for Hot-Bar Reflow soldering, Heat-Seal Bonding, ACF laminating and ACF Bonding as well. The system is developed for joining various product components. The conditions are described in this user manual. Using the system in a different way then the intended use will exclude liability of the supplier.
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Operating principle The system is a Desk-top system and is built up on a chassis with integrated controls. The machine operator is responsible for the manual positioning of the product components. The alignment of the product components is done in a fixture (by means of a micrometer screw, one or more dowel pins and/or a camera-monitor system (optional). After having positioned the product components, the system can be operated by means of the start button(s). The joining cycle will be executed now. After having executed the joining cycle, the joined product can be taken out of the fixture. The joining cycle is defined as follows: The thermode is moved down pneumatically (Z-axis) and heated until the preset temperature has been reached. The joining operation is carried out with a constant thermode temperature. When the preset time has passed, the thermode will be cooled down by forced air cooling until the lift off temperature has been reached. The thermode will move upwards again. The Uniflow scedule is activated and the system is ready for the next joining cycle. The principle of the Desktop system is based on joining the several product components by means of a controlled movement of the thermode, thus creating a known, force at a preset temperature and time.
Noise level The sound level has been measured according to the Machine Directive requirements. The A-weighted equivalent continues sound pressure has been measured on the working place during normal operating conditions. The noise level has been measured on a distance one metre from the machine and at a height of 1,60 m above the reference plane. The measured A-weighted equivalent continuous sound pressure level (LAeq) will not exceed 70 dB(A).
Requirements for the surroundings Generally the equipment requires no special foundation; a level concrete table is sufficient. During production, the machine and the near surroundings must be illuminated well.
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2.2SPECIFICATIONS
Table 3: Technical specifications
General Weight Joining system Dimensions Joining system: Depth Width Height Weight Uniflow power source Dimensions Uniflow power source: Depth Width Height Maximum fixture height Gantry open width Fixture assembly base plate Starting operation Operating temperature Operating humidity
40 kg / 88 Lbs 600 mm / 23.62 Inch 550 mm / 21.65 Inch 510 mm / 20.04 Inch 26.31 kg / 58 Lbs 319 mm / 12.6 Inch 246 mm / 9.7 Inch 411 mm / 16.2 inch 80 mm / 3.15 Inch 520 mm / 20.47 Inch 160x160 mm / 6.30x6.30 Inch Two hand control 15-40 °C / 60-104 °F 93%@40 °C / 93%@104 °F
Connection requirements Input voltage Main fuse Compressed air required
115 Vac, 60 Hz, 1-Phase / earth / zero or 230 Vac, 50 Hz, 1-Phase / earth / zero 16 A max, type delay fuse 6 bar, dry & filtered air
Machine data Maximum current Nominal power Control voltage, internal
16 A 3,5 kW (230V) or 7,5 kW (115V) 24 V, supplied by the transformer (option)
Optional
See system specifications (chapter 6)
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3 SYSTEM CONSTRUCTION 3.1GENERAL The system is divided in several parts. The main components of the Desktop system are pointed out in figure 1 and 2.
Figure 1: Main components system front
1. 2. 3. 4. 5. 6. 7.
Pneumatic head Portal Quick Connect Block & Thermode Base plate & Fixture (option) Control panel Uniflow power source Safety cover power cables
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Figure 2: Main components system back
1. 2. 3. 4. 5. 6. 7. 8.
Warning pictogram 230Vac or 115Vac Power connector 230Vac or 115Vac Uniflow data cables Weld power cable CE mark (option) / model-serial number Weld power cable Pneumatic connectors Head / system cables
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3.2SAFETY MEASURES/DEVICES
Hot parts When touching the thermode there is a real danger of burning injuries. The temperature of the thermode can rise until 600 ºC. The thermode area has been shielded (option). Additional warning pictograms have been placed on the head guarding, warning you for this risk.
Electrical safety
DANGER: Control cabinet and connection boxes may only be opened by technical qualified persons.
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The Desktop system can be isolated from the power supply by means of the black main switch which is mounted at the rear of the system (option). The Uniflow power source can be isolated from the power supply by means of the white main switch which is mounted at the rear of the Uniflow power source.
Emergency stop The Desktop system is equipped with one emergency stop push button which is mounted on the front of the machine. Activation of the emergency stop button will stop all machine movements. Power supply and compressed air will be removed from certain parts of the machine immediately.
WARNING: If the head is in the down position, it will move upwards!
Ergonomics To achieve an efficient and safe interaction with the working equipment, ergonomic principles, as well as technical safety requirements have been taken into account during the design process. Because of the operator being present in the working area constantly the control panel has been mounted and designed so that the working system is consistent with human capabilities. Attention has also been paid to designing the control system of the machine as clear and obvious as possible.
