Oki APR-5000 User manual

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www.okinternational.com - 1 - P/N 7000-1370, Revision B
APR-5000
User’s Manua
l
Specifications
Introduction & General Overview
System Features and Accessories
Set-up
Software Operation
Calibration
Nozzles and Vacuum Tubes
Spare Parts and Accessories
Site Preparation
Warranty & Service
Precision Systems for the Electronics Bench
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www.okinternational.com - 2 - P/N 7000-1370, Revision B
TABLE OF CONTENTS
PREFACE Safety and Regulatory Information
APR-5000 Series Main Unit Specifications
SECTION I Introduction and General Overview
SECTION II System Features and Accessories
SECTION III Set-Up Procedures
SECTION IV Software Operation
SECTION V Hardware Trouble Shooting, Optical and Head Calibration
SECTION VI Nozzles, Vacuum Pick-up Nozzle and Accessories
SECTION VII Calibration Kit and Spare Parts
SECTION VIII Site Preparation
SECTION IX Warranty and Service
PREFACE
SAFETY AND REGULATORY INFORMATION
WARNING
•TO PREVENT FIRE OR SHOCK HAZARD, DO NOT EXPOSE SYSTEM TO
MOISTURE.
•TO PREVENT FIRE OR SHOCK HAZARD, DO NOT USE FLAMMABLE
SOLVENTS NEAR OR ON THE SYSTEM WHILE CONNECTED TO POWER
SOURCE.
•TO PREVENT POSSIBILITY OF INJURY OR DAMAGE TO THE SYSTEM, DO
NOT OPERATE WITH ANY COVERS OR PANELS REMOVED.
•CHANGES OR MODIFICATIONS MADE TO THIS PRODUCT WITHOUT
EXPRESS APPROVAL FROM METCAL COULD VOID THE USERS
AUTHORITY TO OPERATE THE EQUIPMENT.
●Read and understand the entire Operator’s Manual before installation or
operation of the APR-5000. Heed all warnings on the system and in the operating
instructions.
●Use of the APR-5000 is intended only for the removal and placement of
electronic components on to printed circuit boards by properly trained personnel.
If you are not familiar with the proper and safe operation of the APR-5000, do not
operate until proper training has been obtained.
●The unit should be operated only from the type of power source indicated on the
serial number label.
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www.okinternational.com - 3 - P/N 7000-1370, Revision B
●Use only the supplied power cords. Avoid damage to the power cord. If damage
should occur, replace it with the approved Metcal replacement power cord.
This CAUTION symbol on the equipment refers the user to the Operator’s Manual for
additional 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. Please refer to the Operator’s Manual for additional information. This symbol
appears next to the relevant information in the manual.
This HEAVY LIFTING symbol on the packaging warns the user to team lift the APR-
5000 during removal from packaging and installation on the workbench. Please refer to
the Operator’s Manual for additional information. This symbol appears next to the
relevant information in the manual.
Other Safety Tips
●Unplug the unit before cleaning. Clean the exterior of the system with a damp
cloth. Do not use solvent-based cleaners.
●Slots and openings in the system provided for ventilation and to ensure reliable
operation and protection from overheating. The openings should never be
blocked or covered.
●Do not overload power outlets and extension cords. This can result in a risk of
fire or electric shock.
SAFETY AND EMC INFORMATION
Declaration of Conformity
We declare our sole responsibility that the product APR-5000 to which this
declaration relates, is in conformity with the following standards and bears
therefore a CE mark:
●EN 61010-1
●EN 61010-2-010
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www.okinternational.com - 4 - P/N 7000-1370, Revision B
Safety Standards
The APR-5000 is in conformity with international safety requirements and bears
the following safety marks:
●ETLu
●ETLc
EMC Standards
Europe
●EN 61000-3-2/3
●EN 61326-1
North America
●47 CFR part 15 ( FCC Class A ), meets Class A limits
Federal Communications Commission
This equipment has been tested and found to comply with the limits for Class A digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in an industrial installation. This
equipment generates, uses and can radiate radio frequency energy and, if not installed
and used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the system off and on, the user
is encouraged to try to correct the interference by one or more of the following
measures:
●Reorient or relocate the receiving antenna.
