Kurtz Ersa HR 550 XL Operational manual
HR 550 XL
Rework-System
Translation of the original operating manual: 3BA00247-01|Serial
No.:..........................................
Ersa GmbH
Leonhard-Karl-Str. 24
97877 Wertheim
www.ersa.de
Rev. 1
Printing date: 30/03/2020
Phone +49 9342/800-136
Fax +49 9342/800-132
Mobile +49 171 241 846 8
Table of contents
Table of contents
1 Introduction ...................................................................................................................................................... 7
1.1 Product information.......................................................................................................................................... 8
1.1.1 General information about the product.............................................................................................8
1.1.2 Intended use.......................................................................................................................................8
1.1.3 Retrofitting, changes ..........................................................................................................................8
1.1.4 Warranty.............................................................................................................................................8
1.2 Information about this manual ......................................................................................................................... 9
1.2.1 Pictogram and symbol explanations.................................................................................................10
1.2.1.1 Prevailing term definitions in this instruction manual....................................................11
1.2.1.2 Warnings.........................................................................................................................12
1.2.1.3 Binding info about safety shoes .....................................................................................13
1.2.1.4 Prohibition notices..........................................................................................................14
1.2.2 Target readers group ........................................................................................................................15
1.2.3 Copyright, liability.............................................................................................................................15
2 Technical data ..................................................................................................................................................17
2.1 General data.................................................................................................................................................... 18
2.2 Ambient conditions......................................................................................................................................... 19
2.3 Connection data.............................................................................................................................................. 19
2.4 Printed circuit boards and components.......................................................................................................... 19
2.5 Heating system................................................................................................................................................ 20
2.6 Axis system...................................................................................................................................................... 20
2.7 Pneumatics...................................................................................................................................................... 20
2.8 Cameras .......................................................................................................................................................... 21
2.9 PC system requirements ................................................................................................................................. 21
3 For your safety..................................................................................................................................................23
3.1 General safety instructions ............................................................................................................................. 24
3.1.1 Nationally valid safety and accident prevention regulations ...........................................................24
3.1.2 Fire protection ..................................................................................................................................24
3.2 Subject-related safety instructions ................................................................................................................. 24
3.2.1 Dealing with electrical equipment....................................................................................................24
3.2.2 Dealing with process materials and substances ...............................................................................24
3.3 Safety instructions for certain operating phases ............................................................................................ 25
3.4 Safety instructions for maintenance, service, specific work, troubleshooting ............................................... 26
3.5 Safety instructions for certain machine and system parts..............................................................................27
3.5.1 Hot device.........................................................................................................................................27
3.5.2 Laser equipment...............................................................................................................................27
3.5.3 Using a solder fume extractor, plug available ..................................................................................27
3.6 Retrofitting and changes................................................................................................................................. 27
4 Transport, installation, storage, disposal ..........................................................................................................29
4.1 Information concerning machine transport and storage................................................................................ 30
4.2 Information on how to unpack the machine .................................................................................................. 30
4.3 Packaging with TIP n TELL indicator ................................................................................................................ 30
4.4 ESD-hazardous components ...........................................................................................................................31
4.5 Scope of delivery............................................................................................................................................. 32
4.6 Available options............................................................................................................................................. 32
4.7 Unpacking and installing the Rework system ................................................................................................. 35
4.8 Connecting the machine ................................................................................................................................. 39
4.9 Insert the heating head................................................................................................................................... 41
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 iii/157
Table of contents
4.10 Screwing on a soldering nozzle and then removing the transport lock ..........................................................42
4.11 Assembling an RPC camera (optional) ............................................................................................................44