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4 INSTALLATION 4.1TRANSPORTATION The system can be transported manually (by two persons), after having disconnected the separate units. CAUTION: Transportation and handling the DESKTOPsystem must be carried out carefully to avoid any damage.
The Desktop system will arrive in a box. This packaging should be opened carefully. Please follow the next steps to allow for save removal of the system from the shipping crate.
Figure 3: Warning pictograms packing material
4.2GENERAL In this paragraph you are instructed about installing and adjusting the Desktop system. WARNING Installation and adjustment of the Desktop system may only be done by a technical qualified person.
WARNING: The unit may only be operated if all components are completely and correctly installed.
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1. Unpack the unit: • Remove packaging materials • Remove “tie-rap” from the head • Check the unit for possible damage • If any damage is established, contact your supplier 2. Check the location. Place the machine on a level surface and locate the units orderly. 3. Connect the Uniflow power source to the system (see figure 4 and 5 for details). NOTE: Power cables cover is optional
Figure 4:Thermode power cables 1. J4B firing switch / emergency stop / safety switch 2. J4A inposition sensor / start switches 3. J6B Z-axis valve / cool valve 4. Fan 5. J9 thermocouple connector type K 6. Main switch 7. 115 /230 Vac input connection
Figure 5: Uniflow cables
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4. Before connecting the unit, check if voltage and frequency given on the type label of the unit are in accordance with the local power supply values. Connect the Desktop system to the electrical power. The unit requires a 115 Vac 60Hz or 230 Vac 50 Hz 1-Phase power supply with an earth- and zero connection; the supply must be protected with fuses. 5. Connect the unit to the compressed air system. The connection is located at the rear of the Desktop system. Make sure the unit is supplied with constant dry, clean air (min. 6 bar). A shut off valve must be used to isolate the Desktop system from the compressed air system. 6. Start up with reduced settings of the Uniflow power source to prevent unexpected fast heating or burning of the thermodes. Then go to the recommended settings.
INDICATION: Find a place for this manual, in such a way, that it is within reach when operating the unit.
Having completed the installation of the unit, all the employees concerned have to be trained by the installer with regard to construction, supervision, functioning, maintenance, safety measures and specifications. This training must be based upon this user manual.
CAUTION: In case of reinstallation to another place, all safety measures described in this chapter have to be taken into account.
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5 OPERATING THE DESKTOP SYSTEM Before the Desktop system is operated, it must first be installed and adjusted according to chapter 4. 5.1 CONTROL PANELS Main control panel
Figure 6: Main control panel
1. 2. 3. 4. 5.
Left button two-hand control Indicator ‘power on’ (option; only available with power supply) ‘Reset’ button & ‘Error’ Indicator (option; only available with PLC) Emergency stop switch Right button two-hand control
Uniflow power source control panel This control panel is meant to enter and readout parameters for the joining characteristics. (specific temperature time cycle). For further details see manual Uniflow power source.
Figure 7: Uniflow control panel
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5.2 PNEUMATIC CONTROL 1. Speed controller Cooling air 2. Speed controller Head up 3. Speed controller Head down
Figure 8 : Pneumatic speed controllers
INDICATION: Press the orange switches on the valves to manual activate air pressure
1. Hand control Cooling valve 2. Hand control Head valve
Figure 9 : Pneumatic handcontrol valves
WARNING: Operating the joining system may only be done by a competent person. Adjustment and fault analysis may only be done by technical qualified person.
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5.3STARTING UP The Desktop system is operated in combination with a one-, or two-hand control. 1. Put the black main switch at the rear of the system on position ‘1’ / upwards (option). 2. Check if the emergency stop is deactivated. If not, deactivate it by rotating it counter-clockwise. 3. Put the main power switch of the Uniflow power source on ‘1’ (white switch at rear of the Uniflow to upwards position). The power supply of the Uniflow power source is switched on now, and will start it’s initialisation cycle. 4. Clean the parts to be connected. 5. Position the parts to be connected in the fixture (option). 6. Align the parts accurately by means of the camera monitor system and/or the micrometer screw (option). 7. Activate vacuum switch of fixture (option). 8. Press the one-, or two-hand control to start the joining cycle. 9. After the joining cycle is ended, remove the joined product. 10. Repeat step 4 up to 9 for the next product. 5.4 ENDING THE PRODUCTION CYCLE 1. Press the emergency stop button. 2. Put the black main switch at the rear of the system on position ‘0’ / downwards (option). 3. Put the main switch at the rear of the Uniflow power source on position ‘0’ / downwards.
