Table of Contents
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Table of Contents
Summary of Contents for Dage 4000 Series
- Page 1 Series 4000HS An Operators Guide Version 1...
- Page 2 Test & Measurement Equipment, wherever you are located. As you are probably aware, Dage offices are located in six strategic centres in the USA, Asia & Europe and the company’s customer service & support is acknowledged to be ‘the best in the business’.
- Page 3 We have made every effort to ensure that this manual is error free. However if you should discover errors, or omissions we would be pleased to receive your comments. Please send these to: DPI Customer Support, Dage Precision Industries, Rabans Lane, Aylesbury, Buckinghamshire.
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Page 4: Table Of Contents
Contents TYPES OF MACHINE 4000, 4000HS AND 4000HS-Z ..........6 SAFETY INFORMATION..................7 ..................7 YMBOLS AND LABELS LOCATING THE MACHINE...................8 .........8 NPACKING THE MACHINE AND HE WORK STATION 3.1.1 Workbench ......................9 3.1.2 Chair.........................10 ................10 LECTRICAL CONNECTIONS ..................13 NEUMATIC SERVICES 3.3.1 Compressed air....................13 3.3.2 Setting compressed air regulators..............13 3.3.3... - Page 5 6.3.2 Work Holders Available For the Zone Shear XY Table ........40 DOING A TEST....................... 42 ..................... 42 EW SAMPLE 7.1.1 Understanding the screen layout ..............42 7.1.2 Interlocks Open Message................. 43 ................44 ESTING 7.2.1 Tool quality...................... 44 7.2.2 Tool alignment....................
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Page 6: Types Of Machine 4000, 4000Hs And 4000Hs-Z
TYPES OF MACHINE 4000, 4000HS AND 4000HS-Z This manual covers the 4000HS and 4000HS-Z The operation of this machine is very similar to the 4000. Most machine options may be used on either machine. The 4000 is a general-purpose machine that can test 100kg die shear and fine pitch wire bonds. -
Page 7: Safety Information
NO MODIFICATIONS MAY BE MADE TO THE MACHINE WITHOUT THE EXPRESS PERMISSION OF THE MANUFACTURER. ONLY DAGE APPROVED REPLACEMENT PARTS SHOULD BE USED TO SERVICE THE MACHINE AS ALTERNATIVES MAY RESULT IN A DEGRADATION OF THE SAFETY... -
Page 8: Locating The Machine
May cause death or serious injury by crushing LOCATING THE MACHINE NPACKING THE MACHINE AND HE WORK STATION THE DAGE SERIES 4000HS WEIGHS APPROXIMATELY 100KG LIFT WITH CAUTION USING THE LIFTING POINT. Move the crated machine to the unpacking area using a suitably-rated... -
Page 9: Workbench
Inspect the crate for any damage before unpacking. Report any damage immediately to both Dage and the carriers. Remove the spring-metal clips around the top of the crate and remove the lid. Remove all of the remaining spring-metal clips and remove the sides of the crate. -
Page 10: Chair
3.1.2 Chair It should have sufficient height adjustment for the largest and the smallest operator to sit comfortably at the workstation It should also preferably have an adjustable foot and backrest. LECTRICAL CONNECTIONS THIS MACHINE MUST BE EARTHED. THE IEC LEADS REQUIRED TO CONNECT THIS MACHINE TO A POWER SOURCE MUST HAVE AN INTEGRAL EARTH CONNECTION. - Page 11 The electrical leads should be connected as shown below. Connect any additional connections specific to your installation i.e. printers, network cables etc. This is where the power is supplied to the machine. It is located on the left-hand side of the machine underneath the monitor arm.
- Page 12 These connections are on the rear of the machine. Computer Link – The supplied data lead, which plugs into the PC plugs in here. Keypad – The keypad which is part of the joystick assembly’s plugs in here. Foot Switch – This is where the foot switch plugs in. Joystick 1 &...