4.12 Assembling an Accu-TC holder and an air baffle.............................................................................................46
4.13 Disposal........................................................................................................................................................... 48
5 Commissioning .................................................................................................................................................49
5.1 Setting up the PC............................................................................................................................................. 50
5.2 Performing functions [Start Setup] and [Pixel Shift adjustment].................................................................... 52
6 Function description .........................................................................................................................................55
6.1 Read this first!................................................................................................................................................. 56
6.1.1 Target readers group ........................................................................................................................56
6.1.2 Supplementary documents ..............................................................................................................56
6.1.3 ESD-hazardous components.............................................................................................................56
6.2 Overview of the machine parts....................................................................................................................... 57
6.3 Switching on the Rework system and starting HRSoft 2 ................................................................................. 60
6.4 The top bar in the HRSoft 2 program.............................................................................................................. 61
6.5 Temporarily editing the soldering profile in the [Rework] tab ....................................................................... 62
6.5.1 [Rework] tabulator overview............................................................................................................62
6.5.2 Use of the soldering profile in the [Rework] tabulator.....................................................................64
6.5.3 The tabulators [Information], [Heating setting] and the arrow key [Image processing]..................65
6.5.3.1 The three right tabulators ..............................................................................................65
6.5.3.2 The [Information] tabulator under the [Rework] tabulator ...........................................65
6.5.3.3 The [Heating setting] tabulator under the [Rework] tabulator ......................................68
6.5.3.4 The tabulator with the small arrow key (Image processing) under the [Rework] tabu-
lator ................................................................................................................................70
6.5.4 The chart in the [Rework] tabulator .................................................................................................72
6.5.4.1 The heating curves in the [Rework] tab..........................................................................73
6.5.5 The [Process Automation] button row .............................................................................................75
6.6 The [Archive] tabulator ................................................................................................................................... 76
6.6.1 The [Show chart] button...................................................................................................................77
6.7 The [user management] tabulator.................................................................................................................. 79
6.8 Editing the soldering profile in the [Profile management] tab and changing it permanently ........................81
6.8.1 Overview of the [Profile management] tabulator ............................................................................81
6.8.2 Create, copy, delete and save soldering profiles in the [Profile management] tabulator................82
6.8.3 The tabulators [Information], [Heating setting] and the arrow key [Image processing]..................85
6.8.3.1 The [Information] tabulator under the [User management] tabulator..........................85
6.8.3.2 The [Heating setting] tabulator under the [Profile management] tabulator .................88
6.8.3.3 The tab with the arrow button [More] under the [Profile management] tab................90
6.9 The chart in the [Profile management] tabulator........................................................................................... 92
6.10 The heating curves in the chart in the [Profile Management] tab.................................................................. 92
6.11 The [Process automation] buttons under the [Profile management] tabulator.............................................94
6.12 The [Management] tabulator with three dialog windows.............................................................................. 95
6.12.1 The dialog [HRSoft 2 settings]...........................................................................................................95
6.12.2 The [Chart settings] dialog................................................................................................................97
6.12.3 The [device settings] dialog ..............................................................................................................98
6.12.3.1 The [Start teaching] button ..........................................................................................101
6.12.3.2 The [Pixel shift adjustment] button..............................................................................105
6.13 The [Manual Mode] ...................................................................................................................................... 109
6.14 The display and switch row top right ............................................................................................................111
6.15 Switching off the Rework System.................................................................................................................. 113
7 Tutorial – Soldering or desoldering a component............................................................................................115
7.1 Insert the PCB................................................................................................................................................ 116
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 iv/157
Table of contents
7.2 Replacing the soldering nozzle...................................................................................................................... 117
7.3 Position a thermocouple............................................................................................................................... 122
7.4 Shielding heat sensitive components............................................................................................................123
7.5 Activate a soldering profile and prepare the soldering process ...................................................................124
7.6 Start the process and work with the assistant.............................................................................................. 125
7.7 Task 1 “Alignment” ....................................................................................................................................... 127
7.8 Task 2 “Desoldering”..................................................................................................................................... 128
7.9 Task 3 “Deposit”............................................................................................................................................ 130
