Dage 4000 Series Manual

1
Series 4000HS
An Operators Guide
Version 1

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IMPORTANT
INFORMATION
FOR OUR
CUSTOMERS
DAGE SUPPORT SOLUTIONS
Dear Customer,
Congratulations on your purchase of your Dage Test Equipment.
Dage is committed to excellent service Worldwide and our goal is to provide
you with professional assistance in the use of our Test & Measurement
Equipment, wherever you are located.
As you are probably aware, Dage offices are located in six strategic centres in
the USA, Asia & Europe and the company’s customer service & support is
acknowledged to be ‘the best in the business’.
We trust that you find our product an invaluable tool & hope that you will pass
on any comments you may have so we can continue to enhance the product
and service to you. Therefore, could you please spend a couple of minutes
answering our customer satisfaction questionnaire? The questionnaire can be
found on our Web site under the Dage Precision Industries section and
Customer Satisfaction Form. Our Web address is: www.dage-group.com.

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Omissions and Errors
We have made every effort to ensure that this manual is error free.
However if you should discover errors, or omissions we would be
pleased to receive your comments. Please send these to:
DPI Customer Support,
Dage Precision Industries,
Rabans Lane,
Aylesbury,
Buckinghamshire.
HP19 8RG
ENGLAND.
Tel [phone]
Fax [phone]
Email [email protected]
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Microsoft Corporation
Version 5, © Dage Ltd. 1998-2003
PRINTED ON CLEAN ROOM FRIENDLY FILM

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Contents
1 TYPES OF MACHINE 4000, 4000HS AND 4000HS-Z ..........................................6
2 SAFETY INFORMATION........................................................................................7
2.1 SYMBOLS AND LABELS .........................................................................................7
LOCATING THE MACHINE...........................................................................................8
3.1 UNPACKING THE MACHINE AND THE WORK STATION.........................................8
3.1.1 Workbench ........................................................................................................ 9
3.1.2 Chair.................................................................................................................10
3.2 ELECTRICAL CONNECTIONS ..............................................................................10
3.3 PNEUMATIC SERVICES .......................................................................................13
3.3.1 Compressed air.................................................................................................13
3.3.2 Setting compressed air regulators.....................................................................13
3.3.3 Vacuum supply.................................................................................................14
3.3.4 Services connection..........................................................................................14
3.4 FITTING MACHINE MODULES .............................................................................15
3.4.1 Joysticks ...........................................................................................................15
3.4.2 Keyboard Rest..................................................................................................16
3.4.3 Microscope mounting.......................................................................................17
4 SETTING UP THE WORK STATION..................................................................18
4.1 ERGONOMICS AND OPERATOR COMFORT..........................................................18
4.2 SETTING THE MACHINE FOR AN OPERATOR ......................................................19
4.2.1 Setting the chair................................................................................................19
4.2.2 Setting the joysticks..........................................................................................19
4.2.3 Setting the microscope .....................................................................................20
5 UNDERSTANDING THE MACHINE ...................................................................22
5.1 TURNING ON.......................................................................................................22
5.2 TURNING OFF .....................................................................................................24
5.3 EMERGENCY STOP BUTTON ...............................................................................25
5.3.1 Procedure For Returning Machine to Operational Use Following an Emergency
Stop ..........................................................................................................................25
5.3.2 Removal of other Hazardous energy sources....................................................26
5.4 BASIC OPERATOR CONTROLS.............................................................................27
5.4.1 On-screen controls............................................................................................27
5.4.2 Keypad controls................................................................................................28
5.4.3 Footswitch ........................................................................................................29
5.4.4 Keyboard ..........................................................................................................29
5.4.4.1 Starting test and grading – ‘T’ and numerical keys..........................................29
5.4.4.2 Arrow key jogging ...........................................................................................29
5.5 UNDERSTANDING CARTRIDGES..........................................................................30
5.5.1 Cartridge layout................................................................................................31
5.5.2 Tool Guard .......................................................................................................31
5.6 TOOL SAVE FEATURES .......................................................................................32
6 PREPARING FOR A TEST ....................................................................................33
6.1 FITTING A CARTRIDGE .......................................................................................33
6.2 REMOVING A CARTRIDGE, .................................................................................36
6.3 FITTING AND USING WORK HOLDERS.................................................................36
6.3.1 Work holder stands available For the High Speed XY Table...........................37