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5.5 FAILURE MESSAGES
NOTE: Failure messages only available by PLC systems. Failure messages can be checked if red light blinks by pressing the two-hand control. The two-hand control must be pressed for a few seconds till error lamp stops blinking. See column “ERROR” for numbers of blinking. EMERGENCY STOP ERROR 1x 2x
DESCRIPTION Operator has pressed the emergency stop button. Emergency stop, slide or turntable not in position during process.
CHECK Emergency stop Slide or turntable
HEAD / UNIFLOW ERROR 3x
DESCRIPTION Uniflow is not responding within 2 seconds after start signal.
CHECK • Working fire-switch • Z-movement head • Wiring / connectors Uniflow
4x 5x
Uniflow error. Head not at home position. Head must be in home position after process within 2 seconds.
• • •
See Uniflow manual Working home switch Z-movement head
SLIDE 2 POSITIONS ERROR 6x
DESCRIPTION Time-out slide. Slide must be in position within 5 seconds.
CHECK • Air pressure • Working slide
SLIDE 3 POSITIONS ERROR 6x 7x
DESCRIPTION Time-out slide. Slide must be in position within 5 seconds. Illegal sensor state slide. Sensors are activated simultaneously.
CHECK • Air pressure • Working slide • Working position sensors
TURNTABLE ERROR 6x 7x
DESCRIPTION Time-out turntable. Turntable must be in position within 5 seconds. Illegal sensor state turntable. Sensors are activated simultaneously.
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CHECK • Air pressure • Working turntable •
Working position sensors
‘DESKTOP’ SYSTEM
6 SYSTEM OPTIONS PER CATALOG 6.1 Uni-Base systems with no movement DT-150-PH: SH500, Uniflow With the model 150, parts need to be positioned directly beneath the hot-bar (thermode). It is equipped with an anodised aluminum base plate that has a hole – pattern drilled and tapped into it. This hole pattern accepts a fixture base plate. The fixture base plate has dimensions of 160 x 160 mm. It is mounted with bolts, and references on dowel pins.
6.2 Uni-Slide systems with manual front-rear slide DT-250-PH: SH500, Uniflow, 2-position manual slide DT-260-PH: SH500, Uniflow, 3-position manual slide The slide makes loading and (un-) loading the parts easy. When parts need to be aligned, a slide is normally used to load and align the parts in the front position. The rear position is then used to bond the parts. By having two positions for these two actions, operator safety and ergonomics is increased. At the same time ideal camera positioning can be guaranteed.
•
The model 250 offers two positions, one for loading / unloading / alignment, the second one for the bonding process.
•
The model 260 offers three positions. One positions is still for loading, unloading and alignment. The other two are two bonding positions.
A thumb - operated lever unlocks the slide to go to the next position. When the right position is reached, the slide automatically locks into place. This ensures an accurate
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and fast positioning.
For safety reasons, a sensor checks if the slide is in the correct position for the bonding process. Only then the process cycle can be started with the two - hand control. In case there are two bonding positions, two separate sensors are mounted. With these two sensors, independent process settings for both bonding positions can be automatically recalled.
6.3 Uni-Slide systems with left-right slide DT-270-PH: SH500, Uniflow, 2-position manual slide The left/right slide makes it possible to load and unload parts in one position while the bonding process is taking place in the other position. This increases (almost doubles) the output of the slide system. When the right position is reached, the slide automatically locks into place. This ensures an accurate and fast positioning. For safety reasons, a sensor checks if the slide is in the correct position for the bonding process. Only then the process cycle can be started with the two - hand control. Two separate sensors are mounted. With these two sensors, independent process settings for both bonding positions can be automatically recalled.