7.10 Task 4 "Preparation" ..................................................................................................................................... 131
7.11 Task 5 “Alignment” ....................................................................................................................................... 133
7.12 Task 6 “Inspection” ....................................................................................................................................... 135
7.13 Task 7 “Soldering”.........................................................................................................................................137
7.14 Task 8 “Inspection” ....................................................................................................................................... 139
7.15 Task 9 “Complete” ........................................................................................................................................ 141
7.16 Removing residual solder.............................................................................................................................. 141
8 Service and maintenance................................................................................................................................143
8.1 Check the rework system on a weekly basis for any dirt or damages. .........................................................144
8.2 Lubricating the worm gear of the pipette hub every six months..................................................................145
8.3 Change the heating head .............................................................................................................................. 146
8.4 Performing a HRSoft 2 update ...................................................................................................................... 147
9 Spare and wear parts......................................................................................................................................149
9.1 Read this first!............................................................................................................................................... 150
9.1.1 Target readers, permitted spare parts ...........................................................................................150
9.2 Nameplate and machine number ................................................................................................................. 150
9.3 Spare parts .................................................................................................................................................... 151
9.3.1 Nameplate and machine number...................................................................................................152
10 Annex .............................................................................................................................................................154
10.1 EC Declaration of Conformity........................................................................................................................ 155
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 v/157
1| Introduction
1 Introduction
1.1 Product information.......................................................................................................................................... 8
1.1.1 General information about the product.............................................................................................8
1.1.2 Intended use.......................................................................................................................................8
1.1.3 Retrofitting, changes ..........................................................................................................................8
1.1.4 Warranty.............................................................................................................................................8
1.2 Information about this manual ......................................................................................................................... 9
1.2.1 Pictogram and symbol explanations.................................................................................................10
1.2.1.1 Prevailing term definitions in this instruction manual....................................................11
1.2.1.2 Warnings.........................................................................................................................12
1.2.1.3 Binding info about safety shoes .....................................................................................13
1.2.1.4 Prohibition notices..........................................................................................................14
1.2.2 Target readers group ........................................................................................................................15
1.2.3 Copyright, liability.............................................................................................................................15
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 7/157
1| Introduction
Product information
1.1 Product information
1.1.1 General information about the product
This operating manual is universally valid for Ersa Hybride-Rework-System of the
HR 550 XL series.
1.1.2 Intended use
The machine is a state-of-the-art product that has been designed and manufac-
tured according to recognised safety-related rules. However, the machine may
pose residual hazards especially when it is used improperly and operated or ser-
viced by untrained personnel. The HR 550 rework system is design for industrial in-
door use. The machine may be used exclusively for soldering and unsoldering elec-
tronic components on PCBs. Any other or further use is considered improper. The
manufacturer/supplier declines any liability for any damages that may arise as a
result of such use. Proper use also includes compliance with the operating instruc-
tions as well as safety notices.
1.1.3 Retrofitting, changes
Unauthorized modifications and / or changes that affect the security of the ma-
chine are not permitted and exclude any liability of the manufacturer / supplier for
any resulting damage. The machine is only intended for commercial use. Private
use is generally excluded.
1.1.4 Warranty
The warranty period shall be compliant with ERSA GmbH applicable terms of sale,
delivery and payment. ERSA GmbH may only grant a warranty if the unit is returned
in its original packaging.
Any inappropriate use and improper operation on the unit shall void all warranty
and liability claims of the buyer against the manufacturer.
To the extent permitted by law, liability for direct, consequential and indirect dam-
age resulting from the purchase of this product is ruled out.
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 8/157
1| Introduction
Information about this manual
1.2 Information about this manual
For your safety
ERSA products are developed, manufactured and tested in compliance with the ba-
sic safety requirements.
Nevertheless, residual risks still exist!
For this reason, please read these operating instructions before operating the ma-
chine for the first time. The instructions manual helps you master all the functions
and use them optimally.
DANGER
Hazards caused by the improper operation of the machine!
üObserve the operating instructions!
a) Any person involved in the installation, commissioning, operation and/or main-
tenance of the machine must have read and understood the contents of chapter
"Safety instructions", as well as the chapters which are relevant for the specific
activity!
b) The operator is advised to have this confirmed in writing!
c) In addition, for the machine operation, local safety and accident prevention regu-
lations must also be complied with!
d) Always keep these instructions near the machine, in a place accessible to all users
at any time!
