AirVac ONYX29 User manual

ONYX29
User Manual #0029.00.900
Series 7, Revision 2.0
High Performance Automation Rework

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TABLE OF CONTENTS
1 COPYRIGHT ..................................................................................................................................................... 7
2 TERMS OF DELIVERY ..................................................................................................................................... 9
3 DECLARATION OF CONFORMITY ............................................................................................................... 11
4 INTRODUCTION ............................................................................................................................................. 13
4.1 WELCOME ................................................................................................................................................ 13
4.2 DESIGNATED USE OF THE MACHINE ............................................................................................................ 14
5 GENERAL SAFETY INSTRUCTIONS ........................................................................................................... 15
5.1 BASIC SAFETY INSTRUCTIONS ................................................................................................................... 15
5.2 MACHINE WARNING LABELS ...................................................................................................................... 17
5.3 AIRBORNE NOISE EMITTED ........................................................................................................................ 19
6 SPECIFICATIONS .......................................................................................................................................... 21
6.1 GENERAL SPECIFICATIONS ........................................................................................................................ 22
7 SEMI-AUTOMATED SOLDERING SYSTEM ................................................................................................. 23
7.1 HIGH END PLATFORM ................................................................................................................................ 23
7.2 PRECISION FORCE SENSOR TABLE ............................................................................................................. 23
7.3 MANUALMOTION ....................................................................................................................................... 23
7.4 INTERFACE FOR PREHEATER PORTS .......................................................................................................... 24
7.5 THERMO COUPLE MODULES ...................................................................................................................... 24
7.6 FIELD ILLUMINATION .................................................................................................................................. 24
7.7 Z-AXIS ...................................................................................................................................................... 24
7.8 ADVANCED SOLDER HEAD ......................................................................................................................... 25
7.9 NITROGEN GAS FLOW ............................................................................................................................... 26
7.10 SITE CLEAN PNEUMATICS .......................................................................................................................... 26
7.11 VISION SYSTEM (WITH MFOV) ................................................................................................................... 26
7.12 TEACH LASER POINTER ............................................................................................................................. 26
7.13 PREHEATER .............................................................................................................................................. 27
7.14 BOARD CARRIER ....................................................................................................................................... 28
7.15 HEAD TEMPERATURE SENSOR ................................................................................................................... 28
7.16 PC MODULE ............................................................................................................................................. 28
8 MACHINE OVERVIEW AND OPTIONS ......................................................................................................... 29
8.1 PERIPHERALS OVERVIEW OF THE STANDARD HOT GAS SYSTEM ................................................................. 31
8.2 OPTIONS OVERVIEW .................................................................................................................................. 31
8.2.1 70MM (2.75”) TOP SIDE CLEARANCE .................................................................................................. 31
8.2.2 SITE CLEANING SYSTEM .................................................................................................................... 32
8.2.3 IR SENSOR ....................................................................................................................................... 32
8.2.4 BOARD COOLING SYSTEM .................................................................................................................. 33
8.2.5 UNIVERSAL INSERTION TOOL .............................................................................................................. 33
8.2.6 AUTOMATIC COMPONENT SHUTTLE .................................................................................................... 33
8.2.7 PASTE-ON-DEVICE MICRO STENCIL ADAPTER ..................................................................................... 34
8.2.8 FLUX DIP PEDESTALS ........................................................................................................................ 34
8.2.9 DIRECT VIEW CAMERA & MOUNT ASSEMBLY ....................................................................................... 35
8.2.10 FOUR (4) ADDITIONAL THERMOCOUPLE PORTS ................................................................................... 35
8.2.11 FUME EXTRACTION MANIFOLD ............................................................................................................ 36
8.2.12 ERGONOMIC WORKSTATION ............................................................................................................... 36
9 VISUALMACHINES™ .................................................................................................................................... 37
10 INSTALLATION .......................................................................................................................................... 39
10.1 TRANSPORT .............................................................................................................................................. 39
10.2 UNPACKING .............................................................................................................................................. 39