●Increase the separation between the equipment and receiver.
●Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.
●Consult the dealer or an experienced radio / TV technician for help.
Minimum Computer Operation Specification
APR-5000 Rework System
Base Unit Input Voltage 115VAC/230VAC, 50/60Hz
Base Unit Power
Consumption 2000 watts
Circuit Breaker Subzone
Heaters 15 amp
Circuit Breaker Main Unit 15 amp
Max Source Temperature
Bottom-side heater: 350°C (662°F)
Max Source Temperature
from Micro Oven 400°C (752°F)
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www.okinternational.com - 5 - P/N 7000-1370, Revision B
Basic Specifications of the APR-5000
APR-5000 Rework System
Base Unit Input Voltage 115VAC/230VAC, 50/60Hz
Base Unit Power
Consumption 2000 watts
Circuit Breaker Subzone
Heaters 15 amp
Circuit Breaker Main Unit 15 amp
Max Source Temperature
Bottom-side heater: 350°C (662°F)
Max Source Temperature
from Micro Oven 400°C (752°F)
Temperature Control/Range Closed-loop RTD
Maximum PCB Dimensions 250 X 230mm
(10” X 9”)
PCB Thickness 0.5 – 2.0mm
Component Maximum
Weight 55 gm (.92 oz)
Component Types BGA, CSP, LGA, Micro SMD, MLF
Bumped Chip
Airflow 8-24 l/min
L=8lpm, M=16lpm, H=24lpm
Heater Element 350 W top / 1.5kW bottom
Vacuum Pump 15" Hg 381mm Hg
Base Unit Dimensions 50 X 76 X 71 cm (w X d X h)
Base Unit Weight 64 Kg (140Lbs)
Warranty One year parts & labor
90 days heaters & lamps
System Part Numbers
Part Number Item Description
APR-5000 115/230 VAC Array Package Rework
System
APR-5000-COMP Array Package Rework System with
Computer
APR-5000-COMP-F Array Package Rework System with
Computer and Flat Screen Monitor
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Environmental Conditions (all models)
•Suitable for indoor use only at altitudes not exceeding 6500 ft (2km)
•All systems must be grounded
•Maximum relative humidity of 80% at 88°F (31°C) decreasing linearly to 50% at
104°F (40°C)
•Temperature range of 41°F (5°C) to 104°F (40°C)
•Mains supply voltage fluctuations not to exceed ±10% of the nominal voltage
•Pollution degree 2 per IEC 644
•Insulation category II
Vision System
The APR-5000 systems provide a maximum four-sided view of 46mm x 46mm (1.77" x
1.77). The camera magnification has a range of 10X to 27X.
Shipping Data
Size 28" W x 36"D x 32" H
Weight 180 lbs. (82 KG.)
I. INTRODUCTION AND GENERAL OVERVIEW
Thank you for your purchase of an APR-5000 Array Package Rework System. Each unit
has been inspected thoroughly by OK International prior to shipment, and with proper
maintenance will give you years of reliable performance.
This Operator’s Instruction Manual is a valuable resource. It explains the systems
options, features, specifications and the correct operation of your APR-5000 Array
Package Rework System. If any problems should occur during setup or operation of
your system, call or contact Metcal’s Technical Support Department at [phone],
Fax [phone] or You may also contact your local Representative.
APR-5000 Array Package Rework System provides both accurate component
placement and specifically tailored reflow profiles (through OK International patented
single component Micro Oven™) in one user friendly, single platform rework system.
The challenges of Array Package Rework, and the inability to easily inspect placement
accuracy (with BGAs in particular), call for a solution that allows for simultaneous
viewing of PC board pads and component pads or balls for accurate placement. The
APR-5000 fills this need with quick, accurate placement through the use of an optical
system employing dual image overlay technology. The image of the BGA solder balls is
overlaid with that of the PC board pattern. The image is viewed on the computer monitor
then the micrometers permit fine X, Y and theta adjustment at up to 27X magnification.
Finally, the part is placed and the vacuum is released automatically.