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6.3.2 Work Holders Available For the Zone Shear XY Table .................................. 40
7 DOING A TEST....................................................................................................... 42
7.1 NEW SAMPLE ..................................................................................................... 42
7.1.1 Understanding the screen layout ...................................................................... 42
7.1.2 Interlocks Open Message................................................................................. 43
7.2 COLD BUMP PULL TESTING.............................................................................. 44
7.2.1 Tool quality...................................................................................................... 44
7.2.2 Tool alignment................................................................................................. 45
7.2.3 Changing tweezer jaws .................................................................................... 45
7.2.4 Jaw closing force ............................................................................................. 47
7.2.5 Correct jaw opening position ........................................................................... 48
7.2.6 Work Holder Air Pressure Setting .................................................................. 48
7.3 BUMP PULL TEST MODES ................................................................................... 50
7.4 BUMP PULL TEST FAILURE MODES .................................................................... 54
7.5 BALL CLEARANCE USING A DS100KGHS ....................................................... 55
7.5.1 Tool quality...................................................................................................... 55
7.5.2 Changing a shear tool ...................................................................................... 55
7.6 HIGH SPEED TESTING USING A BS5KGHS........................................................... 56
7.6.1 Shear tool quality............................................................................................. 56
7.6.2 Ceramic shear tool removal ............................................................................. 56
7.6.2 Shear Test Work holder.................................................................................... 56
7.7 HIGH SPEED SHEAR TESTS BALL ALLIGNMENT ................................................. 57
7.8 ZONE SHEAR TESTING USING THE ZONE SHEAR TABLE ................................. 58
7.9 TEST RESULTS ................................................................................................... 59
7.9.1 List of results ................................................................................................... 59
7.9.2 Typical XBar/Range trend graph ..................................................................... 60
7.9.3 Grading the test................................................................................................ 61
7.9.4 Number of tests in a sample............................................................................. 62
7.9.5 CPK and other statistics................................................................................... 62
8 CALIBRATION....................................................................................................... 63
8.1 COLD BUMP PULL CARTRIDGE CALIBRATION.................................................... 63
8.2 SHEAR CARTRIDGE CALIBRATION .................................................................... 66
9 GETTING DATA FROM ANOTHER MACHINE.............................................. 71
9.1 SELECTING A REMOTE MACHINE ...................................................................... 71
10 QUESTION AND ANSWERS............................................................................ 72
10.1 DATA STORAGE ................................................................................................. 72
10.1.1 What is a sample.............................................................................................. 72
10.1.2 What happens on the <New Sample> screen ................................................... 72
10.2 CALIBRATION.................................................................................................... 74
10.2.1 How does the calibration work ........................................................................ 74
10.3 JOGGING PROBLEMS ......................................................................................... 75
10.3.1 The cartridge will not drive up or moves in one direction only ....................... 75
10.3.2 The table will not drive, or moves in one direction only.................................. 75

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1TYPES OF MACHINE 4000, 4000HS AND 4000HS-Z
This manual covers the 4000HS and 4000HS-Z
The operation of this machine is very similar to the 4000. Most machine options may be
used on either machine. The 4000 is a general-purpose machine that can test 100kg die
shear and fine pitch wire bonds. The 4000HS is designed for high-speed applications. The
4000HS is capable of testing up to 4M/s in shear and 1.3M/s in pull. The 4000HS-Z is a
zone shear machine capable of testing, in shear, up to 80Kg at speeds up to 600mm/s and
can also be used to perform pull tests up to 1.3M/s in the same way as a 4000HS.

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2SAFETY INFORMATION
IMPORTANT! PLEASE READ THE “SAFETY EQUIPMENT” SECTION
CAREFULLY BEFORE SETUP, OPERATION, MAINTENANCE OR
TROUBLESHOOTING THE EQUIPMENT. STRICTLY FOLLOW ALL
SAFETY PRECAUTIONS TO PREVENT ANY INJURY TO YOURSELF
OR OTHERS.
2.1 SYMBOLS AND LABELS
The following warning labels are attached to the machine to indicate the dangers from high
voltage.
It is important to take note of the safety labels and to follow the specified safety procedures.
Symbol Meaning
Indicates the presence of high voltages within the
equipment. High voltages can cause death or serious
injury.
The following Signal Words are used in this guide. All safety related notes, reminder etc are
highlighted in RED colour, please read carefully.
Symbol Meaning
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation
which, if not avoided could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury. It
may also be used to alert against unsafe practices.
NO MODIFICATIONS MAY BE MADE TO THE
MACHINE WITHOUT THE EXPRESS PERMISSION OF
THE MANUFACTURER. ONLY DAGE APPROVED
REPLACEMENT PARTS SHOULD BE USED TO SERVICE THE MACHINE AS
ALTERNATIVES MAY RESULT IN A DEGRADATION OF THE SAFETY
FEATURES.