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 9/157
1| Introduction
Information about this manual
1.2.1 Pictogram and symbol explanations
Pictograms are used to identify dangers, both in this instruction manual and on the
machine.
Specific information or requirements and prohibitions for the prevention of per-
sonal injury or property damage are shown in the manual with a pictogram, and are
complemented in the text by hierarchically graded, signal words in bold print:
DANGER
It describes an immediately threatening danger
If not avoided, death, serious injury or material damage can result.
a) Measures are described in the following text to avert the danger.
WARNING
It indicates a potentially threatening danger
If not avoided, death, serious injury or material damage can result.
a) Measures are described in the following text to avert the danger.
CAUTION
It indicates a potentially threatening danger
If not avoided, death, serious injury or material damage can result.
a) Measures are described in the following text to avert a danger.
NOTE
The hereinafter highlighted text passages contain explanations, further information
or tips.
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 10/157
1| Introduction
Information about this manual
1.2.1.1 Prevailing term definitions in this instruction manual
In addition to the pictograms described above, we use the following symbols and
notations:
Safety instructions
üThis symbol means: Prerequisite to avert a danger.
a) This symbol means: Measures to avert a danger.
An example:
NOTE
Machine malfunctions caused by improper maintenance!
üShorten service intervals, if necessary!
a) Service intervals in this manual refer to single shift operation! They are to be
shortened accordingly for multi-shift operation!
Operating instructions
the operating instructions contain:
– references to the measures to be adopted
or
– instructions to be followed by all means.
The operating instructions are structured as follows:
üthis symbol means: prerequisite for the implementation of a measure or
üaim of a measure.
a) This symbol means: description of a measure.
ðThis symbol means: intermediate result.
ðThis symbol means: result.
An example: pressure adjustment
üRemove the cover panel.
a) Adjust the (A) regulator air pressure to 2.5 bar.
ðThe symbol on the screen turns green.
b) Reinstall the cover panel.
ðThe air pressure has been properly set.
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 11/157
1| Introduction
Information about this manual
1.2.1.2 Warnings
We use the following pictograms for warnings:
WARNING
Dangerous electrical voltage! Danger of electrocution!
WARNING
Hot surfaces, hot gases! Burn hazard!
WARNING
Laser beam! Risk of retinal burns!
WARNING
Risk of injury! Hand injury risk!
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 12/157
1| Introduction
Information about this manual
1.2.1.3 Binding info about safety shoes
NOTE
Wear safety shoes!
When working in areas which are marked with the symbol shown, suitable safety
shoes must be worn!
NOTE
Wear protective goggles!
NOTE
Disconnect power!
NOTE
Read the operating instructions!
NOTE
ESD-hazardous components!
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 13/157
1| Introduction
Information about this manual
1.2.1.4 Prohibition notices
We use the following pictograms for prohibition notices:
Prohibition, in general!
Do not touch!
No fire and naked light!
Eating and drinking prohibited!
No smoking!!
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 14/157
1| Introduction
Information about this manual
1.2.2 Target readers group
These instructions are intended for people who use, adjust, operate or service the
machine.
DANGER
Personal injury or material damage due to inadequate maintenance and improper
operation of the machine!
üUse only qualified personnel!
a) The machine transport, assembly, connection, commissioning, operation or main-
tainance by people who are not sufficiently qualified and informed can cause
severe damage to the machine or damage to people.
b) Such work may therefore only be performed by properly trained personnel! This
personnel must be able to recognize the hazards that can be caused by the sys-
tem mechanical, electrical or electronic equipment.
c) The people who carry out such work must know and have understood the con-
tents of these instructions.
d) Any person involved in the installation, commissioning, operation and/or main-
tenance of the machine must have read and understood the contents of the
"Safety instructions" chapter, as well as the chapters which are relevant for the
specific activity!
1.2.3 Copyright, liability
Ersa has written these operating instructions with great care. However, no guaran-
tee can be given as to the content, completeness and quality of the information
provided in this manual. The content is continually updated and adapted to current
conditions.
