Metcal RSS-1000-CVSI-NC User manual

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
page 1 of 396
Robotic Soldering System
RSS-1000-CVSI
User Manual
99 Washington Street
Melrose, MA 02176
Phone [phone]
Toll Free 1-800-517-8431
Visit us at www.TestEquipmentDepot.com

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
page 2 of 396
Copyright © 2018 OK International, Inc.
PROPRIETARY NOTICE: This document contains proprietary data of OK International, Inc. The
receipt or possession of this document does not convey any rights to reproduce it, disclose its
contents, or to manufacture the concepts and details disclosed by this document. This document
may not be copied or disclosed in whole or in part to anyone without written permission of an
officer of OK International, Inc.
All rights reserved.

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
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Table of Contents
SAFETY AND REGULATORY INFORMATION............................................................................................. 7
WARNING ......................................................................................................................................................... 7
OTHER SAFETY TIPS .................................................................................................................................... 8
SPECIFICATIONS ............................................................................................................................................... 9
INTRODUCTION AND GENERAL OVERVIEW ........................................................................................... 12
SYSTEM ARCHITECTURE ............................................................................................................................. 13
TIPS BEFORE SETTING UP ........................................................................................................................... 15
UNBOXING INSTRUCTIONS .......................................................................................................................... 16
CONTROLLER BOX CONNECTIONS .......................................................................................................... 20
ROBOT BASE CONNECTIONS ..................................................................................................................... 21
ROBOT GANTRY CONNECTIONS ............................................................................................................... 22
ROBOT HEAD CONNECTION ........................................................................................................................ 22
CV POWER CABLE CONNECTION INSTRUCTIONS ........................................................................... 23
SOFTWARE NAVIGATION ............................................................................................................................. 24
LOGIN SCREEN ............................................................................................................................................ 24
MAIN SCREEN OVERVIEW ........................................................................................................................ 25
MAIN MENU BAR .......................................................................................................................................... 26
HEADER BAR................................................................................................................................................. 28
PROFILE OPTIONS ...................................................................................................................................... 31
ADVANCE PROFILE OPTIONS .................................................................................................................. 33
SOLDER FEEDER OPTIONS ...................................................................................................................... 35
CAMERA TOOLS ........................................................................................................................................... 37
CONNECTION VALIDATION DISPLAY ..................................................................................................... 39
TOOLBAR ....................................................................................................................................................... 43
MOTION CONTROL ...................................................................................................................................... 45
REMAINING MENUS/ BUTTONS ............................................................................................................... 48
SYSTEM OPERATION ..................................................................................................................................... 50
POWERING UP THE UNIT .......................................................................................................................... 50
POWERING OFF THE UNIT ........................................................................................................................ 51
REBOOTING SOFTWARE ........................................................................................................................... 54
LOGGING IN TO SOFTWARE .................................................................................................................... 57
UPDATING SOFTWARE .............................................................................................................................. 60
UPDATING USER MANUAL ........................................................................................................................ 65

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
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SAFETY FEATURES .................................................................................................................................... 69
Z-LIMIT SAFETY ........................................................................................................................................ 69
CLEARANCE HEIGHT SAFETY............................................................................................................... 78
CONNECTION VALIDATION (CV) SAFETY FEATURES .................................................................... 82
CLEAR INDICATORS RADIO FREQUENCY IS ACTIVE ................................................................. 82
AUTOMATIC RF ACTIVATION/DEACTIVATION ............................................................................ 82
SAFETY COVER INSTALLATION & ACTIVATION ............................................................................. 84
COMPONENTS OF AC-RSS-1KSC ....................................................................................................... 85
SAFETY COVER INSTALLATION ....................................................................................................... 86
SAFETY COVER ACTIVATION ........................................................................................................... 98
CHANGING PASSWORD ........................................................................................................................... 102
ADDING NEW USER .................................................................................................................................. 106
DELETING USER ........................................................................................................................................ 112
VIEWING USER LOGIN HISTORY........................................................................................................... 116
CHANGING TIME ZONE ............................................................................................................................ 118
CLEAR PATTERN PARAMETERS ........................................................................................................... 122
RESET TO FACTORY SETTINGS ........................................................................................................... 126
IOT SETTINGS ............................................................................................................................................. 129
PROFILE MANAGEMENT .......................................................................................................................... 130
PROFILE CREATION ............................................................................................................................... 130
SAVING A PROFILE ................................................................................................................................ 131
SAVING PROFILE TO EXTERNAL USB DEVICE ............................................................................... 134
PROFILE REMOVAL................................................................................................................................ 136
FOLDER CREATION ................................................................................................................................ 140
FOLDER REMOVAL ................................................................................................................................ 146
CONNECTION VALIDATION VS STANDARD SOLDERING .............................................................. 150
WHY USE CONNECTION VALIDATION? ............................................................................................ 150
FLOW CHARTS OF SOLDERING PROCESSES .................................................................................... 150
CV TIP SELECTION ................................................................................................................................. 151
CV STATE CODES ................................................................................................................................... 151
SOLDER PARAMETERS AND SETTINGS ............................................................................................. 153
SOLDER POINT ........................................................................................................................................ 153
SOLDER LINE ........................................................................................................................................... 158
FEEDING SOLDER ................................................................................................................................... 163
SOLDER FEEDER SETTINGS ................................................................................................................. 164