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10.3 RE-PACKING ............................................................................................................................................. 40
10.4 REQUIREMENTS (ALSO SEE FACILITY REQUIREMENTS) ................................................................................ 40
10.5 FACILITY REQUIREMENTS .......................................................................................................................... 41
10.6 WORKSTATION (OPTIONAL): ASSEMBLY ..................................................................................................... 42
10.7 INSTALLATION OF THE ONYX MACHINE ...................................................................................................... 45
10.8 REMOVING THE TRANSPORT LOCKS ........................................................................................................... 46
10.9 INSTALL THE PREHEATER WHEN AVAILABLE ............................................................................................... 47
10.10 ELECTRICAL INSTALLATION ................................................................................................................... 48
10.10.1 MAIN POWER SUPPLY .................................................................................................................... 48
10.10.2 HEATER PHASE DETECTION ........................................................................................................... 50
10.11 PNEUMATIC INSTALLATION ..................................................................................................................... 50
10.11.1 MAIN AIR CONNECTION .................................................................................................................. 50
11 POWER ON AND OFF ............................................................................................................................... 51
11.1 POWER ON ............................................................................................................................................... 51
11.2 POWER OFF .............................................................................................................................................. 54
11.3 STATUS BAR AND SAFETY PROTECTION WARNINGS ..................................................................................... 54
11.4 PHASE DETECTION .................................................................................................................................... 55
11.5 OPERATOR PANEL .................................................................................................................................... 56
12 PROGRAM EXECUTION ........................................................................................................................... 57
12.1 EXECUTION VIEW & MAIN EXECUTION ........................................................................................................ 57
12.1.1 PROGRAM HEADER ............................................................................................................................ 58
12.1.2 PROGRAM ERROR CONTROL .............................................................................................................. 59
12.2 EXECUTION MONITOR ................................................................................................................................ 59
12.3 PROGRAM STATUS .................................................................................................................................... 59
12.4 DIRECT SIGNAL MANIPULATION ................................................................................................................. 59
13 MASTER PROGRAM EXECUTION ........................................................................................................... 61
13.1 OPERATOR ACCESS LEVEL ....................................................................................................................... 61
13.2 MASTER PROGRAM ................................................................................................................................... 62
13.2.1 DATA LIBRARY STRUCTURE ................................................................................................................ 62
13.2.2 SELECT OR COPY PART TYPES (DIRECT ACCESS) ............................................................................... 63
13.2.3 SELECT PROCESS LIST ...................................................................................................................... 68
13.2.4 STATUS WINDOW: REMOVAL, SITE CLEANING, SOLDERING .................................................................. 68
13.2.5 INITIALIZATION PROCESS STEPS ......................................................................................................... 69
13.2.6 COMPLETION PROCESS STEPS ........................................................................................................... 70
13.2.7 PART REMOVAL PROCESS STEPS ....................................................................................................... 71
13.2.8 PART SITE CLEANING PROCESS STEPS .............................................................................................. 76
13.2.9 PART SOLDERING PROCESS STEPS .................................................................................................... 79
14 SYSTEM CALIBRATION ............................................................................................................................ 87
14.1 DIRECTIONS .............................................................................................................................................. 87
14.1.1 COORDINATE SYSTEM ....................................................................................................................... 87
14.1.2 ROBOT COORDINATE BAND ................................................................................................................ 88
14.1.3 ADVANCED JOGGING ......................................................................................................................... 89
14.1.4 TEACHING POSITIONS ........................................................................................................................ 90
14.2 CALIBRATION VIEW ................................................................................................................................... 91
14.2.1 MAIN CALIBRATION ............................................................................................................................ 91
14.2.2 AXES CALIBRATION ............................................................................................................................ 92
14.2.3 TEMPERATURE SENSOR AND THERMO COUPLE CALIBRATIONS ............................................................ 92
14.2.4 PRECISION FORCE SENSOR TABLE ..................................................................................................... 92
14.2.5 FLOW CONTROLLER ........................................................................................................................... 92
14.3 FLOW RATE VERIFICATION ......................................................................................................................... 93
14.4 HOT GAS TOOL TEMPERATURE VERIFICATION ............................................................................................ 94
14.5 HOT GAS TOOL CALIBRATION .................................................................................................................... 95
15 PREVENTIVE MAINTENANCE .................................................................................................................. 97
15.1 MAINTENANCE VIEW ................................................................................................................................ 100