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www.okinternational.com - 7 - P/N 7000-1370, Revision B
When operating this equipment, please exercise caution. If this unit is used in
a manner, which it is not intended for, serious personal injury may occur.
Please read this operators manual thoroughly prior to use.
After accurate component placement is achieved, the vacuum pickup tube is
automatically retracted and the reflow nozzle is lowered into place. At this point, the
component is subjected to a 5 zone, full convection reflow profile, specifically tailored to
the requirements of that particular PCB, device and solder paste. Accurate duplication
of original oven reflow parameters is achieved.
During the course of the reflow profile, source temperatures and time intervals can be
modified “On the Fly”, eliminating the need to wait for the current profile to terminate
before modifications can be made. Precise solder joint temperatures are measured and
displayed on a real time graphical display, thus providing the necessary data to
accurately and easily establish the optimum reflow profile for each particular application
within minutes.
II. SYSTEM FEATURES AND ACCESSORIES
APR-5000 SYSTEM INCLUDES:
1. APR-5000 Series Base Unit
2. Adjustable size board holder
3. APR-5000 Accessory Kit (APR-5AK)
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www.okinternational.com - 8 - P/N 7000-1370, Revision B
ACCESSORY KIT INCLUDES:
VNZ-01 APR Vacuum pick up nozzle 1mm O/D
VNZ-03 APR Vacuum pick up nozzle 3mm O/D
VNZ-05 APR Vacuum pick up nozzle 5mm O/D
VNZ-08 APR Vacuum pick up nozzle 8mm O/D
VNZ-12 APR Vacuum pick up nozzle 12mm O/D
SOFT-APR-5000 APR-5000 Installation Software
FS-APR-2 PCB Finger Short (Pack 2)
21104 Thermocouple fine gauge
20534 Squeege Handle
20066 Optical Calibration Gun sight
AC-RP Nozzle Removal Pad
20207 Kapton Tape
FSL-APR-2 PCB Spring Finger Long (Pack 2 )
UBS-APR Under Board Support APR-5000
20987 Adjustable "V" Block for CSP Components
APR-VA USB External Video Adaptor
APR-VRT Vacuum Nozzle Removal Tool
Power Cord
Video Cable
Monitor Cable
Flathead Screwdriver
Phillips Screwdriver
3 Specialty Hex Wrenches
1 Standard Hex Wrench Set
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www.okinternational.com - 9 - P/N 7000-1370, Revision B
Main Unit Components (Figure 1)
1. Power “on” LED
2. Reflow head “X” axis release button
3. Camera & Lighting assembly
4. Reflow head “up” button
5. Reflow head “down” button
6. Type K thermocouple inputs (3)
7. “Y” Axis micrometer
8. Command "Enter" button
9. “X” Axis micrometer
10. Open Frame adjustable printed circuit board holder
11. Reflow head “Y” axis release button
12. Component theta control
Figure 1
12
2
4
10
7
9
3
6
5
1
11
8
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Main Unit Components, Rear View (Figure 2.1 & 2.2)
1. RS-232 connector.
2. Composite video output.
3. Main air connector for reflow head.
4. Nitrogen / Shop air input connector.
5. Fuse Holder (Version 1) / Breaker (Version 2)
6. AC Power input.
7. Reflow head electrical connector
8. Main power switch.
Figure 2:2 (Version 2)
Figure 2:1 (Version 1)
8
7
5
6
1
4
3
2
1
2
3
4 5
6
7
8
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www.okinternational.com - 11 - P/N 7000-1370, Revision B
The main unit is very heavy. Please uncrate it with 2 people.
DO NOT LIFT THE MAIN UNIT BY THE RAILS.
LIFTING BY THE RAILS WILL DAMAGE THEM!
III. SET-UP PROCEDURES
A. APR-5000 Main System
Prior to performing initial set-up, unpack all accessories from their shipping containers.
Ensure that your APR-5000 has arrived complete by verifying that all of the accessories
listed in Section II of this manual have been included. After all components are located,
setup can then begin.
1. Remove the APR-5000 Main Unit and all accessories from their shipping
containers.
When setting up this equipment, be sure to arrange it in a position that allows the user
to operate this machine in a comfortable, well-spaced environment.
