Philips AX-201 User manual

Integrated electronics manufacturing solutions
Option Manual AX-201
Coplanarity

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DOCUMENT DATA
HISTORY
ISSUE DATE ORDER NUMBER REVISION CODE STATUS RELEASE DOCUMENT
First issue June 2008 4022 593 52341 08.01 Current N.A.
Document . . . . . . . . . . . . . . . . . . Option Manual AX-201 coplanarity
Based on . . . . . . . . . . . . . . . . . . N.A.
Order number . . . . . . . . . . . . . . . 4022 593 52341
Supplied with. . . . . . . . . . . . . . . . N.A.
Project number. . . . . . . . . . . . . . . 9466-916-00051

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Table of contents
Table of contents ......................................................................................................................................3
1. Introduction.................................................................................................................................4
1.1. General ..................................................................................................................................4
1.2. Project deliveries....................................................................................................................4
2. Safety .........................................................................................................................................5
2.1. General Information ...............................................................................................................5
2.2. Laser Classification................................................................................................................6
2.3. User Precautions & OEM Responsibilities.............................................................................6
2.3.1. Remote Interlock....................................................................................................................6
2.3.2. Key Control ............................................................................................................................6
2.3.3. Power-On Delays...................................................................................................................7
2.3.4. Beam Attenuators ..................................................................................................................7
2.3.5. Emission Indicator..................................................................................................................7
2.3.6. Warning Signs........................................................................................................................7
2.3.7. Coplanarity Laser Safety Specification ..................................................................................8
3. installation...................................................................................................................................9
3.1. Prerequisites..........................................................................................................................9
3.2. Hardware installation .............................................................................................................9
3.2.1. Parts.......................................................................................................................................9
3.2.2. Diagrams..............................................................................................................................12
3.2.2.1. Wiring diagram ................................................................................................................12
3.2.2.2. Power and Safety Circuit.................................................................................................13
3.2.2.3. Ethernet diagram.............................................................................................................14
3.2.2.4. Sensor-Safety circuit interconnection diagram................................................................14
3.2.2.5. FireSync-Sensor interconnection diagram ......................................................................15
3.2.3. Hardware installation Instruction..........................................................................................16
3.3. Software installation.............................................................................................................18
3.3.1. Parts.....................................................................................................................................18
3.3.1.1. cal.cfg..............................................................................................................................18
3.3.1.2. cpl.cfg..............................................................................................................................19
3.3.1.3. settings.xml .....................................................................................................................20
3.3.2. Software installation instruction ...........................................................................................22
3.3.2.1. Install Machine software..................................................................................................22
3.3.2.2. Check the serial number .................................................................................................27
3.3.2.3. Check Component file names .........................................................................................27
3.3.2.4. Check setting of the service image .................................................................................27
3.3.2.5. Teach x, y coordinates. ...................................................................................................28
3.4. PPS Pro software.................................................................................................................29
3.4.1. Install PPS PRo Software ....................................................................................................29
3.4.2. Update PSI file.....................................................................................................................29
3.4.2.1. Update Ale file.................................................................................................................30
3.4.2.2. Create placement programs............................................................................................30
4. Operation..................................................................................................................................31
4.1. Functional description ..........................................................................................................31
4.2. User instruction....................................................................................................................32
4.3. Troubleshooting ...................................................................................................................33
5. Maintenance and Service .........................................................................................................36
5.1. Maintenance ........................................................................................................................36
5.1.1. Glass plate cleaning.............................................................................................................36
5.2. Spares..................................................................................................................................37
5.3. Repair instruction.................................................................................................................38
5.3.1. Safety sticker .......................................................................................................................38
5.3.2. Laser sensor module ...........................................................................................................39

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1. Introduction
1.1. General
This manual describes the option coplanarity checker for AX-201.
With this option it is possible to check the leads of components for coplanarity during production.
1.2. Project deliveries
With this option the following items are delivered:
•Option manual
•Coplanarity checker module (sensor + controller)
•Cables to connect the laser to power Ethernet and safety circuit
•Hub
•Mounting material for mounting the module in the machine including vacuum calibration plate
and safety relais.
•AX-201 control software installation CD’s including data files for the components SO8 and
TSSOP48 and coplanarity checker module software.
•PPS Pro installation CD's (includes optimizer with Coplanarity support)
•Laser warning labels