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3LOCATING THE MACHINE
3.1 UNPACKING THE MACHINE AND THE WORK STATION
THE DAGE SERIES 4000HS WEIGHS
APPROXIMATELY 100KG LIFT WITH
CAUTION USING THE LIFTING POINT.
1) Move the crated machine to the unpacking area using a suitably-rated
fork lift truck:
TIPPING HAZARD
Higher than normal Centre of Gravity
Do not tip the machine more than 10°as it only has three feet
and so will tip easily
May cause death or serious injury by crushing
CRUSHING HAZARD
The Machine is extremely heavy
Ensure adequate help is available when positioning the
machine, as it may be difficult to control any lifting
equipment even on a gently sloping floor
May cause death or serious injury by crushing

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2) Inspect the crate for any damage before unpacking.
3) Report any damage immediately to both Dage and the carriers.
4) Remove the spring-metal clips around the top of the crate and remove the lid.
5) Remove all of the remaining spring-metal clips and remove the sides of the crate.
6) Unpack all of the accessories to the machine and move to a location, leaving enough
room to move the machine about.
ENSURE THE LIFTING EYE IS SECURELY FIITED
PRIOR TO LIFTING
7) Using the Lifting eye supplied with the machine and a suitable lifting hoist lift the
machine and place on the work bench as outlined in section 3.1.1 in the Operators
Guide. The lifting eye is fixed to the top of the machine.
3.1.1 Workbench
It should be of sturdy construction, rigid and free from vibration
It should be sufficiently high to allow the largest operator to sit under comfortably.
Its maximum thickness, at the operator position, should not exceed 60mm.
Its legs or supports should not obstruct the operator.
Lifting eye fits here

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3.1.2 Chair
It should have sufficient height adjustment for the largest and the smallest
operator to sit comfortably at the workstation
It should also preferably have an adjustable foot and backrest.
3.2 ELECTRICAL CONNECTIONS
THIS MACHINE MUST BE EARTHED.
THE IEC LEADS REQUIRED TO CONNECT
THIS MACHINE TO A POWER SOURCE
MUST HAVE AN INTEGRAL EARTH CONNECTION.
ENSURE THE MAINS SUPPLY TO THE MACHINE IS ADEQUATELY
RATED AND FUSED. IF IN DOUBT, CONSULT A QUALIFIED
ELECTRICIAN.
FOR CONTINUED PROTECTION AGAINST RISK OF FIRE OR
DAMAGE TO THE EQUIPMENT, REPLACE FUSES ONLY WITH
THOSE OF THE SPECIFIED TYPE AND CURRENT RATING.
IT IS VITAL THAT THE CORRECT VOLTAGE
RANGE IS SELECTED ON THE SIDE OF THE
MACHINE.
IF IN DOUBT CONSULT A QUALIFIED ELECTRICIAN.

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The electrical leads should be connected as shown below.
Connect any additional connections specific to your installation i.e. printers, network
cables etc.
This is where the power is supplied to the machine. It
is located on the left-hand side of the machine
underneath the monitor arm.
It is essential that the correct voltage is selected and
the correct fuse is fitted. Plug the mains power lead
into the fused connector. The AC output can be used
to power the PC or monitor. Do not power up the
machine until all the connections are made.
There are two circuit breakers on this panel ensure that
the
y
are de
p
ressed.

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Note: The PC should be powered directly from the 4000HS. As with the 4000 it is
essential that the correct voltage Setting be selected. The PC may also be able to
supply power to the monitor. For instructions on how to connect the mouse,
keyboard and monitor to the PC please consult the instructions supplied with those
items.
These connections are on the rear of the machine.
Computer Link – The supplied data lead, which plugs
into the PC plugs in here.
Keypad – The keypad which is part of the joystick
assembly’s plugs in here.
Foot Switch – This is where the foot switch plugs in.
Joystick 1 & 2 – The joystick assembly’s plug in here.
Joystick 1 is normally the right-hand joystick and
j
oystick 2 is normally the left-hand joystick.
There are also two circuit breakers on the rear of the
machine. Ensure that they are depressed before
p
owering up the machine.