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Page 13: Pneumatic Services
NEUMATIC SERVICES Note: At the time of press the machine only requires compressed air to perform high speed testing. 3.3.1 Compressed air Specification: 4bar (min.) dry, clean 10 l/min (Free air) The bondtester uses compressed air to operate its shear and cold bump pull cartridges. Compressed air is also used to operate the vertical lift table, which is used during pull tests. -
Page 14: Vacuum Supply
3.3.3 Vacuum supply Specification: 500mm Hg (min.) Vacuum may be required for some work holders. A factory supply or a separate pump may provide it. 3.3.4 Services connection There are three service connections on the rear of the machine as shown below: - Found in the Right hand bottom corner of the rear of the pneumatic chassis Note: Any water in the airline is separated and will be discharged from the... -
Page 15: Fitting Machine Modules
ITTING MACHINE MODULES Note: The software will not automatically recognise some module changes. Joysticks and motorised tables must be initialised by re-powering the machine, or by using <Set-up> <Initialise> on the top line menu. 3.4.1 Joysticks Note: Any joystick may be fitted to the left or right hand side of the machine, handing conversion may be required (see the engineers guide). -
Page 16: Keyboard Rest
3.4.2 Keyboard Rest The fitting procedure is as follows: - Adjust the screw feet if fitted so that they support the keyboard rest evenly. Note: A compact P.C. keyboard should be positioned between the emergency stop button and the lamp on/off switch. 4000HS Keyboard Rest Adjustable Feet... -
Page 17: Microscope Mounting
3.4.3 Microscope mounting At the time of press the 4000HS machine is using a Leica microscope. If you experience any difficulties then contact your local Dage representative. Supplied with the machine. Check mounting pod is orientated as shown Supplementary lens must be fitted... -
Page 18: Setting Up The Work Station
SETTING UP THE WORK STATION RGONOMICS AND OPERATOR COMFORT The microscope and machine controls on the machine can be set to suit a range of operator statures. We recommend the following issues are considered in turn when setting up the machine: Comfortable adjustable seat with back straight and upright. -
Page 19: Setting The Machine For An Operator
ETTING THE MACHINE FOR AN OPERATOR Note: It is important that operator adjustments are made with the assistance of an experienced engineer. If you are unfamiliar with the machine operation refer to section 5. 4.2.1 Setting the chair Adjust the height of the chair to set the arm position as shown below. Hands in the normal operating position Lightly supported... -
Page 20: Setting The Microscope
Ask your engineer to add your name to the list of operators and re- configure the controls if the defaults are not suitable. 4.2.3 Setting the microscope Place a work holder and sample on the machine (see section 6.3). Fit an appropriate cartridge and set the tool just above the sample (see section 6.1). Set the zoom to its minimum (smallest number) Raise and lower microscope as required using the black knob on... - Page 21 Loosen fixing screws Height adjustment knob Align microscope to test point and tighten fixing screws Focus on the test point. Making angle adjustments as required Magnification and focus adjustment Eyepieces Set the height of the eyepieces to suit the operator using the black height adjustment knob on the side of the machine.
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Page 22: Understanding The Machine
A screen similar to that shown below will appear. Note: If this does not appear, then you must manually start the Dage software. You will usually find an icon labelled 'Dage Bondtester Series’ directly on the main screen. If not contact your supervisor. - Page 23 The machine is now ready, configured as it was last time it was powered off. The screen should look similar to that shown below. Note: If the above screen is a little small on the monitor, click the maximise button.
