Ersa IR 650 A Bedienungsanleitung

Operating Instructions

ERSA IR 650 A and PL 650 A

Semi-Automatic SMD/BGA Rework System

ERSA GmbH

Leonhard-Karl-Str. 24

97877 Wertheim / Germany

Service Phone +49 9342/800-147

Fax +49 9342/800-256

Email [email protected]

Internet www.ersa.com

Document 3BA00143 Rev.2

Operating Instructions

ERSA IR / PL 650 A

ERSA IR / PL 650 A / Page 2 Document 3BA00143 Rev.2

Contents

1. Introduction 4

1.1 General product information 4

1.2 General information about the operating instructions 4

1.3 Proper use 5

2. Technical data 6

2.1 IR 650 A basic unit 6

2.2 ERSA PL 650 A 7

3. Safety instructions 8

3.1 Aggregates and interfaces 8

3.2 Safety instructions for handling the system 11

4. Transport, storage, assembly, and disposal 12

4.1 Scope of supply 12

4.2 Transport and storage 12

4.3 Assembly 13

4.3.1 Setting up the system 13

4.3.2 Mechanical connections 14

4.3.2 Electrical connections 15

4.4 Disposal 16

5. Commissioning 17

5.1 Switching on for the ﬁrst time 17

5.2 IRSoft installation 17

6. Function description 18

6.1 The IRSoft user Interface 18

6.2 Device controls 19

6.2.1 IR 650 A 19

6.2.2 PL 650 A 19

6.3 Parameter Window 20

6.3.1 Current proﬁle parameters 20

6.2.3 RPC 650 A 20

6.3.2 Measured value and threshold value sensors 21

6.3.3 Specifying threshold value functions 21

6.3.4 System settings 21

6.3.5 The status display 22

6.3.6 The information window 22

6.4 Proﬁle settings 23

6.4.1 Setting the proﬁle parameters 23

6.4.2 Setting the heating element conﬁguration 24

6.4.3 Saving, loading, and managing proﬁles 24

6.5 Desoldering a component 26

6.6 Placing the component and soldering 28

6.7 The optimal proﬁle 31

7. Troubleshooting 33

8. Maintenance 34

8.1 Cleaning 34

8.1.1 IR 650 A 34

8.1.2 PL 650 A 34

8.2 Replacing a silicon suction cup on the IR 650 A 34

9. Spare parts and wearing parts 35

9.1 ERSA IR 650 A 35

9.2 ERSA PL 650 A 36

Operating Instructions

ERSA IR / PL 650 A

Document 3BA00143 Rev.2 ERSA IR / PL 650 A / Page 3

This operating manual is only for service, mounting and operating personnel.

Neither the complete documentation nor parts of it may be reproduced or used for competitive

purposes without prior permission of ERSA GmbH.

Actions to the contrary constitute an obligation for compensation of damages.

Operating Instructions

ERSA IR / PL 650 A

ERSA IR / PL 650 A / Page 4 Document 3BA00143 Rev.2

1. Introduction

1.1 General product information

The ERSA IR / PL 650 A Rework System has been especially developed for extremely large and high-

mass printed circuit boards.

The dynamic heating technology of the IR 650 A, based on ERSA IR technology, offers extensive pos-

sibilities, even for repairing complex components and printed circuit boards. Individual proﬁle design,

as well as high repetitive precision through automatic process control, extending to component cooling,

intelligent measurement technology, and multiple closed loop technology enable ideal process results,

even for lead-free applications. The integrated reﬂow process camera rounds out the process reliability

aspects of the IR 650 A. The IR 650 A is ideally supplemented with the PL 650 A placement system. With

the PL 650 A secure placement of even the smallest, multi-position components succeeds in no time.

Here as well, state-of-the-art cameras and drive technology support the user and ensure optimal compo-

nent placement.

Through the ﬂexible, and for the most part automatic operation of the IR / PL 650 A, cycle times can be

signiﬁcantly reduced in comparison to cycle times achieved with traditional rework systems.

1.2 General information about the operating instructions

The operating instructions are designed to provide the owner of the rework system with complete infor-

mation concerning the product, its set-up and commissioning, basic machine functions, malfunctions and

malfunction resolution, maintenance, as well as spare parts and wearing parts.