6.4 Uni-Slide systems with automatic front-rear slide DT-350-PH: SH500, Uniflow, 2-position pneumatic slide DT-360-PH: SH500, Uniflow, 3-position pneumatic slide
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The automatic slide makes loading and (un-) loading the parts easy. When parts need to be aligned, a slide is normally used to load and align the parts in the front position. The rear position is then used to bond the parts. By having two positions for these two actions, operator safety and ergonomics is increased. At the same time ideal camera positioning can be guaranteed. The model 350 offers two positions, one for loading / unloading / alignment, the second one for the bonding process. The model 360 offers three positions. One positions is still for loading, unloading and alignment. The other two are two bonding positions. The system will automatically move from the first to the second bonding position. Compared to a manual operated system this saves operator time. For safety reasons, a sensor checks if the slide is in the correct position for the bonding process. Only then the process cycle will be started. In case there are two bonding positions, two separate sensors are mounted. With these two sensors, independent process settings for both bonding positions can be automatically recalled. 6.5 Uni-Turn systems with manual rotary DT-440-PH: SH500, Uniflow, manual rotary
The manual rotary table makes loading and (un-) loading the parts easy. When parts need to be aligned, a rotary table is normally used to load and align the parts in the
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front position. The rear position is then used to bond the parts. By having two positions for these two actions, operator safety and ergonomics is increased. At the same time ideal camera positioning can be guaranteed. The rotary table has two positions. For safety reasons, a sensor checks if the table is in the correct position for the bonding process. Only then the process cycle will be started. The position repeatability is accurate within hundredths of a millimetre. This high accuracy level is obtained though the use of a high qualitative guiding. Both bonding positions have a fine adjustment possibility to position the hot-bar (thermode) exactly above the bonding area. The rotary table is supported in the bonding position. This ensures optimum co-planarity and offers the best bonding quality. The turntable moves from one to the other position by manual rotation. The table is locked in each bonding position in an accurate way. 6.6 Uni-Turn systems with automatic rotary DT-450-PH: SH500, Uniflow, PLC controlled pneumatic rotary
The automatic rotary table makes loading and (un-) loading the parts easy. When parts need to be aligned, a rotary table is normally used to load and align the parts in the front position. The rear position is then used to bond the parts. By having two positions for these two actions, operator safety and ergonomics is increased. At the same time ideal camera positioning can be guaranteed. The rotary table has two positions. For safety reasons, a sensor checks if the slide is in the correct position for the bonding process. Only then the process cycle will be started. The position repeatability is accurate within hundredths of a millimetre. This high accuracy level is obtained though the use of a high qualitative guiding. Both bonding positions have a fine adjustment possibility to position the hot-bar (thermode) exactly above the bonding area. The rotary table is supported in the bonding position. This ensures optimum co-planarity and offers the best bonding quality. The turntable will move from one to the other position in less then one second in a controlled and accurate way.
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7 MODULE OPTIONS PER CATALOG 7.1 Uniflow power source The power for heating up the thermode is provided by a micro-processor controlled Uniflow power source. This power supply is specifically designed for pulse -heated Hot-Bar Reflow Soldering, Heat-Seal Bonding, ACF laminating and ACF bonding processes. Joining characteristics meant for a certain product can be defined in joining schedules. The cycle will be carried out completely or partly when interrupted by manual or automatic generated error messages.
Figure 10: Uniflow power source
CAUTION: Remove Uniflow cover and change dipswitches 1 to 4 from ‘AC’ to ‘DC’ see figure 11 Table 4: Uniflow settings control sheet
Not for PLC systems! 1 HARDWARE SETUP HEAD COOL VALVE SOLDER COOL VALVE FOOTSWITCH RESPONSE MODE FOOTSWITCH RESPONSE TIME LIST OF HARDWARE THERMOCOUPLE TYPE DISPLAY CONTRAST BUZZER LOUDNESS END OF CYCLE BUZZER FREQUENCY DETECTION
OFF ON ABORT 10mS Auto Recognized AUTO 50% 80% ON AUTO
SET OUTPUTS RELAYS Relay 1 Relay 2 Relay 3 Relay 4
NC System Ready NC Alarm NC Reflow Not active
INPUT SWITCH SELECT CONTROL SIGN. SELECT
MECH OPEN MECH OPEN
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Figure 11 : Uniflow dipswitches
‘DESKTOP’ SYSTEM
2 COMMUNICATION COMMUNICATION ROLE BAUD RATE ID NUMBER
SLAVE 9600 0
3 REFLOW SETUP PREHEAT IS ALWAYS UPPER TEMPERATURE LIMIT LOWER TEMPERATURE LIMIT AUTOSCALING FEATURE SET SAFETY TIMER (SEC) SET RELEASE TIMER (SEC) MAX TEMPERATURE LIMIT (°C) MAX IDLE TEMPERATURE (°C)
TIMED +50 -50 OFF 10 00 600 NONE
7.2 Bonding head
The bonding head has an adjustment range of 80 mm in height. The bonding head can be adjusted sideways over the full width of the gantry.
The bonding head: • Provides the movement of the thermode (Z-direction) • Ensures determined for the co-planparallelity of the bottom of the thermode Figure 12: Pneumatic Bonding • Provides the building up of the joining-pressure Head 500N There are two options of the pneumatic bonding head: 80N and 500N.
