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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