All the data published in these operating instructions, including the information
provided about products and procedures, was identified by us to the best of our
knowledge and ability, and using the most modern technical aids. These specifica-
tions are non-binding and for information only; they do not relieve users from the
responsibility to carry out their own checks before operating the equipment. We
accept no liability for any infringement of third party rights for applications and
procedures without prior express written confirmation. We reserve the right to
make technical changes with the intention of improving the product.
To the extent permitted by law, liability for direct, consequential and indirect dam-
age resulting from the purchase of this product is ruled out. All rights reserved.
These operating instructions, or any parts thereof, may not be reproduced, modi-
fied, transferred or translated into another language without the written permis-
sion of ERSA GmbH!
NOTE
The original operating instructions were drawn up in the [German] language
The original operating instructions in German are contained in the [\ERSA
\product_data\049\] folder on the drive of your machine PC. All other available lan-
guages are translations of the original operating instructions. Should any discrepan-
cies occur in the translated text, consult the original operating instructions (German)
for clarification or contact the machine manufacturer.
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 15/157
1| Introduction
Information about this manual
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 16/157
2| Technical data
2 Technical data
2.1 General data.................................................................................................................................................... 18
2.2 Ambient conditions......................................................................................................................................... 19
2.3 Connection data.............................................................................................................................................. 19
2.4 Printed circuit boards and components.......................................................................................................... 19
2.5 Heating system................................................................................................................................................ 20
2.6 Axis system...................................................................................................................................................... 20
2.7 Pneumatics...................................................................................................................................................... 20
2.8 Cameras .......................................................................................................................................................... 21
2.9 PC system requirements ................................................................................................................................. 21
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 17/157
2| Technical data
General data
2.1 General data
Designation
Width (mm) 757
Depth (mm) 934
Height (mm) ab. 759
Weight (kg) ab. 102, incl. control unit
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 18/157
2| Technical data
Ambient conditions
2.2 Ambient conditions
Description
Ambient temperature (°C) 18…26, constant
Air humidity (%, non-condensing) 40…60
2.3 Connection data
Fig.1: Plug CEE 16 A, blue
Designation
Mains voltage 3-wire system N/PE (V) 1 x 230 V
Voltage tolerance (%) ± 10
Mains frequency (Hz) 50 - 60
Fuse (A) 16
Power consumption (kW) 3,68
Connection CEE16 A
2.4 Printed circuit boards and components
Designation
PCB cooling from below Blower
Max. PCB size (width x depth, mm) 530 x 610 (20.8“ x 24“)
Min. PCB size (width x depth, mm) 20 x 20
Max. PCB thickness (mm) 10
Min. component dimensions (mm) 0.2 x 0.4
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 19/157
2| Technical data
Heating system
Designation
Max. component dimensions (mm) 70 x 70
Type operating distance above (mm) 35 – 60 to top heating
35 to bottom heating
Clearance below (mm) 35
2.5 Heating system
Bottom radiator
Designation
Heating type Medium wave, infrared, reactive
ceramic heating elements
Radiator cassette dimensions (width x
depth, mm)
530 x 530
Number of heating zones 8
Rated power (kW) at 230 V 6.4 (8 x 0.8)
Top radiator
Designation
Heating type Hybrid radiators, ceramic heating ele-
ments, medium wave, infrared, with hot
air
Component handling Built-in pipette, motorised
Dimensions (width x depth, mm) 80 x 80
Rated power (kW) at 230 V 0.9 hot air and 0.9 infrared
Aperture adapter (mm) 30 x 30, 45 x 45
Temperature sensors
Designation
Sensor type Digital, non-contact infrared sensor
(pyrometer)
Inputs for k-type thermocouples* 3
*An AccuTC is included in the scope of delivery.
2.6 Axis system
Designation
Type Precision rail guide with step motors
Axes Z heating head, Z pipette
Repeat accuracy (µm) ± 25
Control unit Bottom heating X/Y-axis and pipette ro-
tation
2.7 Pneumatics
Designation
Maximum inlet pressure (bar, oil-free) 6
Ersa GmbH Operating instructions HR 550 XL EN 3BA00247-01|Rev. 1 20/157
Table of contents
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