NOTE: Force is fixed to required pressure. Changing height of product and / or target level will change this force! Technical specifications Table 5: Technical specifications bonding head
General Force range standard head Force range light force head Hot bar stroke Force accuracy Force repeatability Actuation type Force generation
30-500 N / 7-112 Lb / 3-51 KgF @ 6 Bar (88.2 Psi) 8-80 N / 2-18 Lb / 0.8-8 KgF @ 6 Bar (88.2 Psi) 25.0 mm / .98 Inch ±2% or ±2 N / .44 Lbs, whichever is greater ±1% or ±1 N / .22 Lbs, whichever is greater Pneumatic Pre-tensioned spring
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500 N head Adjustment of the parallelism between fixture and thermode The adjustment of the paralellity consists of two adjustments: 1. Coarse adjustment > 250 micron 2. Fine adjustment < 250 micron
NOTE: Both adjustments are completely different and therefore they should always be carried out in the order of first the Coarse and then the Fine adjustment.
Coarse adjustment: Course adjustment is carried out by moving the base plate of the head. This means, that with this adjustment is possible to move the base plate in three axis: 1. Horizontally e.g. Head position in X-axis 2. Vertically e.g. Head position in Z-axis; re-calibration of the force might be necessary 3. Rotation e.g. Head adjustment in X-Z axis (parallel adjustment) 1. Mark the old position on the support if possible. 2. Adjust the side support plates into the middle of their adjustment limits (see Fine adjustment) 3. Loosen the four screws that clamps the base plate onto the head support. 4. Use a steel bar and spacers to get the base plate at the correct distance from the working table. (Since the table top at the factory is used as a reference, you may also use this as a reference.) 5. Carefully tighten the fixing screws one by one repeatedly, every time using more force until the base plate is firmly tightened to the support column (Use X selection of the screws to tighten them). 6. Check if the X position is still correct; if not repeat step 3 to 6 until satisfied. 7. Coarse positioning is done; now proceed with Fine adjustment.
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Fine adjustment: Fine adjustment is done by moving one of the side plates very carefully by means of adjustment screws 1. Remove cap from the pneumatic head. 2. Remove air pressure from the system. 3. Select only the left side plate and use only this one during the adjustment procedure! 4. Fasten firmly the not used right side plate to the frame. 5. Press by hand the pneumatic shaft until thermode nearly reaches the fixture. 6. Put on each side of the product support (of the fixture) a strip of pressure paper 67W0003 / 67W0023. 7. Move the head by hand down until it presses on the paper strips. 8. Determine on which side the paper strip clamps by pulling them one by one. • When on the left side the paper clamps, move left plate Up by loosening first the top screw; then fasten the bottom screw. • When on the right side the paper clamps, move left plate Down by loosening first the bottom screw; then fasten the top screw. • Check the clamp force of the paper strips on both sides. If they are equal go to the next step. CAUTION: The adjustment screws should always clamp the side plate in position before checking the clamp force! 9. Remove the paper strips and replace them with a piece of pressure sensitive paper. 10. Make a print on the pressure sensitive paper and check for equal coloration of the print. 11. If one side of the print is darker then he other side move the side plate: • At the darkest position Up by loosening first the top screw; then fasten the bottom screw • At the lightest Down by loosening first the bottom screw; then fasten the top screw • Adjust until the coloration is equal. Every time use a new piece of pressure sensitive paper • If the coloration is equal, the parallelity of thermode and support will be less then 2 micron.
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12. Tighten the three side plate screws and the adjustment screws ( in this order) carefully. CAUTION: length end stop Do not overTravel tighten! (adjustable)
Spring holder/travel length stopper 13. Re-check paralellity with pressure sensitive paper; if some misalignment is present, (fixed length) loosen the side plate screws very carefully (they should clamp slightly) and repeat from step 8.
500 N head Locknut Spring holder/travel length stopper spacer (fixed length)
Firing switch Travel length stopper adjustment Firing switch actuator pin ring Travel Firing length switch stopper actuatorblock bar (application dependant)
Pre-set mechanism Air cylinderof the Force Spring
Force spring pre-set mechanism lock
Quick Connect Block
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Figure 13: Pneumatic Bonding Head 500N details
Examples of alignments with the use of pressure sensitive paper
NOTE: Optional for 500 N head only!