5
2. Safety
2.1. General Information
The laser light sources used in LMI Sensors are semiconductor lasers emitting visible light.
The LMI Laser Sensor used is a 3B/lllb classification.
Caution! Use of controls or adjustments or performance of procedures other than
those specified herein may result in hazardous radiation exposure.
The following safety regulations are applied;
1. International Standard IEC 60825-1 (2001-08) Consolidated edition,
Safety of laser products –Part 1: Equipment classification, requirements and user’s guide
•Special emphasize §10; Safety precautions
•Special emphasize §12.5.2 Class 3B Laser Products
On this Laser NO CORRECTIVE MAINTENANCE is performed. See chapter 5.1.
2. Technical Report TR 60825-10, safety of laser products
–Part 10. Application guidelines and explanatory notes to IEC 60825-1
3. Laser Notice No. 50,
FDA and CDRH http://www.fda.gov/cdrh/rad-health.html

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2.2. Laser Classification
The used laser is a Laser class 3B/lllb laser component:
Class 3B/lllb components are unsafe for eye
exposure. Usually only ocular protection would
be required. Diffuse reflections are safe if viewed
for less than 10 seconds.
Labels reprinted here are examples relevant to
the laser classes. For detailed specifications
observe the label on your coplanarity laser.
2.3. User Precautions & OEM Responsibilities
The specific user precautions as specified in IEC 60825-1 and FDA CFR Title 21 Part 1040 are:
Requirements Class 3B/IIIb Laser
Remote interlock Required See § 2.3.1
Key control Required. See § 2.3.2
Cannot remove key when in use
Power-On delays Required. See § 2.3.3
Beam attenuator Required. See § 2.3.4
Emission indicator Required. See § 2.3.5
Warning signs Required. See § 2.3.6
Beam path Terminate beam at useful length (safety covers)
Specular reflection Prevent unintentional reflections
Eye protection Required under special conditions
Laser safety officer Required (See §10; Safety precautions of the IEC 60825 standard)
Training Required for operator and maintenance personnel
LMI Class 3B/lllb laser components do not incorporate the safety items in the table above. These items
are added and completed by Assembléon. Therefore the LMI Laser Sensor should not be operated
outside the machine.
2.3.1.Remote Interlock
A remote interlock connection must be present in Class IIIB laser systems. This permits remote
switches to be attached in serial with the key lock switch on the controls. The deactivation of any remote
switches must prevent power from being supplied to any lasers.
In the AX-201 with coplanarity checker this is covered by the separate E-stop circuit for the laser. The
'AX-201 Enabling switch' will not enable the Laser. For detailed information see chapter 3.2.2 Electrical
Diagram
2.3.2.Key Control
A key operated master control to the lasers that prevents any power from being supplied to the lasers
while in the OFF position. The key can be removable in the OFF position but the switch must not allow
the key to be removed from the lock while in the ON position.
In the AX-201 with coplanarity checker the Machine Mains switch with pad-lock does not allow any
power being supplied to the laser. For information on use of the Mains switch with a padlock see
chapter H7 Maintenance 1st 'NOTE'

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2.3.3.Power-On Delays
A delay circuit is required that illuminates warning indicators for a short period of time prior to supplying
power to the lasers.
In the AX-201 with coplanarity checker a delay circuit is created in the startup of the pick and place
process.
2.3.4.Beam Attenuators
A permanently attached method of preventing human access to the laser radiation other than switches,
power connectors or key control must be employed. On the laser sensor on the AX-201, the beam
attenuator is supplied with the sensor as an integrated mechanical shutter.
See chapter 5.1 for detailed information.
2.3.5.Emission Indicator
It is required that the controls that operate the sensors incorporate a visible or audible indicator when
power is applied and the lasers are operating. If distance (>2 m between sensor and controls) or
mounting of sensors intervenes with observation of these indicators, a second power-on indicator
should be mounted at some readily observable position. When mounting the warning indicators, it is
important not to mount them in a location that would require human exposure to the laser emissions.
In the AX-201 with coplanarity checker the emission indicator's are integrated in the 'align process
warnings'.
2.3.6.Warning Signs
Laser warning signs must be located in the vicinity of the sensor such that they will be readily observed.
Location and example of the warning stickers on the AX-201 with coplanarity checker
•One sign on the front
cover
•On sign on the rear
cover
•One sign on each side
of the coplanarity
checker

