Unitek 9100 Series User manual

USER’S MANUAL NO. 990-606
REVISION B: February 2000
OPERATION AND MAINTENANCE MANUAL
FOR THE
9100 SERIES SEMI-AUTOMATIC
HIGH PRECISION
REFLOW SOLDERING SYSTEM

9100 SERIES REFLOW SOLDERING SYSTEM
ii 990-606
Copyright © 1999-2000, Unitek Miyachi Corporation
The engineering designs, drawings and data contained herein are the proprietary work of
UNITEK MIYACHI CORPORATION and may not be reproduced, copied, exhibited or
otherwise used without the written authorization of UNITEK MIYACHI CORPORATION.
Printed in the United States of America
Revision Record
Revision EO Date Basis of Revision
A 17789 2/99 Original publication
B 18118 2/00 Production release

9100 SERIES REFLOW SOLDERING SYSTEM
990-606 iii
FOREWORD
Thank you for purchasing a Unitek Precision System 9100 Series Semi-Automatic High Precision Reflow
Soldering System.
Upon receipt of your equipment, please thoroughly inspect it for shipping damage prior to its installation.
Should there be any damage, please immediately contact the shipping company to file a claim, and notify us
at:
Unitek Precision Systems
1820 South Myrtle Avenue
P.O. Box 5033
Monrovia, CA 91017-7133
Telephone: [phone]
FAX: [phone]
e-mail: [e-mail]
The purpose of this manual is to supply operating and maintenance personnel with the information needed
to properly and safely operate and maintain Unitek Precision System's 9100 Series Reflow Soldering
System.
The System consists of three major units: the workstation, the Uniflow® Pulsed Thermode Control
(Uniflow), and the Bonding Head. The latter two items have their own manuals. (See table 1-1) Therefore,
you will need both the Uniflow and Bonding Head manuals, in addition to this manual, to operate and
maintain the system. (The Bonding Head, referred to here, is called a Weld Head or Reflow Solder Head in
its manual.)
We have made every effort to ensure that the information in this manual is accurate and adequate.
Should questions arise, or if you have suggestions for improvement of this manual, please contact us at the
above location/numbers.
Unitek Miyachi Corporation is not responsible for any loss due to improper use of this product.

9100 SERIES REFLOW SOLDERING SYSTEM
iv 990-606
SAFETY NOTES
This instruction manual describes how to operate, maintain and service the 9100 Reflow Soldering System,
and provides instructions relating to its SAFE use. Two companion manuals, as listed in table 1-1, provide
detailed information for the Uniflow and the Bonding Head. Procedures described in these manuals MUST
be performed, as detailed, by QUALIFIED and TRAINED personnel.
For SAFETY, and to effectively take advantage of the full capabilities of the workstation, please read these
instruction manuals before attempting to use the workstation.
Procedures other than those described in these manuals or not performed as prescribed in them, may expose
personnel to electrical, burn, or crushing hazards.
After reading these manuals, retain them for future reference when any questions arise regarding the proper
and SAFE operation of the workstation.
Please note the following conventions used in this manual:
WARNING: Comments marked this way warn the reader of actions which, if not followed, might result in
immediate death or serious injury.
CAUTION: Comments marked this way warn the reader of actions which, if not followed, might result in
either damage to the equipment, or injury to the individual if subject to long-term exposure to the indicated
hazard.