Poor ; turn OUT A ; turn IN B
A
GOOD ; No adjustments necessary
Poor ; turn OUT B ; turn IN A
B Figure 14: Pressure paper
Thermode
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80 N head
mechanical stop adjuster locknut
mechanical stop adjuster
pneumatic cylinder
force adjustment system
upper locknuts force adjustment firing switch Movable block “A” firing switch actuator
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lower locknuts force adjustment force spring
‘DESKTOP’ SYSTEM
force pre-set shaft
Force adjustment of the 80N head: It is important to understand the movements in the head before you made an attempt to adjust the work force of the thermode/head. The system consists of three parts: The cylinder piston and the movable blocks A and B. Block A and B will follow eachothers movements as long as they run freely. Block A can only be stopped by the mechanical stop adjuster. To block B the thermode is mounted and can only be stopped by the thermode which hits your product. As soon block B reaches a stop (e.g. your product surface) and block A is still moving, the spring is depressed (therfore building up force)until the mechanical stop adjuster blocks the movement. If we reduce the distance between block A and block B by means of the locknuts [upper and lower locknuts force adjustment] of the [force pre-set shaft] we pre-tention the spring thus giving a pre-force setting. So if we start the cycle now, the thermode moves down until it hits the product; the force on the product is equal to the pre-set force of the spring. force spring : no tention
force spring with pre-tention
Figure 16: Force adjustment 80N head
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Now the firing switch gets important. The function of the firing switch is to start the heating process. However, when it starts, the force on the product should be stable, e.g. NO movements should take place. The switch has a very small operating area around 1 mm (0.04 inch) and therefore we let block B go down just 1mm more and then we block the movement by the [mechanical stop adjuster]. Firing switch in normal position
Firing switch in actuated position
firing switch
1 mm / 0,04 inch
firing switch actuator lever
Figure 17: Firing switch 80N head
This will activate the switch, stop all movements and the heating process starts. Since all build up force is related to movements, it is extremely important that; if you measure the force for calibration, the tophight of calibration device is at exact the same hightlevel as (the fixture hight + pcb thickness+foil thickness) to avoid missreadings and / or wrong adjustments.
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Relation between movements in this system
The force is determent by the preset spring tension and the distance of travel necessary to activate the firing switch and creation of a safe working area. Formula : F = F0 + (dZ1xC) + (dZ2xC)
HOME
where : F : force on product F0 : pre-set spring force C : spring constant dZ1 : distance of travel (mm) to activate the firing switch dZ2 : distance of travel (mm)
Thermode on product! firing switch activated Safety travel distance
FORCE LEVEL
F0 F=F0+(dZ1xC) F=F0+(dZ1xC)+(dZ2xC)
Air pressure is ONLY used to reach and hold force level; compression of the spring at acceptable speed. Up / down speed is regulated by airbleeder regulators on valves or pneumatic cylinder in the control box.
spring force curve
Spring is completely depressed overload of spring occurs
14 12 10 8
spring force curve
6 4 2
Working Area
17
15
13
11
9
7
5
3
1
0
Working Area
DANGER
Lineair part of spring characteristic
Spring deformation Non lineair area
Avoid this non lineair area
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WARNING: Compressed air is capable to move the aircylinder shaft with force; keep fingers clear from parts in move!! How to adjust the working force on your system:
1. 2. 3. 4. 5. 6. 7. 8. 9.
Switch the generator OFF Remove air pressure from your system Remove front cover of the head Place a product into the fixture Loosen the [mechanical stop adjuster locknut] Press down the [mechanical stop adjuster] until the thermode hits the product. By turning the [mechanical stop adjuster] set the mechanical stop position. Repeat step 5 and 6 until the mechanical stop is correct befor proceed to the next step. Replace complete fixture by a force sensing device. Align it properly e.g. straight under the thermode. Note: measuring level must be equal to : fixture hight + pcb thickness + foil thickness. 10. Unlock the [lower locknuts force adjustment] and turn them max down. 11. Unlock the [upper locknuts force adjustment] and turn them max up. 12. Apply air pressure to the system 13. Manually operate (and hold when needed) the head-up/head-down airvalve in the control box(**). Watch the themode goes down until it reaches the mechanical stop. (set by [mechanical stop adjuster]) 14. Turn the [mechanical stop adjuster] Count Clock Wise until the desired force is reached. 15. Lock the [mechanical stop adjuster] with the [mechanical stop adjuster locknut] firmly. 16. Put a 1mm spacer between [Movable block “A”] and [firing switch actuator] 17. Turn the [upper locknuts force adjustment] until they hit the[firing switch actuator] ; tighten 18. Remove the spacer between [Movable block “A”] and [firing switch actuatorTurn the [lower locknuts force adjustment] until they hit the[firing switch actuator] ; tighten Note : ]; check for the 1mm spacer…it should fit smoothly; not clamp! 19. Move head up/down by actuating the airvalve to check for the correct force. 20. If not correct; unlock the [mechanical stop adjuster locknut] and goto step 14. 21. End of procedure.
NOTE: Do not forget to replace all covers!