8
2.3.7.Coplanarity Laser Safety Specification
•Laser specifications:
Laser Classification: 3B/IIIb laser component
Peak Power: 130mW
Emitted Wavelength: 660nm
Pulse Frequency: 1kHz
Pulse Width: 42 µs fixed
Laser safety connections
The coplanarity laser safety connections are described in chapter 3.2.2 of this manual

9
3. installation
3.1. Prerequisites
•Existing AX-201 must be upgraded to SW version 2.0 or higher.
•Hardware conform PA 2410/00.
•A padlock must be available during installation.
•PPS Pro Installation CD version 8.4 and patch 5 and A-series optimizer CD version 2.2 or
higher.
3.2. Hardware installation
3.2.1.Parts
Nr Description Image
1. Ethernet switch with Ethernet
cables
2. Coplanarity laser sensor module,
including safety relais.

10
3. FireSync station
4. Sensor cable
5. IBB Safety cable

11
6. Safety extension cable
7. Power supply for FireSync
station and Power supply for
Coplanarity sensor
8. Power connection block and
power cable

12
3.2.2.Diagrams
3.2.2.1. Wiring diagram

13
3.2.2.2. Power and Safety Circuit
Remark:
The 12V power supply for “LMI Firesync Station” is connected to PCB L1 position X3 instead of position
X2. The 230V connection block is not available. Both is wrong in this drawing and will be updated!!

14
3.2.2.3. Ethernetdiagram
3.2.2.4. Sensor-Safety circuit interconnection diagram
Basic diagram;
Connection Laser safety relais:

15
3.2.2.5. FireSync-Sensor interconnection diagram

16
3.2.3.Hardware installation Instruction
•Power down the AX-201.
•Lock the main switch with a padlock
•Remove the right side cover to be
able to access the rear of the aPC
and aSC
•Pull out the control supply unit at the
rear of the machine.
•In case the machine is not equipped
with an Ethernet Hub, these steps
are not necessary. Disconnect the
crosslink cable between X63 of the
aPC and X63 of the aSC.
•Discard the cable
•Place the Ethernet switch in the base
underneath the aSC and aPC
•Take the power cable from the
Ethernet Switch and lead this to the
front of the machine
•Connect the new Ethernet cables
from the HUB to the X63 of the aPC
and the X63 of the aSC
•Place the power connection block in
front of the machine
•Connect 220V power cable for the
SVS Pro controller into the power
connection block
•Connect the power cable from the
ethernet switch box.
•Place the FireSync controller and
power supply in front of the machine
•Connect a Ethernet cable from the
Switchbox to the 'OUT' connector of
the FireSync controller. Lead the
cable trough the opening in the base
beside the aPC.
•Connect 220V power from the
extension cord to the power
connection block PCA L1 (position
X3).
•Connect 12V cable from the power
supply to the FireSync station.
•Place Power supply for Coplanarity
sensor in base.
•Connect 220V cable to Power PCB
L3 (position X6).
•Connect LMI cable to 48v connection
of Power supply for Coplanarity
sensor.

17
•Place the coplanarity sensor unit in
the base.
If applicable remove the reuse plate
or camera unit.
•Place the Sensor completely over the
dowel pins.
•Fasten the two bolds.
•Connect the sensor cable to the
sensor and to the 'IN' connection of
the FireSync station.
Lead the cable trough the base.
•Connect the sensor safety cable to
the safety extension cable. Lead the
cable to the IBB board.
•On the IBB board, disconnect X15,
X56 and X57 cables.
•Connect the IBB Safety cable to the
IBB X56, X57, X16 and X15
connector.
•Connect the X56 and X57 cables to
the Safety cable plugs X56 and X57.
•Connect the sensor safety extension
cable to the IBB safety cable.
•Place the FireSync station and power
supply in the SVS-Pro controller slot.
•Close all covers.
•Power-up the machine and close the
'auto start.' window.
•Start with installing the software.