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3.3 PNEUMATIC SERVICES
Note: At the time of press the machine only requires compressed air to perform high speed
testing.
3.3.1 Compressed air
Specification: 4bar (min.) dry, clean 10 l/min (Free air)
The bondtester uses compressed air to operate its shear and cold bump pull cartridges.
Compressed air is also used to operate the vertical lift table, which is used during pull tests.
Compressed nitrogen is a suitable alternative.
Note: The machine will not operate correctly if the supply is contaminated or wet.
3.3.2 Setting compressed air regulators
There are three regulators located on the top right of the machine, which should be set as
follows: -
High Speed
Bump Pull
Rising Table
Regulator
Secondary Regulator
Shear Load Cell Air
Bearing Pressure Set
To 0.19M
p
a
(
1.9Bar
)
Primary
Regulator
Tweezer Jaw
Clamping
Pressure Set To
0.4Mpa (4.0
Bar)

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3.3.3 Vacuum supply
Specification: 500mm Hg (min.)
Vacuum may be required for some work holders.
A factory supply or a separate pump may provide it.
3.3.4 Services connection
There are three service connections on the rear of the machine as shown below: -
Note: Any water in the airline is separated and will be discharged from the
drain automatically. A suitable receptacle must be provided
Found in the Right hand bottom corner of the rear of the pneumatic
chassis

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3.4 FITTING MACHINE MODULES
Note: The software will not automatically recognise some module changes. Joysticks and motorised
tables must be initialised by re-powering the machine, or by using <Set-up> <Initialise> on
the top line menu.
3.4.1 Joysticks
Note: Any joystick may be fitted to the left or right hand side of the machine, handing conversion
may be required (see the engineers guide).
A standard configuration would have the joystick with the keypad on the right.
The fitting procedure is as follows: -
Plug in the electrical connector on the rear of the machine using the left-hand right hand labels as a guide.
Plug in the keypad at the rear of the machine.
Joystick and Keypad Leads to the
rear of the machine

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3.4.2 Keyboard Rest
The fitting procedure is as follows: -
Adjust the screw feet if fitted so that they support the keyboard rest evenly.
Note: A compact P.C. keyboard should be positioned between the emergency
stop button and the lamp on/off switch.
When the emergency stop button is pressed it will require a reset. To reset the
switch, twist and pull. If this is not performed the machine cannot be powered up.
4000HS
Ke
y
board Res
t
Connect the connectors together that supply the emergency stop
buttton and the on/off switch for the lamp. Connect the earth strap.
Install the keyboard rest using the two screws provided.
Adjustable Feet

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3.4.3 Microscope mounting
At the time of press the 4000HS machine is using a Leica microscope. If you experience any difficulties
then contact your local Dage representative.
Supplied with the machine.
Check mounting pod is
orientated as shown
Supplementary lens must be fitted

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4SETTING UP THE WORK STATION
4.1 ERGONOMICS AND OPERATOR COMFORT
The microscope and machine controls on the machine can be set to suit a range of
operator statures. We recommend the following issues are considered in turn
when setting up the machine:
1. Comfortable adjustable seat with back straight and upright.
2. Feet flat on the floor or on a suitable footrest.
3. Head upright or leaning slightly forward, when looking down microscope.
4. Elbows below shoulders or slightly forward.
5. Fore arms horizontal or slightly raised.
This drawing shows the features needed to set the ideal operating position.
Note: Attention to these points result in a relaxed sitting position with little or
no muscular tension.
Upright
Position
Adjustable
Seat Height
Adjustable
Reach
Adjustable
Eyeline
Supported Feet

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4.2 SETTING THE MACHINE FOR AN OPERATOR
Note: It is important that operator adjustments are made with the assistance of an experienced engineer.
If you are unfamiliar with the machine operation refer to section 5.
4.2.1 Setting the chair
Adjust the height of the chair to set the arm position as shown below.
Adjust the footrest and backrest to support the correct seating position as shown.
4.2.2 Setting the joysticks
The joysticks have been designed for left or right handed use.
If one configuration does not suit all operators extra joysticks may be needed.
It will be necessary to reconfigure the joystick axis to move (for example) the motorised table controls
from the left to the right joystick. See your engineer.
Note: The standard configuration is described in section 3.4.1.
Hands in the normal
operating position
Lightly supported
forearm
Move chair in as close
as possible
Leads to the rear of
the machine.

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4.2.3 Setting the microscope
Place a work holder and sample on the machine (see section 6.3).
Fit an appropriate cartridge and set the tool just above the sample (see section 6.1).
Set the zoom to its minimum (smallest number)
Angle the microscope to the tool tip and test point in the Y-axis
Angle the microscope to the tool tip and test point in the X-axis
Ask your engineer to add your name to the list of operators and re-
configure the controls if the defaults are not suitable.
Zoom Control knob
Raise and lower microscope as
required using the black knob on
the left-hand side of the machine
Angle adjustment centre. Loosen
screws