TWS AUTOMATION PICK & PLACE QUADRA DVC User manual

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PICK-AND-PLACE
QUADRA DVC
USER MANUAL (original instructions)
Version 1.3 Issued on 06/04/11

INTRODUCTION
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WARNINGS
Carefully read all the instructions given in this manual before using this product.
The present manual is a part of this PICK AND PLACE and it contains all the
information you need for a correct and safe use of the machine, together with all the
instructions for right maintenance operations.
Take care of the manual and store it in a easy-to-be-reached place. Be sure that each
operator read it before approaching the oven. It should be read by all the people in
charge of handling and using the machine, a special attention should be paid by:
•owner of the company,
•emergency and safety workers
•operators.
The manual is valid throughout the machine’s lifespan and it is strictly related to its
technical conditions.
This manual should be kept close to the machine, ready to be consulted. Customer
should make a copy of this manual and store it in a dedicated file.
The TWS Automation Quadra DVC meets applicable safety standards.
The operator must be properly trained to comply with all the requested safety standards.
TWS Automation srl declines any responsibility due to any damage and injuries to
persons and properties derived either by an improper use of the machine or not in
accordance with the user's manual.
If the machine is resold, the customer must inform the manufacturer, who will inform
the new owner of any changes and improvements which should be applied to the
machine to grant a correct use.
No parts of this manual can be reproduced, transmitted, stored in a retrevial system, or
translated into any language or computer language, in any form or by any means,
without prior written permission. All rights reserved.
This manual is divided into eleven parts, relating to the different aspects of the use and
maintenance of the machine.
At first you should read the whole manual to begin understanding menus and having an
overall view of how to operate and maintain the machine.
Then, you may start using the machine, even if you have not reached a full
comprehension of the system. You might wish to modify one of the demo programs
already stored in the machine memory, just changing the placement positions of the
components, teaching fiducials and exploring the menus.
Once you have become familiar with the operation of the machine, read Parts 3, 4, 5
and 6 of this manual more carefully and then start assembling.
TWS Automation srl is entitled to change parts of the machine or pages of this manual
without notice.

INTRODUCTION
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PICK & PLACE QUADRA DVC
Quadra model DVC
Serial number N°______________
Year of manufacture _____/____/______
Electrical power 1 Kw
Power supply 220 V
Frequency 50 / 60 – Hz
Max. length 1000 mm
Max. width 850 mm
Max. height 1800 mm
Max. weight 215 kg
Max. weight with packaging 300 kg

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INDEX
WARNINGS....................................................................................................2
DICHIARAZIONE CE DI CONFORMITÁ/CE CERTIFICATE OF COMPLIANCE
.......................................................................................................................9
MANUFACTURER LIMITED LIABILITY ....................................................... 10
DISPOSAL ...................................................................................................11
PART 1:........................................................................................................ 12
DESCRIPTION OF THE MACHINE............................................................... 12
CHAPT. 1 GENERAL FEATURES.........................................................................................................13
CHAPT. 2 TECHNICAL SPECIFICATIONS ........................................................................................16
2.1) COMPONENT SIZE AND TYPE....................................................................................................16
2.2) COMPONENT FEEDERS...............................................................................................................16
2.3) PLACEMENT HEAD......................................................................................................................16
2.4) PLACEMENT AREA......................................................................................................................17
2.5) ACCURACY....................................................................................................................................17
2.6) REPEATIBILITY.............................................................................................................................17
2.7) PRODUCTIVITY.............................................................................................................................17
2.8) NOISE..............................................................................................................................................17
2.9) DIMENSIONS AND WEIGHT........................................................................................................18
2.10) POWER SUPPLY ..........................................................................................................................18
2.11) UNIT CLEARANCE......................................................................................................................18
CHAPT. 3 PARTS DESCRIPTION.........................................................................................................19
CHAPT. 4 ELECTRIC CONTROL DESCRIPTION ............................................................................22
PART 2:........................................................................................................ 23
INSTALLATION............................................................................................ 23
CHAPT. 1 TRANSPORTATION.............................................................................................................24
CHAPT. 2 COMPUTER INSTALLATION............................................................................................25
CHAPT. 3 MAINS AND COMPRESSED AIR CONNECTION ...........................................................25
CHAPT. 4 SET UP....................................................................................................................................25
PART 3:........................................................................................................ 27