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3.3. Software installation
3.3.1.Parts
With the coplanarity checker, 3 files are changed or introduced in the AX-201.
The cal.cfg (only changed), the cpl.cfg and the settings.xml
3.3.1.1. cal.cfg
The cal.cfg new fields are added with reference to the position of the coplanarity checker on the AX-
201.
The new files are:
[COPLANARITY_UNIT_FRONT]
; MCS position of measurement beam centre
UNIT_REF_POS_XY = -344.228, 6.0
; MCS Z-level of measurement beam. This is the reference level
UNIT_REF_POS_Z = 15.0
; X offset w.r.t. UNIT_REF_POS_XY to be applied as starting
; point for trajectory to measurement centre [in mm]
FLY_IN_ZONE = 4.0
; X offset w.r.t. UNIT_REF_POS_XY to be applied as end
; point for trajectory to measurement centre [in mm]
FLY_OUT_ZONE = 12.0
[COPLANARITY_UNIT_REAR]
; MCS position of measurement beam centre
UNIT_REF_POS_XY = -6.244, 663,816
; MCS Z-level of measurement beam. This is the reference level
UNIT_REF_POS_Z = 15.0
; X offset w.r.t. UNIT_REF_POS_XY to be applied as starting
; point for trajectory to measurement centre [in mm]
FLY_IN_ZONE = 4.0
; X offset w.r.t. UNIT_REF_POS_XY to be applied as end
; point for trajectory to measurement centre [in mm]
FLY_OUT_ZONE = 12.0

19
3.3.1.2. cpl.cfg
In the cpl.cfg file specific configuration settings are stored that enables the AX-201 to communicate with
the coplanarity checker.
The settings are:
[GENERAL]
SYNTAX_VERSION = 1
[CPL]
; Communication Timeout in [ms]
; Timeout in connection to the Coplanarity Host
COMM_TIMEOUT = 5000
; Measurement Result Timeout in [ms]
MEASURE_TIMEOUT = 10000
; Connection IP Address of the Coplanarity Host
HOST_IP = 192.168.1.10
; Save Measurement Result Images
; (Please note that this setting only has effect
; if the 'DiagnosticsLevel' setting in the SETTINGS.XML file = 1 or 2)
; Possible values:
; 0 = SAVE IS DISABLED
; 1 = SAVE ON MEASUREMENT ERRORS
; 2 = SAVE EACH MEASURED COMPONENT
SAVE_IMAGES = 1
; Special setting for internal testing only
RUN_WITH_HOST_SIMULATOR = 0

20
3.3.1.3. settings.xml
In the settings.xml all data is stored that allows the coplanarity checker to check specific components
according specification.
An example of the file:
<?xml version="1.0" ?>
<ServerSettings>
<ScanSpeed>40</ScanSpeed>
<DiagnosticLevel>0</DiagnosticLevel>
<ComponentTypes>
<Type>
<Name>SO08P127W060</Name>
<Leads>8</Leads>
<LeadType>GW</LeadType>
<LeadTipWidth>450</LeadTipWidth>
<LeadTipLength>780</LeadTipLength>
<LeadPitch>1270</LeadPitch>
<Lead_zTolerance>80</Lead_zTolerance>
<BodyDimension_ShortSide>3800</BodyDimension_ShortSide>
<PackageDimension_ShortSide>6000</PackageDimension_ShortSide>
<BodyDimension_LongSide>5000</BodyDimension_LongSide>
<PackageDimension_LongSide>5000</PackageDimension_LongSide>
<BodyDimension_Tolerance>500</BodyDimension_Tolerance>
<ScanLines>650</ScanLines>
</Type>
<Type>
<Name>TSOP54P080W222</Name>
<Leads>54</Leads>
<LeadType>GW</LeadType>
<LeadTipWidth>400</LeadTipWidth>
<LeadTipLength>530</LeadTipLength>
<LeadPitch>800</LeadPitch>
<Lead_zTolerance>80</Lead_zTolerance>
<BodyDimension_ShortSide>10160</BodyDimension_ShortSide>
<PackageDimension_ShortSide>11760</PackageDimension_ShortSide>
<BodyDimension_LongSide>22220</BodyDimension_LongSide>
<PackageDimension_LongSide>22220</PackageDimension_LongSide>
<BodyDimension_Tolerance>1000</BodyDimension_Tolerance>
<ScanLines>1000</ScanLines>
</Type>
</ComponentTypes>
<Capture>
<Enabled>0</Enabled>
<Source>2</Source>
<Divisor>1</Divisor>
</Capture>
<Members>
<SensorGroup>
<Name>1</Name>
<Members>
<Sensor>
<Name>Coplanar</Name>
<SerialNumber>1676</SerialNumber>
<Enabled>1</Enabled>
</Sensor>
</Members>
</SensorGroup>
</Members>
</ServerSettings>