Download
Share
Print this page
Hakko Electronics FR-1418 Operation And Maintenance Manual
  1. Manuals
  2. Brands
  3. Hakko Electronics Manuals
  4. Rework stations
  5. FR-1418
  6. Operation and maintenance manual
Hakko Electronics FR-1418 Operation And Maintenance Manual

Hakko Electronics FR-1418 Operation And Maintenance Manual

Bga rework system
Hide thumbs

Advertisement

Quick Links

Operation and Maintenance Manual
Rev 2005-08

Advertisement

loading

Related Manuals for Hakko Electronics FR-1418

Summary of Contents for Hakko Electronics FR-1418

  • Page 1 Operation and Maintenance Manual Rev 2005-08...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Section Item Page System Overview Unpacking & Installation Rework Process Overview Operation Options Maintenance & Troubleshooting HMI Software Guide Advanced Rework Profiling and Control Software...

  • Page 3: System Overview

    1.0 System Overview Figure 1: FR-1418 ITEM NO. DESCRIPTION BASE ASSY BRIDGE ASSY HEAD ASSY WITH REAR ENCLOSURE LCD ADAPTER PLATE LCD MONITOR PC CPU (OPTIONAL) PC MNTR, KBD, TRACKBALL (OPTIONAL) NOZZLE SET STANDARD CAMERA/ZOOM LENS ASSY PCB (BOARD) FIXTURE...
  • Page 4 FR-1418 BGA Rework System. The figures below describe the specific features and controls found on the FR-1418 BGA Rework Systems. Not all features and controls will be found on all systems, as they vary according to the specific model and options purchased.
  • Page 5 Figure 3: FR-1418 HMI Panel Details Item Description LCD Screen / Message Window L.E.D. Status Indicators Vacuum Toggle Switch and Indicator Start Button, or <Start> Stop Button , or <Stop> or <Esc> or <No> Menu Up Button , or <M >...
  • Page 6 Figure 6: Thermocouple Inputs (TCH Shown) The FR-1418 has (2) Thermocouple (T/C) inputs. The LH input is the TEACH or TCH input, and the RH input is the SPARE or TC2 input.
  • Page 7 Board Fixture and Axis Definition: Figure 7: Board Fixture The standard board fixture consists of front (1) and rear (2) dovetail rails with adjustable spring clips (3) attached to them. The rear dovetail rail may be adjusted front to back to allow holding boards (also called PCB or PWB) of varying depths.
  • Page 8 Axis Adjustment Controls: Figure 8: X-Axis Fine Adjust Knob Figure 9: X-Axis Adjust Handle Figure 10: Y-Axis Fine Adjust Knob Figure 11: Y-Axis Adjust Handle Figures 8 through 11 show the X and Y Axis adjustment controls for positioning the heater head relative to the board loaded into the board fixture.
  • Page 9 Figure 12: Theta Adjust The lower heater head can be rotated by turning the Theta Adjust knob. This rotates the nozzle and the vacuum pick-up, so the component and/or nozzle can be aligned to the PCB in the Theta, or rotational, direction. The Theta adjust is a precision assembly with limited travel in either direction.
  • Page 10 Figure 15: Z-Axis Rack Gear Assembly Adjusting the heater head height (figures 13 and 14): The Z-Axis adjust handle (1) is attached to the heater head. It is used to select the rough position of the heater head (7). This position is either UP or DOWN. Squeezing the adjust handle disengages a pin from the Z-Axis fine adjust rack gear assembly (3), allowing the head to be...
  • Page 11 Heater Head and Nozzle Installation: Figure 16: Lower Heater Head Details The lower heater head assembly is supported by the theta adjustment bearings, which are mounted to the heater plate (7). The lower heater housing (1) rotates using the theta adjust (8).
  • Page 12 Video Camera and Optical Alignment System: (Figures 17 & 18) A video/optical system aids the operator in aligning the nozzle or component to the board. To use the alignment system, put the head in the UP position, and slide the optics train (10) to its right-most position underneath the nozzle.
  • Page 13 Component Nest: Figure 19: Component Nest The component nest (1) is provided for aligning a component to the heater nozzle, and for receiving a hot component after it has been removed from the board. The system is furnished with a generic plate (not shown) which fits into the component nest to aid in aligning new components with the heater nozzle (5).