IMPORTANT: Every APR-5000 Rework System has been factory assembled and
calibrated. Recalibration is not necessary after initial setup. However verifying
calibration and product functionality is strongly recommended prior to initial use. This
procedure is thoroughly discussed later in the manual in the section titled “Calibration.”
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www.okinternational.com - 12 - P/N 7000-1370, Revision B
B. Computer and Software Setup
System Requirements
To run the APR-5000 you will need the following:
●PC with Pentium III processor (600 MHz or higher recommended)
●128 MB of (RAM) memory
●3.5” floppy disk drive
●Hard disk drive with at least 20 Megabytes of free space
●CD-ROM
●32MB AGP video card or equivalent
●17” Monitor ( .28dpi )
●Windows® 98, 2000 or Windows® NT operating system (The APR-5000 is
not Windows XP compatible)
Set-up
1. Unpack the computer and all its accessories.
2. Using the documentation supplied by the PC Manufacturer make all the
necessary connections and power the computer “ON”.
3. Using the supplied disks, install the APR-5000 software.
The software will automatically start the “Installshield Wizard”.
Follow all the prompts and the software will self install.
4. Connect the PC to the APR-5000 utilizing the supplied RS-232 cable.
5. Connect the video output (Figure 2. #2) to the video input on the PC utilizing the
supplied RCA video cable.
C. Final Power-up Sequence
1. Plug in the power cord on the APR-5000 Main Unit.
2. Set the APR-5000 Main power switch to the “on” position.
3. On the “desktop” Double click the icon.
Your APR-5000 Series Rework System is now ready for operation!
IV. Software Operation
Once your system has been setup and your software has been installed you must follow
this sequence for everyday operation of your APR-5000 system.
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www.okinternational.com - 13 - P/N 7000-1370, Revision B
1. Set the APR-5000 Main power switch to the “on” position.
2. On the “desktop” Double click the icon. Allow system to initialize.
Your startup screen will appear as follows:
From this startup screen you have 3 options:
1. Process Run – This selection allows you to open and run a previously created
and stored profile for either placement or removal.
2. Process Setup – This selection allows the modification of a previously stored
profile or the creation of either a placement or removal profile.
3. System Setup – This selection allows you to set the system parameters, security
levels and enter the calibration modes.
Process Run - Placement
1. Select Process Run from File Menu. Open the desired profile.
2. Attach vacuum cup.
3. Attach reflow nozzle. Click Next
4. Pull out camera to continue. Insert centering fixture. Click Next
5. Use action buttons to pick up the component. (Camera view pops up on the
screen) Press action buttons to move head into focus. Click Next
6. Manually fine adjust component to vacuum tube, this brings the component into
focus using the Up Down buttons on the screen. Align the component using the X
Y and Theta axes adjusters. Click Next and return camera home
7. Display will now change to the profile view. “Hit action buttons to move the reflow
head down into placement position.” Adjust component height using computer
screen buttons. Click Next
8. Select Next to release the component onto its target pads.
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www.okinternational.com - 14 - P/N 7000-1370, Revision B
9. “Hit action buttons to lower reflow head to set nozzle height.” Fine adjust nozzle
height using computer screen buttons or APR-5000 manual keys.. Click Next
10.Select Next and then click Start to begin the profile.
11.When profile is completed. Click Next
12.“Hit action buttons to move head to home position.”
13. Save Saves graphics as a .DAT file.
14.Click “Finish” to complete process.
Process Set Up – New Process- Placement
1. Click on “process set up”
2. Click on “Placement only”
3. Click on “new process” and enter chip package information.
4. “Attach Vacuum Cup” and Reflow Nozzle.
1. Yes – Enter the vacuum cup part number.
2. No
Click Next
Attach Reflow Nozzle during process?
•Yes – Enter the Nozzle part number.
•No
Click Next
5. Camera – Pull out camera to continue.
Click Next
6. Select Component Pick-up Method.
Click Next
7. Component – Set the height and the method for picking up the component.
•Component Pick Up – This mode picks up the part for a placement onto a
previously prepared board.
•Component Pick Up with Paste – This mode picks up a component that has been
stenciled with solder paste for placement onto the PCB.