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
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WAY POINTS ............................................................................................................................................ 165
SOLDER WIRE FEEDER ADJUSTMENT ............................................................................................... 166
ADVANCED PROFILE FUNCTIONS ........................................................................................................ 168
EDIT PROFILE .......................................................................................................................................... 168
EDIT PROFILE OVERVIEW ................................................................................................................ 168
SOLDER PARAMETER EDIT .............................................................................................................. 170
PROFILE EDIT ...................................................................................................................................... 175
Edit Transition Speed .......................................................................................................................... 180
Edit Parameter ..................................................................................................................................... 182
Editing a Point Coordinate .................................................................................................................. 183
Editing Line Coordinates .................................................................................................................... 185
Editing Coordinates Using Record Coordinate Function ................................................................... 188
Editing Coordinates Using Offset All Function.................................................................................. 192
Editing Feeder Settings ....................................................................................................................... 197
Edit Order of Features Within a Profile .............................................................................................. 199
Remove a Feature from a Profile ........................................................................................................ 200
MERGE PROFILE ..................................................................................................................................... 201
COMPONENT BASED MERGE........................................................................................................... 201
PRINTED CIRCUIT BOARD ASSEMBLY BASED MERGE ............................................................ 208
GENERATE ARRAY ................................................................................................................................ 216
Examples of Generate Array Settings ..................................................................................................... 218
Single Point Array ................................................................................................................................... 229
Multiple Pattern Array ............................................................................................................................ 232
SET GO-TO LOCATION........................................................................................................................... 238
OFFSET PROFILE ..................................................................................................................................... 239
DRY RUN ................................................................................................................................................... 243
TIP ALIGNMENT .......................................................................................................................................... 245
TIP ALIGNMENT ...................................................................................................................................... 245
CENTER POINT ALIGNMENT ............................................................................................................... 248
CAMERA CALIBRATION & FUNCTIONS ............................................................................................... 256
CALIBRATION ......................................................................................................................................... 256
POSITION VERIFICATION TEST ........................................................................................................... 268
FINE ADJUSTMENT AFTER CAMERA CALIBRATION .................................................................... 270
TAKING A SCREENSHOT....................................................................................................................... 273
OPENING AN IMAGE/SCREENSHOT/ DXF/ GERBER ....................................................................... 277

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
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IMAGE ZOOM ........................................................................................................................................... 278
ESTABLISHING FIDUCIAL POINTS (Future Feature, Not Present in this Release) ............................. 282
PATTERN RECOGNITION ...................................................................................................................... 286
Template Creation ................................................................................................................................... 287
Pattern Recognition Using Template ...................................................................................................... 289
Layout Creation ...................................................................................................................................... 305
Component Layout Creation ................................................................................................................... 311
Pattern Recognition Using Layout .......................................................................................................... 315
MECHANICAL ADJUSTMENT OF COMPUTER VISION CAMERA ................................................. 330
TIP CLEANING ............................................................................................................................................. 332
OVERVIEW ............................................................................................................................................... 332
TIP CLEANING PROFILE SET UP .......................................................................................................... 333
ADVANCE TIP CLEANING PROFILE ................................................................................................... 336
IMPLEMENTATION OF TIP CLEANING PROFILE ............................................................................. 341
TIP CLEANING TROUBLE SHOOTING ................................................................................................ 346
EDITING A CLEANING PROFILE .......................................................................................................... 347
CUSTOM CLEANING LOCATIONS ....................................................................................................... 354
BRUSH REPLACEMENT ......................................................................................................................... 356
INSTALLATION & USE OF FUME EXTRACTION & NITROGEN ......................................................... 359
FUME EXTRACTION .................................................................................................................................. 359
NITROGEN ................................................................................................................................................... 360
TROUBLESHOOTING .................................................................................................................................... 362
MAINTENANCE & INSPECTION ................................................................................................................. 367
REPLACING CV-H8-AV .............................................................................................................................. 369
CHANGING SOLDER WIRE FEEDER..................................................................................................... 381
REPLACING A FUSE .................................................................................................................................. 392
WHEN TO CHANGE SOLDERING CARTRIDGE .................................................................................. 396