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MENU AND SOFTWARE DESCRIPTION...................................................... 27
CHAPT. 1 MAIN MENU..........................................................................................................................28
CHAPT. 2 "PROGRAMMING AND ASSEMBLING" MENU ............................................................31
2.1) PROGRAMMING AND ASSEMBLING.........................................................................................31
2.2)CAD DOWNLOADING ..................................................................................................................68
2.3) FILES MANAGEMENT..................................................................................................................72
CHAPT. 3 “PRINT” MENU.....................................................................................................................76
CHAPT. 4 "UTILITY" MENU ...............................................................................................................76
4.1) COMMANDS CONFIGURATION..................................................................................................76
4.2) WORK PARAMETERS ..................................................................................................................77
4.3) HARDWARE TEST ........................................................................................................................98
4.4) BACKUP .......................................................................................................................................110
4.5) NETWORK OPERATION.............................................................................................................111
CHAPT. 5 "EXIT PROGRAM" MENU ................................................................................................112
5.1) EXIT PROGRAM..........................................................................................................................112
5.2) RESTART......................................................................................................................................112
CHAPT. 6 KEYBOARD .........................................................................................................................113
CHAPT. 7 FUNCTIONS ALWAYS ACTIVE.......................................................................................115
CTRL+F1 .............................................................................................................................................115
CTRL+F2 .............................................................................................................................................115
CTRL+F3 .............................................................................................................................................115
CTRL+F4 .............................................................................................................................................115
CTRL+F5 .............................................................................................................................................115
CTRL+F6 .............................................................................................................................................115
CTRL+F7 .............................................................................................................................................115
CTRL+F8 .............................................................................................................................................115
CTRL+F12 ...........................................................................................................................................115
PART 4:...................................................................................................... 116
UNIT OPERATION...................................................................................... 116
CHAPT. 1 WORK PROCEDURE .........................................................................................................117
CHAPT. 2 UNIT ORIGIN SETTING....................................................................................................118
CHAPT. 3 SET UP..................................................................................................................................118
3.1) OVERVIEW...................................................................................................................................118
3.2) TAPE FEEDERS ...........................................................................................................................119
3.4) TRAYS ..........................................................................................................................................124
3.5) FIXING THE BOARD TO THE PLACEMENT AREA ................................................................124
CHAPT. 4 PREPARATION OF THE MOUNTING PROGRAM ......................................................126
4.1) OVERVIEW...................................................................................................................................126
4.2) BOARD FIDUCIALS TEACHING................................................................................................126
4.3) PROGRAMMING BY CAMERA TEACHING.............................................................................127
4.4) PROGRAMMING BY CAD DATA ..............................................................................................128