•Component Pick Up with Flux Dip – This mode picks up of a component and
allows the additional steps required to dip the part into a dip transfer plate.
Click Next
8. Screen Prompt “hit action buttons to return head to home position.”
Click Next
9. Screen Prompt “remove the centering fixture from the camera housing” Select
Next to continue.
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www.okinternational.com - 15 - P/N 7000-1370, Revision B
Click Next
10.Vision – Adjust camera parameters; lamp intensity, focus, zoom and iris controls.
Click Next
11.Camera – Return camera to home position to continue.
12.Component – Set the height for placing the component.
•Coarse – action buttons
•Fine – Up / Down software buttons on screen or the action buttons
Move head down to place position.
Click Next
Adjust the nozzle height.
Click Next
13.“Create Profile” – This screen allows the setup of the air flow and heating
parameters of the reflow cycle.
•Select the airflow rate: High, Med, Low/.
•Grab and move the temperature and time bars to the desired positions to create
the thermal characteristics of the profile.
Click Start to run profile or Next to continue without running the profile.
•The display will prompt you to “Hit action buttons to move reflow head to the
home position” the head will move at high speed to the top position. A window
automatically opens to allow for the profile to be saved.
14.Save – This allows you to run the new process in verify mode, permitting you to
change the settings while it runs and then save the profile. Or you can just save
the process.
Process setup – New Process – Removal
1. Process Info
2. Software prompts “Select Yes” to attach vacuum cup and reflow nozzle during
process Run and creates a custom user’s prompt.
3. “Pull out camera to continue”
4. Adjust camera settings; focus height, zoom, lamp intensity, and iris controls.
Click Next
5. “Return camera home to continue.”
6. Adjust the reflow nozzle height. “Using action buttons move nozzle into position
on PCB.” Click Next
7. Set method of lifting. Click Next
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www.okinternational.com - 16 - P/N 7000-1370, Revision B
Please do not use your hand to catch the component.
Even after the cooling cycle the component can be extremely hot.
8. Retract Vacuum Tube
9. Raise head
10.Do not remove
11.Select airflow rate and make adjustments to the profile settings in the profile
window. Click Next
12.L M H
13.”Hit action buttons to move reflow head to the home position.” Click Next
14. Start To verify your new process.
15.When completed click Next. Software prompts select Next
16.Select Next to release component. Window opens to save profile
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www.okinternational.com - 17 - P/N 7000-1370, Revision B
V. HARDWARE TROUBLE SHOOTING & CALIBRATION
The following trouble shoot guide details a step-by-step process software trouble-
shooting guide that will help identify APR-5000 hardware faults. If needed, Optical
Calibration and Head Calibration is also detailed. For more in-depth calibration
procedures and required parts refer to the APR-5000 Calibration Kit, part number
APR-CALKIT.
APR-5000 Hardware Trouble Shooting Guide
Set Up
1. Turn APR-5000 unit on and boot the APR-5000 Software.
2. Open System Set-Up by clicking System Set-Up.
3. Click on “No Password” button and enter the APR password 94025.
4. Click on the Test tab.
5. This test window must be exited as shown below to avoid any process run
issues.
Click Here for
System Set Up
Option
Type in 94025
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www.okinternational.com - 18 - P/N 7000-1370, Revision B
Notes
Press Action Buttons
as noted. Check mark
identifies if buttons
are workin
g
p
ro
p
erl
y
.
Press Action Buttons
as noted. Check mark
identifies if buttons
are workin
g
p
ro
p
erl
y
.
Press Next Button as
noted. Check mark
identifies if button is
workin
g
p
ro
p
erl
y
.
Head Home switch
check mark must be
checked.
Physically lift head up.
Head Switch must go
off when head is
lifted.
Inputs are not to
be altered or
tested.
Inputs are not to
be altered or
tested.
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Notes
Physically pull
camera out.
Check mark
moves from
Camera Home
switch to
Camera EOT
switch.
Physically pull
camera out.
Check mark
toggles from
Camera Home
switch to
Camera EOT
switch.
Physically press
the head X and Y-
axis switches on
the APR-5000
heater head.
Check mark must
turn on
momentaril
y
.
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