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
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SAFETY AND REGULATORY INFORMATION
WARNING
 IN ORDER TO BE IN COMPLIANCE WITH REQUIREMENTS OF CE DIRECTIVES, THE
ROBOTIC SOLDERING SYSTEM MUST BE EQUIPPED WITH THE AC-RSS-1KSC SAFETY
COVER ACCESSORY. THE SAFETY INTERLOCK OF THE ENCLOSURE WILL
AUTOMATICALLY CEASE ALL MOVEMENT AND HOME THE SYSTEM ONCE AN
OPERATOR COMES IN CLOSE PROXIMITY OF THE WORKING ENVELOPE.
 THIS PRODUCT IS HIGH VOLTAGE! MAKE SAFETY THE NUMBER ONE PRIORITY
WHEN OPERATING THIS UNIT.
 TO PREVENT FIRE OR SHOCK HAZARD, DO NOT EXPOSE SYSTEM TO MOISTURE OR
OPERATE UNIT WITH WET HANDS.
 TO PREVENT FIRE OR SHOCK HAZARD, DO NOT USE FLAMMABLE SOLVENTS NEAR
OR ON THE SYSTEM WHILE CONNECTED TO A POWER SOURCE.
 FAMILIARIZE ONESELF WITH EMERGENCY STOP BUTTON’S LOCATION AND HOW TO
USE IT.
 TO PREVENT POSSIBILITY OF INJURY OR DAMAGE TO THE SYSTEM:
o DO NOT USE THE UNIT IF THERE ARE ANY VISIBLE BROKEN OR DAMAGED
WIRES/CABLES.
o DO NOT OPERATE WITH ANY COVERS OR PANELS REMOVED.
o DO NOT MOVE THE ROBOT IN ANY AXES BY HAND
o ALWAYS USE THE SILICONE REMOVAL PAD WHEN CHANGING OUT
CARTRIDGES
o ALWAYS CHECK FOR AND REMOVE OBSTRUCTIONS FROM THE WORKING
ENVELOPE OF THE ROBOT
o ALWAYS USE THE ROBOT WITHIN THE STANDARD REQUIREMENTS (SUCH AS
VOLTAGE, AIR PRESSURE, POWER FREQUENCY, ETC.) AS DETAILED IN THE
SPECIFICATIONS ON PAGE 9
 CHANGES OR MODIFICATIONS MADE TO THIS PRODUCT WITHOUT EXPRESS
CONSENT FROM OK INTERNATIONAL WILL VOID THE USERS AUTHORITY TO
OPERATE THE EQUIPMENT.
 DO NOT PLACE ANY MAGNETS ON THE CONTROLLER BOX OF THE ROBOT, AS THIS
WILL PRODUCE UNDESIREABLE EFFECTS ON THE SYSTEM
 Read and understand the entire User’s Manual before installation or operation of the Robotic
Soldering System. Heed ALL warnings on the system and in the operating instructions.
 The Robotic Soldering System is only for point to point and line soldering of printed circuit
board assemblies. If you are not familiar with the proper and safe operation of the unit, do not
operate it until properly trained.
 Operate the unit from the type of power source indicated on the serial number label.
 Use only the supplied power cord. Avoid damage to the power cord. If damage should occur,
replace it with the approved OK International replacement power cord.
 This CAUTION symbol on the equipment refers the user to the user guide for additional
important information. This symbol appears next to the relevant information in the manual.
 This HOT symbol on the equipment warns the user of a hot surface and potential injury if
touched. This symbol appears next to the relevant information in the manual.