  • Page 14: Unpacking & Installation

    2.0 Unpacking and Installation: The rework system packaging may vary due to the specific model purchased, options installed, and shipping/transportation requirements. The following figures provide a general guide for unpacking the system. Figure 21: Outer cardboard or crating removed Figure 22: Bracing and Plastic Removed To unpack the machine: Remove the outer cardboard or wooden crating material.
  • Page 15 Power and Air/N2 Connections: Connect air or nitrogen to the rear panel fitting using ¼ inch plastic tubing. (See Fig. 20 on page 11) The supply gas must be clean, dry and regulated to 60PSI. The supply should be capable of delivering 5 CFM minimum continuous supply at 80 PSI.

  • Page 16: Rework Process Overview

    This section is intended to provide a brief and general overview of the SMT rework process using the FR-1418. Your process and corresponding requirements may vary considerably. The typical rework process using this equipment would include the following three phases, each of which has several steps.
  • Page 17 Rework Phase III – Component Installation typically consists of the following steps: 1. Load PCB onto adjustable board fixture (Fig. 7) 2. With the head UP, load the component in the nest and slide it under the nozzle (Fig. 13-15, 19) 3.

  • Page 18: Operation

    Figure 27: Aligning the Component 4.0 Operation Note: The operation and programming of the FR-1418 requires that the operator have reasonable proficiency with the features, controls and processes described in Sections 1.0, 3.0, 7.0, and 8.0 (if applicable) of this manual. Read and understand sections 1.0, 3.0, 7.0, and 8.0 (if applicable) before proceeding to operate and program the equipment as described in this section.
  • Page 19 Powering the System: 1. Check that air/N and power are properly connected. 2. Turn the power switch to the 1 (On) position. (Fig. 20) 3. Observe startup messages on LCD screen. Wait for READY. (Fig. 3 and Section 7.0) 4. The system is in INSTALL/RUN or REMOVE/RUN mode, with the last-used recipe loaded in memory.
  • Page 20 Note: When in REMOVE/TCH mode, the step times in the recipe are updated automatically upon the completion of the TCH cycle. Operation for Component Installation (Soldering): 1. Load the desired Recipe using the MENU buttons (Fig. 3 and Section 7.0) 2.

  • Page 21: Options

    5.0 Options A variety of nozzles, vacuum tips, accessories and factory installed options are available to meet the needs of different rework applications. Consult your sales representative for the most up-to-date information on accessories and options. Some major system options are briefly described below. Additional operation and maintenance supplements to this manual may be supplied with some options.
  • Page 22 Figure 29: Automatic Motorized Z-Axis Option...

  • Page 23: Maintenance & Troubleshooting

    6.0 Maintenance and Troubleshooting Important: Always disconnect the unit from the electrical and pneumatic supplies before servicing or performing maintenance. Maintenance: Linear Bearing Rails All linear bearing rails should be cleaned once a month with a tack rag to remove debris, dust and dirt from the rails.
  • Page 24 Troubleshooting: Below is a general guide for troubleshooting certain operational problems. Consult a qualified service technician if you do not understand basic troubleshooting techniques, or if the problem can not be identified and corrected using the information provided in this manual. Troubleshooting table: Symptom Possible Cause...
  • Page 25 Figure 30: Rear Head Enclosure Details Item Description Item Description Rear head enclosure Low air flow control needle valve Vacuum generator Head distribution/dimmer board Medium air flow solenoid valve Heater power connections Low air flow solenoid valve Heater T/C connection Vacuum generator feed solenoid valve Ground connections Air pressure switch...
  • Page 26 Figure 31: Removing the lighting cover Remove the four corner screws (1) securing the top or bottom lighting cover (2) as required. Carefully pull the cover straight out of the housing (3) with the bulb mount (4) still attached. See Fig. 32, replacement bulbs must be of the exact type as the original equipment (75 W Max.) Figure 32: Changing halogen bulbs...
  • Page 27 Figure 35: Power Distribution Board Figure 36: I/O Board Table for Figures 35 and 36: Item Description Item Description Power distribution board Main power connections to/from power switch I/O board Thermocouple input terminals Fuses (Individually identified on board) CPU board (plugs into I/O board) Top and bottom heater power terminals 12 and 24 VAC from power board Optional Zone-2 heater power terminals...
  • Page 28 Optical Calibration and Adjustments: Figure 37: Calibration Plate Figure 38: Calibration Tip Calibration Procedure: 1. Remove the covers from the camera lens and light housing (Fig. 17) and install the calibration plate (1) onto the board support. 2. Remove the nozzle and vacuum tip (Fig. 29) and install the calibration tip (2). Adjust the optics train stop according to Figure 39 if necessary.
  • Page 29 Figure 40: Mirror adjustment Return the head to its uppermost position and turn on the LCD monitor. Move the optics train (7) to its right-most position. Loosen the locking screw (5) on the mirror bracket very slightly and, using the three set screws (6), adjust the mirror so the nozzle tip appears in the center of the video image.
  • Page 30 Figure 43: Prism Front/Rear Image Adjustment To Adjust The Prism: The prism (11) is bonded to an adjustable mount (12), which allows it to be oriented squarely to the Z- Axis. This can correct any optical image misalignment observed during the calibration procedure, above.