9100 SERIES REFLOW SOLDERING SYSTEM
990-606 v
CONTENTS
CHAPTER 1: System Description....................................................................................................... 1-1
Section I: Features ...................................................................................................................... 1-1
Features............................................................................................................................ 1-1
Section II: System Components.................................................................................................. 1-2
Major Components........................................................................................................... 1-2
Controls and Indicators.................................................................................................... 1-4
Control Panel ....................................................................................................... 1-4
Tabletop Controls ................................................................................................ 1-5
Access Doors ................................................................................................................... 1-6
Electrical Connectors....................................................................................................... 1-6
CHAPTER 2: Getting Started............................................................................................................. 2-1
Section I: Planning for Installation............................................................................................. 2-1
Space Requirements......................................................................................................... 2-1
Power Requirements........................................................................................................ 2-1
Compressed Air Requirements........................................................................................ 2-1
User Manufactured Jigs, Mounting Hole Requirements ................................................. 2-1
CHAPTER 3: Operating Instructions ................................................................................................ 3-1
Section I: Operating Precautions ................................................................................................ 3-1
General Operator Safety .................................................................................................. 3-1
Set-Up Safety................................................................................................................... 3-1
Section II: Preparing for Operation ............................................................................................ 3-1
Pre-Operational Checks................................................................................................... 3-1
Turning the Equipment On .............................................................................................. 3-2
Section III: Operation ................................................................................................................ 3-2
Set-Up.............................................................................................................................. 3-2
Installing the Jigs................................................................................................. 3-2
Aligning the Bonding Head................................................................................. 3-3
Establishing the Reflow Schedule ....................................................................... 3-5
Operation ......................................................................................................................... 3-5
Section IV: Shutdown................................................................................................................. 3-6
Emergency Shutdown...................................................................................................... 3-6
Normal Shutdown............................................................................................................ 3-6

9100 SERIES REFLOW SOLDERING SYSTEM
vi 990-606
CHAPTER 4: User Maintenance ........................................................................................................ 4-1
Section I: Precautions ................................................................................................................. 4-1
General Operator Safety .................................................................................................. 4-1
Section II: Operator Maintenance............................................................................................... 4-1
Preventive Maintenance Schedule................................................................................... 4-1
Clean Vacuum Generator Filter...................................................................................... 4-2
Grease Rotary Table Ring Gear and Refill Lubricators .................................................. 4-2
Check Play in Unislide and Adjust.................................................................................. 4-4
Clean Bonding Edge of Thermode .................................................................................. 4-4
APPENDIX A: Specifications.............................................................................................................. A-1
INDEX.....................................................................................................................................................Index-1
ILLUSTRATIONS
Figure Title Page
1-1 9100 Series Reflow Soldering System, Major Components........................................................ 1-2
1-2 Control Panel .............................................................................................................................. 1-4
1-3 Workstation Tabletop .................................................................................................................. 1-5
1-4 Location of Access Panels and Electrical Connectors................................................................. 1-6
3-1 Installing a Typical Jig................................................................................................................. 3-3
3-2 Making the Unislide Adjustments ............................................................................................... 3-4
3-3 Making Co-Planarity Adjustment................................................................................................ 3-5
3-4 Aligning Items to be Bonded with Micrometer........................................................................... 3-6
4-1 Removing Vacuum Generator from Workstation........................................................................ 4-2
4-2 Removing Filter Assembly from Vacuum Generator.................................................................. 4-2
4-3 Removing Filter from Filter Assembly........................................................................................ 4-2
4-4 Removing Vacuum Generator Hose to the Hub.......................................................................... 4-3
4-5 Removing Rotary Table............................................................................................................... 4-3
4-6 Lubricating Gears and Lubricators .............................................................................................. 4-3
4-7 Adjustment of Gib Strip............................................................................................................... 4-4
A-1 Outline Drawing of Workstation ................................................................................................. A-3
A-2 Hole Pattern for Typical Segment of Rotary Table..................................................................... A-4
TABLES
Figure Title Page
1-1 Technical Manuals for Use with the 9100 Series Reflow Soldering System.............................. 1-3
4-1 Preventive Maintenance Schedule............................................................................................... 4-1
A-1 Specifications .............................................................................................................................. A-2

9100 SERIES REFLOW SOLDERING SYSTEM
990-606 1-1
CHAPTER 1
SYSTEM DESCRIPTION
Section I: Features
Features
The 9100 Series Semi-automatic High Precision Reflow Soldering System, herein called the reflow
soldering system, is a stand-alone workstation designed for high-volume, repeatable reflow soldering
operations, with the following features:
Rotary turntable allows simultaneous loading and bonding operations.
Flexible programming for up to six product nests and three different product types.
Software is configured to allow automatic changeover between product types or variants.
Uniflow®pulse-heated soldering control provides temperature and timing control for the thermode
heating.
Optimized thermode heating and automatic cooling allow for fastest production rates.
Twin start operator controls and interlock guard for operator safety.
Precision slide head adjustment and manual override for ease of set-up.