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
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 This HEAVY LIFTING symbol on the packaging warns the user to team lift the Robotic
Soldering System during removal from packaging and installation on the workbench. This
symbol appears next to the relevant information in the manual.
 This PINCH POINT symbol on the equipment warns the user of a potential injury. This symbol
appears next to the relevant information in the manual.
 This EYE PROTECTION symbol on the equipment warns the user of potential injury due to
flying debris. This symbol appears next to the relevant information in the manual.
OTHER SAFETY TIPS
 Once the unit has been unboxed, inspect unit and remove any obstructions that may have
been put in place to ship the unit securely.
 Unplug the unit before cleaning or performing any maintenance. Clean the exterior of the
system with a damp cloth. Do not use solvent-based cleaners.
 Slots and openings in the system are provided for ventilation and to ensure reliable operation
as well as protection from overheating. The openings should never be blocked or covered.
 Do not overload power outlets and extension cords. This can result in fire or electric shock.
 Unit to comply with CE, UL, & CSA standards.
 When operating this equipment, please exercise caution. If this unit is used in a manner in
which it is not intended for, serious personal injury may occur. Please read this user manual
thoroughly prior to use.
 The main power cord is a means for disconnecting the equipment from an operating energy
source. Position the equipment in a way that impedes the disconnection of the main power
cord in case of an emergency.

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
page 9 of 396
SPECIFICATIONS
Microprocessor
Core Logic
64-bit Intel® Atom™ E3826 Series SoC
Integrated Intel HD Graphics with Open Source Hardware-
A
ccelerated Drivers for Linux OS
Memory 2GB DDR3L RAM - System Memory
8 MB SPI Flash - S
y
stem Firmware Memor
y
Video Intel HD Graphics (1920x1080 max resolution)
HDMI 1.4a
(
micro HDMI connector
)
A
udio Di
g
ital via HDMI
I/O
Micro SDSDIO
SATA2 3Gb/sec
USB 3.0 (host)
USB 2.0 (host)
Serial debug via FTDI cable
1 GB Ethernet RJ-45 connecto
r
8 x Buffered GPIO pins (2 pins support PWM)
I2C & SPI bus
2 x 16550 HS UARTs, one with CTS/RTS
System Firmware Flash Programming Header (compatible with
Dedi-Pro
g
pro
g
rammer
)
Board Dimensions 99 x 74mm
(
2.9 x 3.9in
)
Temperature Ran
g
e 0
–
40 °C
Power 5V (min 2.5A) DC
Operating System Linux O/S
Lan
g
ua
g
e Unicode supported
Motion Control 4-
A
xis
Pro
g
rammin
g
Methodolo
gy
Icon Driven / Graphical Pro
g
rammin
g
Lan
g
ua
g
e
Motion Interpolation 2D, 3D and 4D
Interface with Solder Iron &
Feeder Control Required
File Importin
g
DXF, GER, JPEG
Teach Mode Displa
y
/ Solder Coordination in Real Time
Run Mode Displa
y
/ Solder Coordination in Real Time
Setup Mode Vector speed, acceleration, delay, unit measurement,
programmable cleaning & origin location, relative snap distance
and continuous jog, programmable retract height, programmable
dot & line.
Operatin
g
Temperature 0
–
55° C
ESD housin
g
10
9 ohms
–
1011 ohms
Li
g
htin
g
Minimum 3W LED
Communication Protocol USB 2.0/3.0

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
page 10 of 396
Power Supply & Soldering Iron
Metcal CV-PS5200-R with Communications Port
A
pplication Dependent CV Cartrid
g
es
Ambient Operating Temp. 10 to 40 °C
Max. Enclosure Temp. 55 °C
Input Line Voltage 100 – 240 VAC, Grounded Circuit
Input Line Frequency 50/60 Hz
Rated Power Consumption 125 W
Output Power 80 W Max.
Output Frequency 13.56 MHz
Heating Method Induction
Communications USB
Power Supply Dimensions
W x D x H 121 x 130 x 235 mm
Power Supply Weight 3.35 kg
Certification / Marking CE TUV
Tip-to-Ground Potential <2 mV
Resistance <2 Ohms
Idle Temp. Stability ±1.1°C in Still Air
Tip Temp. Accuracy Meets or exceeds IPC J-STD-001 Standard
Soldering Iron Cable Length 183 cm (72”), Burn Proof, ESD Safe
Soldering Iron
Connectors
Radio Freq.
Connecto
r
F-type Power Connector
Power
Connecto
r
6 pin DIN
Touch Screen Monitor
Diagonal Size 396.24 mm [15.6”]
Aspect Ratio 16:9
Native (Optimal) Resolution 1366 x 768
Response Time 10 ms
Computer Vision Camera
Me
g
apixels 3.2 MP
Resolution 2048 x 1536
Power Consumption <3 W maximum
Interface USB 3.0
Witness Camera
Resolution 720 x 480
Power Consumption <1 W maximum
Interface Wire Harness