(**) • •
Open the control box (6 screws on top side) locate the airvalves close to air input side (one is cooling; one is head-up/down) • operate manually (e.g. press in) the head-up/head-down valve actuator, e.g. the orange button on top. press in : head down release : head up • Close box after procedure
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7.3 Thermo-Plane thermode The thermode is heated by means of a controlled PWM (phase with modulated) output of a Uniflow power source. The maximum stroke of the thermode in vertical direction is 25 mm. Position repeatability of the thermode in X-Y direction is within hundredths of a millimetre.
Figure 18 : QCB & Thermode
7.4 Quick Connect Block The connection of the Thermo-Plane Thermode of the bonding head is achieved by using a Quick Connect Block (QCB), which is mounted to the bottom of the bonding head. The special shaft of the screws guarantees the position reproducibility of the thermode. Standard size options of a QCB to support the corresponding thermodes: • QCB 50 up to 50 mm thermode length • QCB 100 up to 100 mm thermode length • QCB 150 100 up to 150 mm thermode length NOTE: Use a QCB and thermode as a set!
Figure 19: Main components QCB & Thermode
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1. 2. 3. 4. 5. 6. 7.
Quick Connect Block Thermo-couple cables pull relief Thermode Power cables screws (2x) Insulating bush (2x) Thermode screws (number of screws depend on length thermode) Quick Connect Block screws (2x)
NOTE: Loosen the welding cable screws (pos 4) and QCB screws (pos 7) is enough to remove the Quick Connect Block 7.5 Optical Alignment Module The optical alignment module allows the user to examine and position parts before and after heating / bonding process. The camera can be either B&W or colour and it is also possible to have a dual optical alignment module, with two camera’s en two monitors.
Figure 20: Optical alignment module (example)
Standard camera’s: • Black & White camera • Colour camera Standard monitors / TFT screens: • Black & White monitor • Colour monitor • 6" TFT colour screen For further details see manual camera and monitor.
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7.6 Interposer Module
WARNING: Installation, technical maintenance, repair and (de)mounting Of the Interposer may only be done by technical qualified persons, unless specified otherwise. NOTE: The Interposer is NOT needed for soldering!
Interposer (Interlayer) can be used between the hot-bar (thermode) and the products. This is common practice for heats-seal and ACF Bonding. The Interposer is normally an aluminum oxide filled silicon rubber tape, 5 mm wide, 0.45 mm thick and 10 meter long. The module consists of two reels (spools). One spool holds a full spool of Interposer, the other one is used for winding the used interposer. The module connects to each standard quick connect block. The Interposer is pulled loose from the hot-bar to prevent it being squashed to one side by the repeated squashing. The tension on the Interposer is being kept constant by a spring-operated lever. The interposer has several functions: 1. It protects the hot-bar (thermode) against glass splinters. 2. On the PCB side it forces the adhesive in between the tracks, making a stronger mechanical connection from the flex to the PCB. 3. The Interposer is flexible, and events out small flatness imperfections that can be present in the parts.
There are two options of the Interposer module: Manual: The interposer material needs to be manually transported by the operator.
Figure 21: Manual Interposer module
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To refresh the tape proceed as follows: 1. Loosen the two locking screws (2) in front of the Interposer mounting blocks. 2. Lead the tape through the reels (left to right) until an unused piece of tape is positioned underneath the thermode (6). 3. Fasten the two locking screws in front of the interposer mounting blocks.
NOTE: The Interposer must be refreshed regularly. Periodically, for example twice a day, lead the tape through the reels over a distance, equal to the thermode width.
Automatic: After a programmable number of cycles, electrical motors automatically transport a programmable length of interposer. This length is normally equal or slightly more then the length of the hot-bar.
Figure 22: Automatic Interposer module
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Figure 23 : Main components Interposer / Kapton module
1. 2. 3. 4. 5. 6.
Reel Locking screw Mounting block Conductor reel Interposer tape Thermode
NOTE: Check if the control current is switched off. If not press the emergency stop. Air pressure will be shut off now (so the tape can be lead through the stepper-unit).
NOTE: The tape must unwind when turning the wheel anticlockwise.
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7.7 Kapton Feeder Module
NOTE: The Kapton Feeder is optional for soldering only!
A Kapton Interposer can be used to prevent pollution between the hot-bar (thermode) and the products. The Kapton has 25 microns thickness, 5 mm width and is supplied on reels holding 200 meters. The module consists of two reels (spools). One spool holds a full reel of Kapton, the other one is used for winding the used Kapton After each soldering cycle, electrical motors automatically transport a programmable length of Kapton. This length is normally equal or slightly more then the length of the hot-bar. The module connects to each standard quick connect block. The Kapton is pulled loose from the hot-bar to enable transportation. The tension on the Kapton is being kept constant by a spring-operated lever.
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7.8 Water Cooling Module A water cooling module can be used if the hot-bar (thermode) can not be cooled by air.