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15.1.1 MACHINE MAINTENANCE .................................................................................................................. 100
15.1.2 HEAD MAINTENANCE ....................................................................................................................... 101
15.1.3 FORCE SENSOR MAINTENANCE ........................................................................................................ 102
15.1.4 MACHINE OPERATOR PANEL MAINTENANCE VIEW ............................................................................. 102
15.1.5 VISION UNIT .................................................................................................................................... 103
15.1.6 HOT GAS TOOL ............................................................................................................................... 104
15.2 UPPER HEATING ELEMENT REPLACEMENT ............................................................................................... 106
15.3 TEMPERATURE CALIBRATION: ................................................................................................................. 110
16 SOFTWARE BACKUP ............................................................................................................................. 113
16.1 CREATE SOFTWARE ARCHIVE .................................................................................................................. 115
17 PNEUMATIC ............................................................................................................................................. 117
17.1 ADJUSTING THE BLOW-OFF AIR ............................................................................................................... 117
17.2 VACUUM FILTER ...................................................................................................................................... 117
17.3 VENTURI VALVE ...................................................................................................................................... 118
18 ELECTRIC MODULE ................................................................................................................................ 119
18.1 WIRE COLOR .......................................................................................................................................... 119
18.2 MAIN MODULE ........................................................................................................................................ 120
18.2.1 ELECTRIC MODULE MACHINE BASE .................................................................................................. 121
18.2.2 ELECTRIC MODULE MACHINE LEFT SIDE ........................................................................................... 122
18.2.3 ELECTRIC MODULE MACHINE HEAD .................................................................................................. 122
18.3 FUSES .................................................................................................................................................... 123
18.3.1 GENERAL PURPOSE CONTROLLERS .................................................................................................. 123
18.4 CONTROL SYSTEM .................................................................................................................................. 124
18.4.1 HARDWARE ..................................................................................................................................... 125
19 TROUBLE SHOOTING ............................................................................................................................. 127
19.1 NO POWER AVAILABLE ........................................................................................................................... 127
19.2 E-STOP CANNOT GET RELEASED ............................................................................................................ 127
19.3 NO AIR PRESSURE .................................................................................................................................. 127
19.4 NOT ENOUGH VACUUM ON NOZZLES ....................................................................................................... 127
19.5 HOT GAS HEATER CANNOT BE ENABLED & NO HEAT IS BEING GENERATED ............................................. 127
19.6 HEIGHT DURING SITE CLEAN PROCESS IS NOT CONSTANT ....................................................................... 127
20 DISPOSAL OF THE MACHINE ................................................................................................................ 129
21 APPENDIX: PACKAGING ........................................................................................................................ 131
21.1 TRANSPORT LOCK ON MOVABLE AXES .................................................................................................... 131
21.2 IMAGE SEQUENCE PACKAGING ................................................................................................................ 132
22 APPENDIX: STANDARD HOT GAS FLOW TABLES ............................................................................. 135
23 APPENDIX: MASTER PROGRAM "FINGER PRINTS" .......................................................................... 137
23.1 EXECUTION ............................................................................................................................................. 138
23.2 PART TYPE ............................................................................................................................................. 146
23.3 THERMO PROFILES .................................................................................................................................. 172
23.4 MASTER PROGRAM ................................................................................................................................. 178
23.5 MASTER DISPENSING PROGRAM .............................................................................................................. 186
24 APPENDIX: EXPORTING AND IMPORTING PROGRAMS .................................................................... 193
25 PARTS LISTS, ELECTRICAL & PNEUMATIC DOCUMENTATION ....................................................... 197