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4.5) PROGRAMMING BY KEYBOARD.............................................................................................129
4.6) FEEDER AUTOMATIC ASSOCIATION .....................................................................................129
4.7) COMPLETING DATA IN THE MOUNTING TABLE..................................................................129
4.8) VERIFICATION OF THE PROGRAM .........................................................................................130
4.9) MULTIPLE CIRCUIT ....................................................................................................................131
CHAPT. 5 ASSEMBLING......................................................................................................................132
5.1) TOTAL ASSEMBLING.................................................................................................................132
5.3) STEP ASSEMBLING....................................................................................................................132
5.4) ASSEMBLING INTERRUPTION .................................................................................................132
5.5) ASSEMBLING RE-START...........................................................................................................133
5.6) BOARD REPLACEMENT ............................................................................................................133
5.8) SAVING AND LOADING PROGRAMS ......................................................................................133
CHAPT. 6 MACHINE SWITCH OFF...................................................................................................133
PART 5:...................................................................................................... 135
DISPENSER USER MANUAL..................................................................... 135
PREFACE .................................................................................................................................................136
CHAPT. 1 ADJUSTING THE HEIGHT OF THE DISPENSING ASSEMBLY AND OF THE
SYRINGE..................................................................................................................................................137
CHAPT. 2 ADJUSTING THE LOWERING AND RAISING SPEED OF THE SYRINGE..............138
CHAPT. 3 ADJUSTING THE DISPENSER-CAMERA DISTANCE .................................................138
CHAPT. 4 DETERMINING THE BEST DISPENSING PARAMETERS...........................................139
CHAPT. 5 DEFINING A PACKAGE ....................................................................................................142
CHAPT. 6 DEFINING THE TEST GLUE DOT POSITION ..............................................................144
CHAPT. 7 DISPENSING ADHESIVE...................................................................................................145
CHAPT. 8 FURTHER INFORMATION ABOUT DEFINITION OF A GLUE DOT TO SUIT A
DEFINED PACKAGE..............................................................................................................................145
CHAPT.9 CHANGING THE DISPENSING UNIT...............................................................................146
PART 6:...................................................................................................... 147
FEEDER BANK DATA BASE ..................................................................... 147
CHAPT. 1 INTRODUCTION ................................................................................................................148
CHAPT. 2 FEEDER BANK IDENTIFICATION ..................................................................................148
CHAPT. 3 FEEDER BANK DATABASE..............................................................................................148
CHAPT. 4 MAGAZINES DATABASE MANAGING FUNCTIONS ..................................................151

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4.1) FEEDERS......................................................................................................................................151
4.2) FIND SERIAL NUMBER ..............................................................................................................151
4.3) FIND USER’S SERIAL NUMBER................................................................................................152
4.4) FIND MAGAZINE NUMBER .......................................................................................................153
4.5) FIND NOTES ................................................................................................................................154
4.6) FIND FEEDER ..............................................................................................................................156
4.7) MAGAZINE RECOGNITION .......................................................................................................156
4.8) FEEDER DATA IMPORT.............................................................................................................159
4.9) ADVANCED SEARCH.................................................................................................................160
4.10) EXPORT INVENTORY ..............................................................................................................160
4.11) FEEDER UNMOUNTING...........................................................................................................160
CHAPT. 5 UPDATE OF THE DATA CONTAINED IN THE FEEDER TABLE..............................162
CHAPT. 6 USING A FEEDER DATABASE IN A LAN ......................................................................163
CHAPT. 7 “308” AND “408” FEEDER BANK UPGRADE .................................................................164
PART 7:...................................................................................................... 165
LAN OPERATION....................................................................................... 165
CHAPT. 1 LAN ACTIVATION .............................................................................................................166
PART 8:...................................................................................................... 168
OPTICAL CENTRING DEVICE ................................................................... 168
CHAPT. 1 CONFIGURATION..............................................................................................................169
CHAPT. 3 PACKAGE PARAMETERS TEACHING..........................................................................173
PART 9:...................................................................................................... 180
MAINTEINANCE......................................................................................... 180
CHAPT. 1 PERIODICAL MAINTENANCE ........................................................................................181
1.1) CLEANING AND LUBRICATION OF GUIDES AND BEARINGS OF X AND Y AXIS ...........181
1.3) CLEANING OF NOZZLE..............................................................................................................181
1.4) CLEANING OF THE VACUUM CIRCUIT...................................................................................181
1.5) SNIPER DEVICE CLEANING......................................................................................................181
1.6) CAMERA MODULE CLEANING.................................................................................................182
1.7) WATER DISCHARGE FROM COMPRESSED AIR FILTER......................................................182
1.8) CLEANING THE CPU COOLING FAN INSIDE THE PC ...........................................................182
PART 10:.................................................................................................... 183
SAFETY ..................................................................................................... 183
CHAPT. 1 SAFETY.................................................................................................................................184

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CHAPT. 2 GLOSSARY..........................................................................................................................187
PART 11:.................................................................................................... 188
APPENDIX ................................................................................................. 188
APP.1 Q-IMPORT..................................................................................................................................188
APP.2 EXTERNAL ALARM CONNECTION......................................................................................197
WARRANTY CONDITIONS......................................................................... 198