Before placing the machine in service, you must carefully read and have understood the section

on safety. Our service department is available to respond to any questions and problems you

might have with this product.

Explanation of symbols

This symbol warns of electric shock hazard. Touching voltage-conducting parts can

result in serious bodily injuries which can be fatal.

This symbol warns of hazards of any type that can result in bodily injuries that can be

fatal.

This symbol indicates a hazard of burn injuries caused by touching hot objects or ma-

chine parts.

ATTENTION! Attention indicates instructions, which if not complied with, result in damage to the sol-

dering machine or other material damages!

Operating Instructions

ERSA IR / PL 650 A

Document 3BA00143 Rev.2 ERSA IR / PL 650 A / Page 5

1.3 Proper use

The ERSA IR / PL 650 A rework system has been built in accordance with the state of the art and stan-

dard health and safety regulations. Residual hazards can exist with the system, particularly if it is oper-

ated improperly by untrained personnel, or if it is used for purposes for which it is not intended (proper

use).

The ERSA Rework System has been designed exclusively for the placement of electronic components

and subsequent soft soldering (selective reﬂow soldering) of electronic assemblies that are suitable

for this process. Any other use, or use exceeding this speciﬁcation, is considered to be improper. The

manufacturer/supplier assumes no liability for damages resulting from improper use.

Proper use also includes compliance with the Operating Instructions, including all of the safety instruc-

tions.

Unauthorized reconstructions and/or modiﬁcations that inﬂuence the safety of the ERSA Rework Sys-

tem are prohibited, and the manufacturer/supplier is not liable for any damages resulting from such

additions or modiﬁcations.

The system is designed exclusively for commercial use. Private use is excluded.

Operating Instructions

ERSA IR / PL 650 A

ERSA IR / PL 650 A / Page 6 Document 3BA00143 Rev.2

2. Technical data

2.1 IR 650 A basic unit

Device dimensions

Length: 794 mm

Width: 602 mm

Height: 462 mm

Weight: approximately 75 kg

Electrical data

Voltage: 1 x 230 V / N / PE

Voltage tolerance +6 % / -10 %

Frequency: 50 / 60 Hz

Rated power: 3600 W without PC

Protection class I

Upper heating element

IR upper heating element output 4 x 300 W

4 separately switched heating zones

Maximum heating element surface 120 x 60 mm

Upper heating element with motorized positioning

Lower heating element

Lower heating element output 2 x 800 W + 4 x 400 W

5 separately switched heating zones

Maximum heating element surface 350 x 470 mm

IR heating element wavelength 2 - 5 µm

Control

Controlled via a PC

(Windows 2000 or XP required)

Universal Serial Bus (USB) interface

Integrated 4-character LED display

Temperature measurement

1 x IR sensor

4 x thermocouple channel(K-type, potential-free)

Additional data

Component size 1 x 1 mm to 60 x 60 mm

Maximum PCB size 460 x 560

Environmental speciﬁcations

Operating temperature: 0 – 40 °C

Relative humidity: 0 – 80 %

Temperature increase in the process to 2.5 K/sec.

Maximum stroke 70 mm

Working distance

From the PCB to the upper heating element 60 mm

From the PCB to the work table 140 mm

Volume ﬂow int. cooling fans

Upper 182 m³/h lower 120 m³/h

Vacuum nozzle switching point

Up to 15 mm above the upper edge of the PCB.

Operating Instructions

ERSA IR / PL 650 A

Document 3BA00143 Rev.2 ERSA IR / PL 650 A / Page 7

2.2 ERSA PL 650 A

Device dimensions

Length: 600 / 700 mm

Width: 200 mm

Height: 520 / 690 mm

Weight: approximately 21.5 kg

Electrical data

Via external power supply 1 x 100-230 VAC

Supply voltage: 24VDC / 50 W

Frequency: 50 / 60 Hz

Visionbox

Component size 1x1 mm to 60 x 60 mm

Split optics optional for QFP processing

Component placement force app. 2 N for Auto

Pick&Place, or position controlled.