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1 Copyright
Operating Instructions
The information contained in this Operating Instructions is the property of Infotech AG/Air-Vac Engineering and
shall not be reproduced or published to a third party or in part without prior written approval of Infotech AG/Air-
Vac Engineering.
Please read this Operating Instructions carefully before the initial set-up, to insure the optimal start-up and
maintenance of the equipment and to help avoid the possible creation of danger points within the systems.
Every effort has been made to ensure that the information herein is complete and accurate.
However, the information in this document is subject to change without notice. Infotech AG/Air-Vac Engineering
assumes no responsibility for any error or damages resulting from faulty operation or in observance of this
manual.
Critical evaluations and comments about this manual by the user are welcomed. Your comments assist us in
preparation of future documentations.
Trademark acknowledgments:
VisionPro is a registered trademark of Cognex Corporation.
Microsoft, Windows, Visual C++, Visual Basic, Visual C# and Visual Studio are trademarks of Microsoft
Corporation, Inc.
VisualMachines™ is a registered trademark of Infotech AG.
Printed: 14.07.2020 in Solothurn, Switzerland
© 2020 Infotech AG
Publisher:
Infotech AG
Vogelherdstrasse 4
CH . 4500 Solothurn/Switzerland
Tel: +41 / 32 626 86 00
Fax:+41 / 32 626 86 09
E-mail: [e-mail]
Web: www.infotech.swiss

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2 Terms of Delivery
General Delivery Terms
I. General Provision
1. The present GDT applies to all Air-Vac services as long as no written differing agreements have been made.
2. Customer Orders must be made in writing and, in order to be binding, require an order confirmation which only applies to the contents of the agreement
(unless otherwise agreed)
3. Air-Vac retains all rights to proposals, drawings, and other documents as long as nothing to the contrary has been contractually agreed upon. In particular,
documents from Air-Vac may only be made available to third parties after prior approval.
4. The delivered software remains the sole property of Air-Vac, even if license fees have been made.
II. Prices and Methods of Payment
1. All prices are net prices in freely available Swiss Francs (CHF) - if there is no other agreement - and are ex works excluding packaging. All incidentals,
including taxes, fees, etc. are the responsibility of the buyer, barring other agreements.
2. As long as nothing specific has been agreed upon, one third of the purchase price is payable upon order confirmation, and the balance upon delivery.
3. All invoices must be paid within 30 days of the invoice date. Discount deductions are not allowed. For late payments, interest will be charged starting on the
31th day after the invoice date, without prior reminder. The interest will be at least 4% above the rediscount rate of the Swiss National Bank.
4. The buyer may only offset such claims that are undisputed or legally binding.
III. Methods of delivery
1. The time of delivery begins with the order confirmation or after clarification of all technical details and any queries.
2. For as long as Air-Vac is hindered in executing or delivering the order due to force majeure, the delivery deadline will be suspended. Force majeure also
includes serious conditions without fault such as strike, fire enactments of import embargos, or a considerable increase of import duties as well as considerable
delays by suppliers that are essential to executing the order.
3. Partial deliveries are allowed, as long as their acceptance can be expected of the buyer.
4. Installation work will be charged separately, unless agreed upon otherwise.
IV. Retention of Ownership
1. Air-Vac retains ownership of its delivery until the invoice has been paid in full and is authorizes under its own onus to register the reservation with the
responsible registry.
2. In case of resale, even in an integrated condition, the purchase price claim counts as being ceded to Air-Vac. The goods subject to retention of ownership
may not be pledged nor conveyed as a security.
3. Furthermore, Air-Vac reserves the right to cede its invoices either in whole or part.
4. If a customer's situation deteriorates considerably during the term of an order, Air-Vac has the right to make its services dependent on a security. If this
remains undone, Air-Vac is authorized to withdraw from the contract and to claim the resulting damages.
V. Risk Acceptance
1. The buyer assumes risk as follows:
a.) for deliveries without setup or installation: from point of shipping or pick up. Upon request and at the expense of the buyer, deliveries from Air-Vac will
be insured against usual transportation risks.
b.) for deliveries with setup or installation: on the day they are taken over in the buyer's own company, or if agreed upon, after an error free probation
period.
2. If the buyer ends up delaying acceptance, then he assumes all the risk.
VI. Warranty / Guarantee
1. Air-Vac offers a guarantee period of 12 months after the customer accepts responsibility.
2. The customer must check the delivery within 8 workdays and register any deficiencies in writing. Hidden deficiencies must be registered in writing within 8
workdays of their discovery. If this is not done, the goods are deemed to be approved.
3. Air-Vac must be awarded sufficient time and opportunity to correct and deficiencies. If this is denied, then Air-Vac is released from the warranty.
4. The warranty does not cover natural wear and tear or damages that occur after responsibility acceptance or as a result of incorrect or negligent treatment,
excessive demand, unsuitable operational resources, and non-reproducible software errors, among others.
5. Under no circumstances does the buyer have a claim to compensation for damages that are not related to the delivery, such as loss of production, loss of
use, loss of orders, loss of profit, as well as other direct and indirect damages. This liability exclusion does not apply to illegal intent or gross negligence on
the part of supplier.
VII. Court of Jurisdiction and Applicable Law
1. The court of jurisdiction is Solothurn. However, Air-Vac has the right to summon the customer to his responsible court.
2. Swiss law is applicable (excluding the United National Convention on Contracts of the International Sale of Goods, CISG).