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Page 24: Turning Off
Close down the Dage screen by pressing the close button in the top right of the screen. Select <Start> <Shutdown> from the Windows taskbar at the bottom of the screen. -
Page 25: Emergency Stop Button
MERGENCY STOP BUTTON The machine is fitted with an Emergency Stop button so that if something should go wrong or a condition arises that presents a hazard to the machine or the operator the machine can be stopped extremely quickly. This Emergency Stop button is situated on the right of the keyboard rest as shown in the picture below. -
Page 26: Removal Of Other Hazardous Energy Sources
Remove the load cell if fitted and store safely in the storage spaces provided on the side of the machine. If the Emergency Stop button has been used then it may be necessary to move the Y stage out of the way by hand in order to prevent any damage to the load cell or prevent the flipping guard from fouling on the work holder. -
Page 27: Basic Operator Controls
ASIC OPERATOR CONTROLS There is a lot of flexibility in the control layout of the Dage 4000HS due to the variety of options that may be fitted to your machine. Note: Keypad and joystick button operations can be changed to suit individual preferences. These are linked to your name. -
Page 28: Keypad Controls
5.4.2 Keypad controls The keypad by default operates the more useful controls, but they can be changed. Note: Some machines may not have a keypad fitted. These options will not work if the guards are open. KEYPAD BUTTON SCREEN CONTROL Grade Test grade codes Available... -
Page 29: Footswitch
5.4.3 Footswitch An optional footswitch can be used to start or stop a test. Note: For comfort the footswitch may need to be raised from the floor. 5.4.4 Keyboard There may be a PC style keyboard connected to the machine. It is usually used to enter information at the start of a test run. -
Page 30: Understanding Cartridges
NDERSTANDING CARTRIDGES All cartridges are precision engineered and should be handled carefully. They should be stored on the two storage shelves on the right-hand side of the machine or other secure shelving. The load cells are loaded into the storage shelves from the front of the machine. -
Page 31: Cartridge Layout
When retracted the guard should be firmly against the under side of the cartridge. Note: If the guard hangs loose it has been damaged and should be serviced by a qualified Dage representative. The guard does not lift when storing the cartridge on the side of the machine. -
Page 32: Tool Save Features
The guard may be operated manually off the machine as follows: - Push the actuating lever on the rear of the cartridge against the spring. The latch is now released Rotate the lever to move the guard to the raised or lowered position. Retracting the guard gives improved access to the tool. -
Page 33: Preparing For A Test
PREPARING FOR A TEST It may be necessary to make a number of changes to the machine configuration to suit the product you are testing. ITTING A CARTRIDGE Note: It is not necessary to move the microscope to fit a cartridge. Drive the cartridge holder up to the top of its stroke. - Page 34 This screen is shown if the guards are not closed quickly enough after load cell installation. As mentioned previously to remove this error close the guard doors if they are not already closed and press retry. Note: If a Zone shear XY table has been fitted to the machine the guards will differ slightly but will function in the same manner as those shown here.
- Page 35 Take the cartridge keeping your hands and fingers clear of the tool guard. Engage the lower left-hand edge of the cartridge 'V' slide as shown below. Push the cartridge towards the machine and slide it to the left so that it engages with the upper slide.
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Page 36: Removing A Cartridge
EMOVING A CARTRIDGE Note: It is not necessary to move the microscope to remove a cartridge. Drive the cartridge up to the top of its stroke and open the guard doors as shown in the previous section. THERE MUST BE CLEARANCE TO ENSURE THE GUARD DOES NOT COLLIDE WITH THE TEST PIECE OR WORK HOLDER... -
Page 37: Work Holder Stands Available For The High Speed Xy Table
6.3.1 Work holder stands available For the High Speed XY Table To ensure ease of operation the work holder stand should be orientated with the jaw tightening screw located towards the rear of the machine. As indicated this stand is also used to hold the calibration weight support (for CBP5KgHS load cell only). - Page 38 To avoid potential collisions between the work holder and the Z stage it is very important to ensure that the work holder and stand are orientated so that the pneumatic air fitting is located towards the rear of the machine. Slide towards or apart from each Up and down...
- Page 39 Both the shear work holder and the pull work holder fix to this plate which is part of the XY table assembly picking up on the indicated holes as required. The pull stand will only pick up on three of these holes due to the pneumatic air inlet.