CHAPTER 1: SYSTEM DESCRIPTION
9100 SERIES REFLOW SOLDERING SYSTEM
1-2 990-606
Section II: System Components
Major Components
The 9100 Series Semi-automatic High Precision Reflow Soldering System comprises three major units: the
actual workstation with its rotary turntable (workstation), a Uniflow Pulsed Thermode Control (Uniflow),
and a bonding head. (In the separate manual for the bonding head, it is usually referred to by the more
generic term “weldhead.”) The location of these major units is shown in figure 1-1.
Figure 1-1. 9100 Series Reflow Soldering System, Major Components

CHAPTER 1: SYSTEM DESCRIPTION
9100 SERIES REFLOW SOLDERING SYSTEM
990-606 1-3
The workstation with its rotary turntable is described in this manual.
The Uniflow Pulsed Thermode Control brings precise temperature and time control to heat the thermodes.
Depending on which configuration you ordered, you may have the standard Uniflow or the Remote
Operation Control (ROC) unit. The manual for those units are listed in table 1-1 and is considered part of
the technical manual suite for your equipment.
Depending on which configuration you ordered, you will have one of three Bonding Heads, 87SA/24,
84SA/24, or 180SA/24. You will receive the respective manual for your module, as shown in table 1-1, as
part of your technical manual suite.
Related manuals, which you may wish to procure from Unitek Precision Systems, are Uniflow Advanced
Serial Datacom Communications Interface, Manual No. 990-341; and Pulse Heated Thermode Selection
Guide, No. 991-410. Please consult your Unitek Precision Systems representative to obtain these manuals.
Table 1-1. Technical Manuals for Use with the 9100 Series Reflow Soldering System
Component Type Technical Manual Number
Workstation 990-606
Uniflow Remote or Manual 990-225
Bonding Head 87SA/24 or 84SA/24 990-121
180SA/24 990-125
Optional Reference Manuals
(see above)
Communications Interface 990-341
Thermode Selection Guide 991-410

CHAPTER 1: SYSTEM DESCRIPTION
9100 SERIES REFLOW SOLDERING SYSTEM
1-4 990-606
Controls and Indicators
Control Panel
The control panel, shown in figure 1-2, contains the
following controls and indicators.
1BONDING CYCLES COMPLETED indicator -
(Grey LCD indicator with built-in reset button)
Indicates number of bonded parts.
2 EMERGENCY STOP switch - (Red mushroom-head
pushbutton) Turns off power in an emergency. Not
intended for normal use.
3 RESET switch/indicator - (Blue pushbutton with built-in
indicator) Used to reset guard switches on initial startup or
after an emergency stop. The blue indicator lights when
resetting is required; the light goes out after the RESET
switch is pressed.
4 CONTROL OFF switch - (Red pushbutton) Used to
remove power to the control circuits and electrical sensors
and switches.
5CONTROL ON switch/indicator - (Green pushbutton with
built-in indicator) Used to apply power to the control circuits
and electrical sensors and switches.
6 MONITOR/CAMERA Not used.
7JIGS IN PLACE switch - (Four-position rotary switch)
Used to select either jig sets 1, 2, or 3, or all three jig sets.
8GUARD OVERRIDE indicator - (Red indicator) Lights
when override is in effect.
9GUARD OVERRIDE key switch - Allows operation of the
rotary table and jigs (for indexing) when the guard door is
open. Permits access to MANUAL BOND switch for set-up.
COUNTS
BONDING CYCLES
COMPLETED
RESET
CONTROL ON
CONTROL OFF
MONITOR/CAMERA
ON/OFF
JIGS
IN PLACE
1
23
ALL
GUARD OVERRIDE
TABLE
INDEX MAINS ON

MAIN ISOLATOR
1
O
Figure 1-2. Control Panel