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3 Declaration of Conformity

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4 Introduction
Notes and Warnings
This manual contains safety instructions wherever these are required or prescribed. These instructions are
divided into two categories as follows:
Note
A note describe special actions, procedures, instructions and information that are relevant to the subsequent
section or step. Inobservance of the instructions can result in damage to the machine or to the process material.
Warning
A warning indicates that inobservance of the instructions can result in personal injury.
4.1 Welcome
This user guide must be studied carefully before the setup process and the initial operation of the machine can
take place. Thus, in order to guarantee a trouble-free operation of the machine "ONYX 29 Series 7".
This user guide has been compiled in accordance with ISO 9000 and the EC machine guidelines. It contains all
important information and instructions to operate the machine "ONYX 29 Series 7" safe and trouble-free.
Warning
Considering the complexity of this system, trained and qualified personnel must be present at the installation.
This user guide must always be kept in reach next to the machine. It is an essential part of the machine. The
safety precautions were tested in accordance with the machine guidelines 2006/42/EC.

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4.2 Designated use of the Machine
The ONYX 29 Series 7 machine provides the capability to semi-automated removal, site cleaning and soldering
advanced technology components such as BGA's, CSP's, Flip Chip, Micro-Discretes, surface mount connectors
and fine pitch QFP's as well as traditional leaded devices such as PLCC's, SOIC's and sockets.
The ONYX 29 Series 7 machine is especially configured to support all lead-free soldering processes. All
peripherals are matched to fulfill the higher temperature and tighter tolerance requirements.
It is possible to use the machine in a semi-automated mode. If a process has to be executed multiple times, the
process executes fully automated, except of the vision alignment processes.

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5 General Safety Instructions
5.1 Basic Safety Instructions
In addition to the safety instructions in this document, the following guidelines must be observed to prevent
personal injuries in general:
Warning
Because strong magnetic fields are associated with the system motor coils and magnet assembly, persons
having active implants (pacemakers, etc) or having any other ferromagnetic products are not qualified and are
not allowed either to operate the equipment or enter within a 0,5m perimeter around the system.
Warning
The hot gas tool and the pre-heater are required to reach temperatures well above 60 °C. Hot Surface Warning
Labels are found on the covers of each heated surface. It is not allowed to touch the system and especially
these surfaces by not authorized personnel. Skin contact with these surfaces would result in a shock reaction
and therefore presents an inherent potential thermal danger to the operators.
Warning
If flux is used during the soldering processes and flux is evaporating, be careful not breathing the evaporating
gases.
In case of strong evaporating gases, be sure to install a fume extraction unit. Evaporating flux gases can be
dangerous for the operator.
Warning
Only qualified personnel is allowed to work on the peripherals with high voltages. The governing laws and
regulations must be observed.
Warning
The ONYX 29 Series 7 semi-automated soldering systems use an open platform design to allow the operator
having optimum access to the working area. During the CE-certification procedure, the possible risks for injuries
on the open platform design have been reviewed and danger analyzes processes have been performed
The safety installations in combination with the reduced speed of the X-/Y-axes of the platform of maximum
0,15 m/s and the reduced force on the these axis are acceptable and are reducing the risk of injuries of upper
body parts.
Further safety shields such as safety light curtains or safety covers have been reviewed. These additional
possible safety guards would obstruct the easy operation of the system.
Each operator of the system must be instructed about the danger points of the open system.