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Page 40: Work Holders Available For The Zone Shear Xy Table
6.3.2 Work Holders Available For the Zone Shear XY Table The zone shear XY table can be used to perform zone shear tests up to 600mm/s and high-speed single ball shear up to 600mm/s using the same work holder. The pull work holder can also be fitted to the zone shear table and used as described in the previous sections. - Page 41 Fitting the 80Kg shear work holder to the zone shear table. Four fixing holes used to attach the 80Kg-work holder to the carriage on the y-axis of the XY table (one in each corner) Fitting the 5Kg-pull work holder to the zone shear table. High-speed pull testing with a zone shear table is the...
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Page 42: Doing A Test
DOING A TEST EW SAMPLE A sample is a group of tests on the same part, usually 5 to 50 tests. Tests are grouped in this way to help analyse process trends. You need to use the New Sample screen before starting a test. Note: The screen will appear automatically when you attempt the first test. -
Page 43: Interlocks Open Message
Note: Start a test when finished and the result screen appears automatically. 7.1.2 Interlocks Open Message As an extra safety feature the guard doors are fitted with an interlock system. This means that, if they are open there will be no response from the joysticks or software commands. If the doors are opened during a test then the test will stop. -
Page 44: Cold Bump Pull Testing
ESTING 7.2.1 Tool quality The tweezers must be checked on a regular basis for quality. Check the alignment of the jaws when closed. Note: It may be possible for skilled technicians to repair damaged jaws The tweezers must be checked on a regular basis for quality. The cavity should be clear and undamaged These jaws are the same as the jaws used for standard Testing on the 4000 machine. -
Page 45: Tool Alignment
Test the action of the jaws manually using the button or key. Note: This will not work if the guard doors are open. 7.2.2 Tool alignment Align the air pipe with the tweezer jaws as shown below Hold Air pipe Rotate Notes: The tool guard must be free to operate without hitting the air pipe. - Page 46 Holding the body still, rotate the main shaft until a grub screw is visible down the access hole Rotate Grub screw Hold Release the grub screw two turns using a 0.9mm key. Note: Do not remove the screw Unscrew the tweezer jaws from the body Fitting is the reverse of removal DO NOT OVER TIGHTEN SCREWS Note: - Bump pull tweezer jaws are precision parts and quite expensive.
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Page 47: Jaw Closing Force
7.2.4 Jaw closing force IT MAY BE POSSIBLE TO DAMAGE COLD PULL JAWS BY INCORRECT SETTING OF THE CLOSING FORCE. ENSURE THIS FORCE IS SET CORRECTLY AS BELOW. Check the pressure regulators are set correctly (section 3.3.2). Tweezer force is adjusted using the rotary control fitted on the cartridge. The pressure will be stable once set and should not require adjustment. -
Page 48: Correct Jaw Opening Position
only function if the guard doors are closed. 7.2.5 Correct jaw opening position The jaw opening width should be set to suit the ball size. Note: A variety of cold bump pull jaws sizes are available. The jaws are specifically designed for the size of the solder ball to be tested. If in doubt, consult your engineer. - Page 49 The top section is the only part of the rising table, which is not stationary. Air supply should be connected to the rising table via the 4mm tube connected to the bulkhead fitting situated behind the front cover. Set the rising table air pressure using the regulator situated on the side of the pneumatic chassis so that during a test the table will rise at the same rate as the load cell.
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Page 50: Bump Pull Test Modes
UMP PULL TEST MODES These test modes are set by pressing the <Options> button. Hook mode set to None Programmable close time Test starts Test complete... - Page 51 Hook mode set to Delayed. Programmable landing force Jaws close Programmable close time When the test has occurred and the load cell has reached the end of its upward travel the cycle will stop allowing the bond site to be inspected and graded. For Test starts the cycle to continue the user should press the T button or the start icon.
- Page 52 Hook mode set to Auto Programmable landing force Jaws close Programmable close time Test starts Test complete...