Illumination LED row light (each side separately

adjustable for component and PCB)

LED ring light for RPC camera (adjustable)

RPC camera

Illumination: LED ring light white (adjustable)

Camera: CCD color camera

Focus: 25x optical 12x digital

Swivel area: 180°

Interface: System bus

Operating Instructions

ERSA IR / PL 650 A

ERSA IR / PL 650 A / Page 8 Document 3BA00143 Rev.2

3. Safety instructions

3.1 Aggregates and interfaces

The interfaces and aggregates of the IR 650 A = PL 650 A are shown in the following photo.

IR 650 A displays

DIGITAL 2000 A

display

Upper heat-

ing element

Lower heating

element

Placement

table with

change-frame

Placement

head

Illumination

Switch for

IR 650 A

RPC module

Placement table ﬁne adjustment

IR temperature

sensor

Display of the integrated DIGITAL 2000 A soldering station

The display with the three buttons represents a complete DIGITAL 2000 A soldering sta-

tion. The respective soldering iron is connected to the side connector. Operating and safety

instructions for this unit are in the included ERSA DIGITAL 2000 A Operating Instructions.

Placement head

The placement head positions the respective component on the PCB in conjunction with

IRSoft

Attention crushing hazard!

When placing components do not reach between placement head and PCB.

Video output

USB interface

* PC, monitor, mouse, and keyboard are not include in scope of supply

Switch for

illumination

Operating Instructions

ERSA IR / PL 650 A

Document 3BA00143 Rev.2 ERSA IR / PL 650 A / Page 9

Upper heating element

The required heat from above for soldering/desoldering electronic components is generated

via this aggregate. Temperature selection is speciﬁed via the IRSoft control software.

Attention burn hazard!

Upper heating element and surrounding housing parts reach high temperatures dur-

ing a soldering process.

Placement table

Via the placement table the PCB is aligned so that the placement head places the compo-

nent precisely on the PCB.

Lower heating element

The required heat from below for soldering/desoldering electronic components is generated

via this aggregate. Temperature selection is speciﬁed via the IRSoft control software.

Attention burn hazard!

Lower heating element and surrounding housing parts reach high temperatures dur-

ing a soldering process.

Fine adjustment

Use the ﬁne adjustment to precisely position the placement table.

IR temperature sensor

The sensor detects the surface temperature of the component that will be soldered/desol-

dered, in a contactless process.

Reﬂow process camera

The reﬂow process camera provides a live image of the soldering process to the monitor.

The optionally available IDView or Imagedoc software is necessary for this application.

Illumination

The lighting provides optimal, glare-fee illumination of the workstation. It can be switched on

or off via the side-mounted switch.

Switch for illumination

The switch activates or deactivates the system illumination.

IR 650 A display

The display shows the current actual temperature of the selected temperature sensor.

Operating Instructions

ERSA IR / PL 650 A

ERSA IR / PL 650 A / Page 10 Document 3BA00143 Rev.2

Video output:

Two cinch sockets are located on the rear of the IR 650 A. The video signal from the RPC

camera and the PL camera are available on these sockets.

This signal is transmitted to the video inputs of the FALCON Frame Grabber card in the PC

via two video cables.

USB interface, system bus:

The IR /PL 650 A is connected to a PC via a USB cable (type A-B). All control functions, and

the process parameter documentation, are available via the IRSoft software.

The control signals to the individual system modules are distributed via the system bus. PL

650 A and RPC module are connected on the rear of the IR 650 A for this.

The video signals of the two motorized zoom cameras are also transmitted internally via

these cables.

Master switch / EMERGENCY-STOP switch:

The entire IR / PL 650 A system is switched on and off via this switch, and in the event of

hazard it is all-phase disconnected from the power supply.

Safety temperature monitoring:

The upper heating element and the lower heating element of the IR 650 A are equipped

with thermal safety switches.

In the event of uncontrolled heating they automatically switch off the energy supply to the

heating elements, to prevent damage to the device or to objects in the vicinity.

The ring core transformer for the upper heating element is likewise equipped with a safety

switch.

Vacuum supply:

The IR / PL 650 A does not require any external compressed air or vacuum supply.

The IR 650 A has two integrated vacuum pumps.

One supplies the hand vacuum VacPen grip, the second supplies the vacuum nozzle of the

IR 650 A and also of the PL 650 A.

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