  • Page 31: Hmi Software Guide

    7.0 HMI Software Guide FR-1418 FRONT PANEL OPERATION POWER-ON & RUNNING A RECIPE --PLEASE WAIT-- First application of power: AMERICAN HAKKO REV X Unit says: REWORK SYSTEM ”American Hakko Rework System” Note: The current software revision (X ) is displayed on the right side of the screen.
  • Page 32 EDIT/TEACH SETTINGS? Select “EDIT/TEACH SETTINGS” <^><v> OR <MENU>=YES to Edit or Teach a Recipe. --OR-- <STOP> TO EXIT SETUP/DIAGNOSTICS? <^><v> OR <MENU>=YES Select “SETUP/DIAGNOSTICS” to enter Setup Mode (pgm password) --OR-- or run Diagnostics. <STOP> TO EXIT MANUAL MODE? <^><v> OR <MENU>=YES Select “MANUAL MODE”...
  • Page 33 *PASSWORD INCORRECT* If the Password was incorrect, push the <MENU> TO TRY AGAIN <MENU> key to try again. --OR-- <STOP> TO EXIT *PASSWORD ACCEPTED* <v> FOR CHOICES If the Password was correct, push the MENU DN key to begin. --OR-- <STOP>...
  • Page 34 EDIT HEAT 1 SETTINGS Note: Manual displays default values. Note: PH = Preheat PH TOP TEMP =250C Edit HEAT 1 Top Temp using SET UP, <^><v> OR <SET>=ENTR and SET DN. Push <SET> to enter the value. PH AIR FLOW =MED Edit HEAT 1 Air Flow using SET UP, <^>...
  • Page 35 SK TIME MM:SS 01:00 Edit HEAT 1 Time using SET UP, <^><v> OR <SET>=ENTR and SET DN. Push <SET> to enter the value. SK ZONES = 1 2 Edit HEAT 1 Zones using SET UP, <^><v> OR <SET>=ENTR and SET DN. Push <SET> to enter the value. Repeat for both zones.
  • Page 36 When you are done editing, push the <STOP> EXIT & SAVE CHANGES? key. If you have made any changes, the unit <^><v> OR <MENU>=YES asks if you want to: Exit & Save = <MENU> key or... --OR-- Exit without Saving = <STOP> key <STOP>=EXIT W/O SAVE RUNNING THE RECIPE Push <START>...
  • Page 37 TEACHING A RECIPE PASSWORD? (6 DIGITS) From MAIN MENU, select EDIT/TEACH SETTINGS and enter the password. When the password is entered & accepted EDIT SETTINGS? <^><v> OR <MENU>=YES (see ENTERING THE PASSWORD) the Unit asks if you want to Edit Settings. Push the MENU DN key to get the teach.
  • Page 38 SYSTEM SETUP: (PROGRAMMING A NEW PASSWORD) Use the SET UP, SET DN keys to select the PGM 6 DIGIT PASSWORD: 1st digit of the new password and push <SET> to enter it. Repeat until all 6 password digits are entered. After all 6 digits are entered, this screen is EXIT &...
  • Page 39 TESTING THE THERMOCOUPLES XXXC XXXC XXXC The LCD shows the thermocouple temps. XXXC <STOP>=EXIT Push <STOP> to stop the thermocouple testing. MANUAL MODE Note: Manual Mode is a bottom heat only mode. Manual mode runs the bottom heaters TCH=XXX TC2=XXX MANUAL manually.
  • Page 40 FAULT MODE If you run the machine with no air pressure, FAULT... NO AIR you will receive this error message. Push <MENU> TO CLR FAULT <MENU> to clear the message and try again.