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Note
Read this manual carefully before you operate, service or repair the machine. The machine may only be
operated by qualified personnel who have received an appropriate training.
When cleaning parts and peripherals of the machine, use only the sub-stances recommended. When
maintaining and servicing the machine, use only the tools admitted therefore.
Before you re-start the system after maintenance or repair, make sure that other personnel, tools and foreign
materials are removed from the motion area of the subsystems of the machine.
When working with high voltages, always ensure that another person is near you who is familiar with all
emergency power off controls and can give you medical assistance.
When removing the board carrier, pre-heater and the application base plate, the main switch in the back of the
machine must be switched off and locked.
Note
When processing electronic boards with active devices, the operator must be grounded with the machine, to
avoid damaging the active components on the board.

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5.2 Machine Warning Labels
The following warning labels were used on the machine "ONYX 29 Series 7":
Warning
Each removed or defective warning label on the machine "ONYX 29 Series 7" must be replaced immediately.

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Warning of magnetic field
Warning labels on the machine:
• IP-500 Y-Axis left side in the back
• IP-500 Y-Axis left side in the front
• IP-500 X-Axis left side
• IP-500 X-Axis right side
This warning label indicates areas with strong magnetic fields.
In the close area of the linear motor of the X and Y axis strong magnetic fields occur. Due to the strong forces in
the immediate area of the permanent magnet rails (distance of less than 100 mm) particular prudence is required.
Persons with magnetically influenced implants (e.g. pace makers) or with other ferromagnetic prostheses are not
allowed neither to operate the machine nor to perform any maintenance work on the machine. For those persons
a safety distance of 0.5 m to the linear drives and the magnet rails of the linear drives must be observed!
There are no special measures of precaution to be taken when people operate outside the machine.
Warning of dangerous voltage
Warning labels on the machine:
• Head cover X-Slider
• On cable channel at power inlet
This label indicates the presence of electrical equipment.
Labels are found beside all removable covers where electrical equipment is mounted. They are used to indicate
a possible shock hazard. Only qualified personnel are allowed to work on the peripherals with high voltages. The
governing laws and regulations must be observed.
Warning of hot surfaces
Warning labels on the machine:
• In the front of the hot gas system
• On each pre-heater
• In the front of the fume extraction unit (optional)
This label indicates hot surfaces well above 60 °C. It is not allowed to touch these surfaces without safety gloves.
Skin contact with these surfaces would result in a shock reaction and therefore presents an inherent potential
thermal danger to the operators.

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Warning of laser
Warning labels on the machine:
• In the front of the vision system
This label indicates the danger of laser beams. Lasers generate a very intensive, strong bundled beam. The
intensive light beam can especially harm the eyes and the skin.
No access with cardiac pacemaker or implanted defibrillators
Warning labels on the machine:
• On the front of the Machine, right side
Anyone having active implants (pacemakers) or having any other ferromagnetic prosthesis is not qualified to work
with these kinds of devices, or to approach them. For those persons a safety distance of 0.5 m to the linear drives
and the magnet rails of the linear drives must be observed!
5.3 Airborne Noise Emitted
The emission sound pressure level of the machine is less 75 dB(A).

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