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DICHIARAZIONE CE DI CONFORMITÁ/CE
CERTIFICATE OF COMPLIANCE
CE Certificate of Compliance
Dichiarazione CE di Conformità
LCM s.r.l.
Via Martin Ferraro, 3
54100 MASSA (ITALY)
Mandatario:
TWS AUTOMATION s.r.l.
Viale Zaccagna, 6
54033 Marina di Carrara (ITALY)
States under its own responsibility that the machine / Dichiara sotto la propria
responsabilità che la macchina:
BRAND/MARCA: LCM
TYPE/TIPO: Pick&Place “QUADRA”
Serial number/Numero di Serie:
Year of manufacturing/Anno di costruzione:
described in this certificate complies with the following regulations/ alla quale questa
dichiarazione si riferisce, è conforme alle seguenti norme:
CEI EN 61000-6-4:2007
CEI EN 61000-3-2:2007
CEI EN 61000-6-2:2006
CEI EN 60204-1:2006
CEI EN 61000-3-3:2009
CEI EN 55011:2009
and it is therefore in accordance with the main requirements of these directives / e quindi
rispondente ai requisiti essenziali delle direttive:
- Machinery 2006/42/CEE /Direttiva Macchine 2006/42/CEE
- Electromagnetic Compatibility 2004/108/CEE /Direttiva Compatibilità Elettromagnetica
2004/108/CEE.
- Low voltage electrical equipment 2006/95/CEE /Direttiva Bassa Tensione 2006/95/CEE
Massa li ../../…. Arrighi Claudio
Director/Amministratore

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MANUFACTURER LIMITED LIABILITY
The producer declines any responsibility due to an improper use of the machine
such as:
♦
♦♦
♦) Non-compliance with the manufacturer's instructions;
♦
♦♦
♦) Non-compliance with the safety rules;
♦
♦♦
♦) Incorrect installation of the machine;
♦
♦♦
♦) Incorrect installation of the safety parts after maintenance;
♦
♦♦
♦) Defected external power supply;
♦
♦♦
♦) Lack of maintenance;
♦
♦♦
♦) Alteration of the equipment without authorisation from the manufacturer;
♦
♦♦
♦) Use of non-original spare parts;
♦
♦♦
♦) Non-observance of the instructions contained in this manual;
♦
♦♦
♦) Allowing untrained personnel to operate the machine;
♦
♦♦
♦) Exposing the appliance directly to atmospheric agents such as rain, sun,
humidity etc.;
♦
♦♦
♦) Making faulty or temporary electrical connections to the machine;
♦
♦♦
♦) Allowing maintenance to be carried out while the machine is switched on;
♦
♦♦
♦) Unauthorised personnel using the machine.

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DISPOSAL
Please do not dispose equipment
with this label together with
ordinary domestic rubbish.
For these products a specific disposal
system is provided
CE Countries
Warning: when the lifespan of the
machine is over you should dismantle it
in order to dispose of the different
components according to the existing
directives: iron units must be separated from electric and electronic ones.
Electric and electronic equipments must be disposed in accordance with in force
directives about the refurbishing and recycling of this type of waste as well as batteries
and accumulators.
In accordance with the requirements carried out by the CE member states, the CE users
can take their electrical and electronic waste to dedicated collection centers, free of
charge.
In a few countries the these products can be returned to the retailer who will take them
back if the owner will purchase a new and similar product.
To get all the information about differentiated collection and recycling for this type of
products, users are invited to contact the retailer or the local office in charge.
The right disposal of electric and electronic units and their recycling and refurbishing
help protect the environments which surrounds us and avoid bad effects on our health.
Other Countries
Please contact the local authorities for information about the correct way to dispose
products

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PART 1:
DESCRIPTION OF THE MACHINE