  • Page 41: Advanced Rework Profiling And

    This operator manual supplement is a guide for operating the FR-1418 Rework Systems using the Thermal Analysis and Control Software Package. This software is available as an option on the FR- 1418 Rework Systems.
  • Page 42 This is the first screen shown upon starting the software. The bottom area of the screen shows the temperature profile graphing area, while the upper part of the screen shows the operation buttons, status, data, timers, recipe name and description. Figure 1A: FR-1418 Thermal Analysis and Control Software – Main (Run) Screen with standard Manual Z-Axis...
  • Page 43 Main Screen (Continued): Figure 1B: FR-1418 Thermal Analysis and Control Software – Main (Run) Screen with optional Automatic Z-Axis The following menus are available in the Main Screen: Displays a dialog box for opening recipe files File -> Open Saves any changes made to the current recipe File ->...
  • Page 44 Toggles between these two modes of operation. In “Run” mode the Run/Teach Buttons software will use recorded times for stage control. In “Teach” mode the software will monitor the machine’s thermocouples for stage control and will record the times between stages to be used in “Run” mode Opens the Camera View window (discussed below) Camera View Button Jog Button...
  • Page 45 Recipe Setup Screen (Figure 2A/Figure 2B): This screen is accessed by clicking on the “Edit Recipe” button on the Main Screen. This screen allows the operator to set the thermal process requirements and the Z-Axis locations for the recipe. The thermal cycle starts with the Board Heater settings and runs through the heating and cooling steps to the end of the process.
  • Page 46 Recipe Setup Screen (Continued): Figure 2B: Recipe Setup Screen with optional Automatic Z-Axis The following is a description of the various items on this screen. This is the same information that appears on the Main Screen. The File Name & Description Description can be edited from here.
  • Page 47 Board Heater Section: These buttons toggle which board heaters are active during the process. Heat Zones 1 & 2 Sets the power from 0 (off) to 100 (full power) during the Board Preheat Board Heater Power Stage. Start Preheat At When running in Teach Mode, once the Board Thermocouple reaches this temperature the software will advance to the Heat 1 (Preheat) stage.
  • Page 48 Nest Place When placing a component into the nest (or picking up when “Nest/Board Place” is selected in the “Part Detect” section) the Z-Axis will slowly seek to this height with the vacuum turned on. This height is typically set at the point where the vacuum tip just touches the top of the component to avoid placing too much load on the component.
  • Page 49 Save Image Clicking this button will capture the camera view to a JPG file. The file is named “capture.jpg” and is stored in the application directory. (Frame grabber equipped systems only.) Both of these buttons will close the Camera View window. When running Continue &...
  • Page 50 Manual Control (Fig.5): This panel is used for toggling several of the machine’s outputs such as Vacuum and heaters. The machine can be manually operated by using these controls. (Some fields shown may depend upon optional equipment.) Figure 5: Manual Control Panel Options Panel (Figure 6): The Options Panel is accessed by clicking on the “View”...
  • Page 51 Z Axis CPI This stands for “Counts Per Inch” and represents the number of stepper counts per inch of travel on the Z-Axis. This is determined by hardware and must not be changed. This is the speed (in Inches Per Second) the Z-Axis moves during full- Full Speed IPS speed motions.
  • Page 52 Working with Recipes Creating a new Recipe: 1.) Click on the “Edit Recipe” button from the Main Screen 2.) Select File>>New and then select a recipe template. (A default recipe template default.rct comes with the software. You may create your own templates from any recipe using the Save As file options.) 3.) Edit the recipe parameters as desired.
  • Page 53 Figure 7 – Screen capture from system operating in Teach Mode. The graph shows that the part thermocouple has passed the Preheat Target (PH: 140) and is approaching the Soak Target (SK: 175). Note that the “Soak” indicator is highlighted bright yellow. This is the active step. The paler colored steps have already been completed.
  • Page 54 28920 Avenue Williams Valencia CA 91355-4182 United States of America Tel: 661.294.0090 Fax: 661.294.0096 Toll Free: 1.800.88.HAKKO (42556) www.HakkoUSA.com...