1. Motor 230 Vac / 50 Hz 2. Coolant OUT tubing Pun 8x1,25 3. Coolant IN tubing Pun 8x1,25 4. Coolant reservoir 5. Grasp (2x)
Figure 24: Water Cooling module
For further details see coolant data sheet:
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Figure 25: Liquid specifications
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8 MAINTENANCE AND REPAIR 8.1PREVENTIVE MAINTENANCE Regularly preventive maintenance according to the maintenance instructions is essential for keeping the performance of the system at high level. Doing so will prevent failures and breakdowns. CAUTION: Do not replace parts yourself. Parts replacement can only be done by a technical qualified person.
WARNING: Preventive maintenance may only be done by competent persons.
The Desktop system has no parts that need service / adjustment / lubrication during normal operation. Cleaning and preventive checks though could identify and prevent possible problems.
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Table 6: Technical Maintenance daily
Item
Maintenance
Action
Fixture (optional)
- Clean dust parts:
- Use damp cloth / compressed air
Thermode
- Remove contamination: - Check plan parallelism:
- Thermode cleaning module 61W0002; - Polishing disk 69C0000 Use pressure paper 67W0003 or use low pressure paper; 67W0023
Control box
- Clean dust parts:
- Disconnect system from power supply; - Use clean cloth (& tweezer).
Thermode head
- Clean dust parts:
- Disconnect system from power supply; - Use damp cloth
Power supply
- Clean dust parts:
- Disconnect system from power supply; - Use damp cloth
Emergency control system
- Check if system is disconnect from power supply in case of an emergency stop activation:
- Press all emergency stop push buttons in sequence.
Camera (optional) - Lens
- Clean surface:
- Don’t use a dry cloth or a piece of paper (scratches); - Blow against the lens and clean it softly by means of a special lens cloth. - Correct the position of the camera.
- Position
Monitor (optional)
- Check if the joining process is clearly visible in the centre (of the monitor): - Clean dust parts:
- Use damp cloth; - Never use strong solvents like thinner or benzine.
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Table 7: Technical Maintenance weekly
Item
Parts
Action/maintenance
Electrical cables and wiring
- Clean dust parts:
- Disconnect system from power supply; - Use clean cloth / clear water. - Disconnect system from power supply:
- Check: - weak connections: - bad fuses: - error messages:
- Make new / better connection. - Replace fuse. - Consult user’s manual.
Sensors - Position
- Check sealing:
- Disconnect system from compressed air supply; - Use appropriate tools.
- Mechanical functions
- Bad connection:
- Use clean cloth / compressed air.
- Clean dust parts:
- Use compressed air, clean cloth, lubricants or clear water(?). - Use lubricants to grease (check slide & bearing specifications!)
Slides & bearings
- Rust: Mechanical connections
- Check all mechanical connections on the system:
- Use appropriate tools.
Performance
- Check positions and settings
- Consult: - setting parameters power source; - table parameter list power source - machine parameter list; - machine calibration data
Table 8: Technical Maintenance monthly
Item
Parts
Action/maintenance
Calibration
- Force calibration:
- Use load cell 67W000-0-1-2; - Consult user’s manual.
- Temperature calibration: - Check plane parallelism thermode:
- Use readout 67W0007 / 67W0008; - Consult user’s manual. Use pressure paper 67W0003 or use low pressure paper 67W0023 - Consult user’s manual.
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8.2TECHNICAL MAINTENANCE
WARNING: Installation, technical maintenance, repair and (de)mounting may only be done by technical qualified persons, unless specified otherwise.
Call UNITEK EAPRO At all times the first attempt at solving the problems will be by telephone with a UNITEK EAPRO authorised person. We have highly qualified technicians who can help you to solve your problem. Contact UNITEK EAPRO help desk for maintenance activities. Conditions will be quoted after receipt of information or requirements.
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8.3 SPARE PART LIST
Table 9: Spare part list
RECOMMENDED SPARE PART LIST Model number: Serial number:
Qty
xxXxxxx xxxxxxx
Ordering
Part
Supplier
Pos.
Code
Description
Code
No.
1 30B0508 # 1 30B0509 # 1 69G0000 1 69H0500-037 1 69H0501 # 1 69H0801 # 1 69Q0001 1 69T # 1 69Z9998 2 96W0002 1 96Y0004 2 96Y0022 1 96Y0023 # 1 97H0000 1 97K0001 1 97S0100 1 97S0101 1 97X0100
Uniflow 240 V Uniflow 120 V Cable protection cover Linear Slide + Bearing Air actuated Head 500N Air actuated Head 80N QCB + Thermode