PART 1 DESCRIPTION OF THE MACHINE
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CHAPT. 1 GENERAL FEATURES
The QUADRA DVC pick-and-place machine is designed for sequential assembly of
SMDs, specifically for small and medium production batches. The unit is supplied with a
two-nozzle optical centring head, moving along the X and Y axes. The placement area is
fixed.
Its low price, flexibility, ease of use and low maintenance, makes the QUADRA an
extremely attractive machine for first time users of surface mount technology.
Main features of the QUADRA are:
•Cost effectiveness
This machine has been conceived to be less expensive than other chip mounters
available on the market, having similar features and capabilities.
•High reliability with an optimal precision and productivity
The machine is made with high quality components and of proven durability and the
reliability of the machine has been thoroughly tested in order to ensure a long working
life without problems.
The high level of precision allows the assembly very small components, like 0402 chips
and 0.5 pitch IC
•High flexibility
The machine can handle most commonly used components and accommodates 15
feeder magazines having eight 8 mm tapes each, for a maximum of 120 feeders.
Feeder magazines may be loaded off-line, thus reducing changeover time.
For each magazine configuration the software is able to automatically identify to the
new program the components already present on the machine.
The low cost of the magazines allows the user to keep a high number in stock, dedicating
their use to a specific board or to different customer’s boards.
The feeder magazines can accommodate tapes of different widths, both optimising
feeder use and reducing costs.
The user can configure the feeder banks, for instance having 8, 12, 16, 24 mm or larger
width tapes mixed on the same bank, so optimising feeder performance and minimising
costs.
The placement area consists of a replaceable plate, where tooling pins holds the board.
The same plate may be used for many different boards.
Boards with components on both sides as high as 10 mm may be assembled.
As an option a metal plate with magnetic fixture is available
Boards usually have at least two fiducial marks to be used as reference points. The first
one is usually in the lower left corner and is called “board origin”; the second one is
usually in the opposite corner and is called “reference point”.

PART 1 DESCRIPTION OF THE MACHINE
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The board origin is a point representing the origin of the X and Y-axes of the board; the
reference point is used to determine the actual position on the work area.
The machine automatically searches for the board origin and the reference point with
the vision system every time a new assembly process starts.
The machine has a double head sniper centring system. Components that are too large to
be centred by the head sniper centring system are centred by an external centring.
Each head has a wide range of nozzles for picking up components; the nozzle change is
automatic.
Four methods of programming are possible: teaching through camera, data loading via
CAD file, data loading via keyboard, programming by digitizer table.
Programming of multi-panels is done by automatic copying of the first board. Skipping
of scrap boards is possible, as well as skipping of components.
A dispenser for adhesives and solder paste is also available. The dispenser can be retro-
fitted to machine.
•Easy to use
The software enables the operator to quickly acquire a good level of knowledge of the
machine, by means of easy-to-understand colour displays.
The unique board positioning system, with the tooling pins inserted in a fixture plate,
gives good positioning repeatability of boards. The fiducial mark recognition system
detects a skewed board and automatically re-calculates the placement position.
The machine is supplied with a complete guide describing the surface mount technology.
The full board production process is described in detail: SMD component
characteristics, solder paste and adhesive features, solder paste printing, assembly,
reflow soldering, board inspection, rework, and cleaning are all described.
•Easy to maintain
DVC QUADRA is a solid and reliable unit, controlled by an industry standard PC,
designed for long trouble-free operation.
The user may test via software all functions such as head movement in the three axes,
centering system, vacuum generation, etc. Spare parts can be easily obtained at a low
price from the distributor, enabling a technically competent user to repair the unit
himself avoiding any additional cost for skilled technician or machine downtime.

PART 1 DESCRIPTION OF THE MACHINE
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•Easy to install
Installation and start-up are very simple and are usually done by the customer himself.
•Full assistance
A direct phone line and a stock of spare parts allow a quick communication and an
immediate shipment of spare parts to the customer.
Our technicians may help the customer to overcome any installation and operating
problem.
•Safety
The machine has been designed in compliance with all the CE safety regulations. An
emergency push button allows quick stop of operation.
During assembling, the user is protected from contact with the placement head by a
transparent screen. When opening this safety screen, the machine operation is
momentarily interrupted; operation at low speed with safety screen open is allowed.

PART 1 DESCRIPTION OF THE MACHINE
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CHAPT. 2 TECHNICAL SPECIFICATIONS
2.1) COMPONENT SIZE AND TYPE
The machine may handle:
-Chip components starting from size 0402
-Cylindrical components like MELF and MINI-MELF
-SOT diodes and transistors
-Integrated circuits up to 35 mm side.
-Integrated circuits with 0.5 mm
-Trimmer, inductors and aluminium electrolytic capacitors.
ATTENTION: At least these conditions must be satisfied to obtain a well placement for
fine pitch components (0,5 mm):
•Machine’s working parameters perfectly setted
•PCBs completly planar
•Very accurate printing
2.2) COMPONENT FEEDERS
The unit accommodates up to 120 feeders, 8mm wide, 6.5 mm thick, in 7” or 13” reel.
Other feeders available are:
- Tape feeders 12, 16, 24, 32, 44 mm wide, 10.5 mm thick, in 7”, 13” or 15” reel.
- Stick feeders (any size of stick)
- Matrix tray
2.3) PLACEMENT HEAD
The unit is supplied with a two-nozzle optical centring head. The two nozzles work
together: when the head approaches the feeders the PC commands the picking up of two
components; when the head is over the board the two components are placed. This
system optimises the placement timing and increases productivity.
Both nozzles have an angular accuracy of 0,09° and can assemble components whose
maximum side dimension is 13 mm, using the head centring device.
Components having the side dimension longer that 13 mm. can be assembled off line on
a dedicated device. Several kinds of nozzles can be used and the nozzle change is
handled by the software.

PART 1 DESCRIPTION OF THE MACHINE
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The presence of the component on the head is detected by the optical centring, the
vacuum sensor or both of them.
The rotation stepper motor is driven by a controlled ramp, so there is controlled
accelleration and decelleration of the head. Each component may be given different
speed and acceleration values.
2.4) PLACEMENT AREA
The placement area and the printed circuit board maximum dimensions are 440 x 360
mm. For larger boards, the placement area can be extended by removing feeder
magazines on one or two sides of the unit. As a maximum, an area of 550 x 420 mm may
be obtained, by using only feeder banks on the left side of the machine.
2.5) ACCURACY
Accuracy is expressed as the max deviation between the programmed mounting position
and the actual mounting position.
±0,10 mm on X and Y axis
±0,18° on the Theta axes rotation
In case of placement onto adhesive instead of solder cream, accuracy may worsen, due
to the lack of a flat surface on both sides of component. In this case, lowering the speed
of the nozzle down stroke and other adjustments to increase accuracy may be needed.
2.6) REPEATIBILITY
±0,06° mm on X and Y axis
±0,18° on the Theta axes rotation
.
2.7) PRODUCTIVITY
On a short pickup distance, the highest throughput is about 3600 components per hour.
In real working conditions, with the head travelling to the 4 sides of the machines, the
speed will be approximately 2800 components per hour.
2.8) NOISE

PART 1 DESCRIPTION OF THE MACHINE
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The noise coming from the machine is 65 dBA (average value) and 90 dBA
(instantaneous peak value), measured at 1 metre from the machine and 1.6 metres from
the ground.
2.9) DIMENSIONS AND WEIGHT
The machine measures 85 x 100 x 180 cm (width x length x height), weight is
approximately 160 kg.
2.10) POWER SUPPLY
The unit works with AC 220 Volts ±10%, 50/60 Hz. Power consumption is less than 1
kW.
An 8 - 10 bar air compressed source is required. Air consumption is 60 l/minute as an
average.
2.11) UNIT CLEARANCE
The machine needs at least an area of 2 m2(including the unit itself) to correctly
operate.

PART 1 DESCRIPTION OF THE MACHINE
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CHAPT. 3 PARTS DESCRIPTION
The layout of the machine is shown in pictures from Pic. 1 to Pic. 3.
The user has good access to all areas of the machine to easily carry out all necessary
operations, but the usual operating position is in front of the machine, as shown in the
picture.
Pic. 4 describes the machine identification plate and the legal requirements.
Pic. 1 Machine front view
VGA
Monitor
Placement
head
Electric control
panel
locking door
switch
Hatch to the
machine’s
machine
electronic boards

PART 1 DESCRIPTION OF THE MACHINE
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Pic. 2 Machine side view
Transparent
screen
VGA Monitor
Feeder
magazines
connectors