- Page 53 Hook mode set to Auto Replace Programmable landing force Jaws close Programmable close time Test starts Programmable hold delay Test complete Auto replace Note: - Depending on the sample, auto-replace may not always work. It is specifically designed for failure mode 2, as described under failure mode below.
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Page 54: Bump Pull Test Failure Modes
UMP PULL TEST FAILURE MODES A number of failure modes are possible depending on the type of test performed. Mode 2 Mode 1 Ball Ball lift failure Mode 3 Mode 4 Ball lift extrude Mode 1: The soldering of the ball to the site failed. Mode 2: The bonding of the ball exceeded the tensile strength of the solder. -
Page 55: Ball Clearance Using Ads100Kghs
DS100KGHS LEARANCE SING A 7.5.1 Tool quality The tool tip must be sharp or what’s left of the balls may obstruct the ceramic tool tip of the BS5KGHS during high speed testing. Note: At the time of press the DS100KGHS in conjunction with the XY table is only rated for 10Kg at 10mm/s. -
Page 56: Igh Speed Testing Using A Bs Kghs
Ball clearance is necessary for high-speed shear testing due to the high speeds involved and the need to allow acceleration to the test point and deceleration after test. The aim of this ball clearance is to remove all the balls on the sample except the balls on one edge. -
Page 57: High Speed Shear Tests Ball Allignment
IGH SPEED SHEAR TESTS BALL ALLIGNMENT High-speed shear tests are performed using the same work holder as used for the ball clearance. During high speed testing it is very important to ensure that the ceramic tip will not hit anything during a test. -
Page 58: Zone Shear Testing Using The Zone Shear Table
HEAR ESTING SING THE HEAR ABLE As mentioned in the previous section Zone shear testing can only be performed using the designated zone shear table and the 80Kg-work holder. The test is set up in the same manner as a high speed shear test and as always care must be taken to ensure that no collisions can occur. -
Page 59: Test Results
EST RESULTS All of the results are shown on the results screen. Re-grade any test by clicking on grade box 7.9.1 List of results Look up and down the list using the scroll controls Failures did not meet the Add any comments to a test by specified minimum load clicking on comments box and typing... -
Page 60: Typical Xbar/Range Trend Graph
Upper and lower control limits 7.9.2 Typical XBar/Range trend graph are shown in pink Mean force of each sample Force range of each sample Note; many other graphs are available, speak to an engineer or your supervisor to establish which you need to use. -
Page 61: Grading The Test
7.9.3 Grading the test Depending on how your machine is configured, grading may operate in a number of different ways: Grading is optional; i.e. you are not forced to grade. Grading of failures; i.e. those tests that fail to meet a minimum load. Forced grading;... -
Page 62: Number Of Tests In A Sample
7.9.4 Number of tests in a sample Tests are grouped together into samples to allow variations in the process to be more easily monitored. Your engineer may have set the machine to expect a fixed number of tests in the sample, or it may allow any number. -
Page 63: Calibration
Note: - It is preferable to wait 10 minutes after fitting a cartridge before calibration. BAD CALIBRATION MAY RESULT BY USING INCORRECT PARTS COLD BUMP PULL CARTRIDGE CALIBRATION Cold Bump Pull cartridges are calibrated by using Dage designed weights and a special hook. To calibrate, proceed as follows: Select <Calibration> as shown below... - Page 64 A small attachment is used for hooking the weight as shown below: - Remove any jaws, which may be fitted to This calibration hook should be the cartridge included with the load cell Clamp screw Fit the hook to the Cold Bump Pull cartridge as shown below: - Tighten the clamp screw...
- Page 65 Remove any jaws that may be fitted to the cartridge, and fit the special calibration hook in the orientation shown. As the hook is heavier than normal, press the null button. Place the special work surface onto the XY stage. Bring the calibration hook down, and align with the weight as shown: - calibration hook weight...
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Page 66: Shear Cartridge Calibration
5Kg, 2.5Kg, 1Kg and 500g. 8.2 S HEAR CARTRIDGE CALIBRATION Shear cartridges are calibrated by using Dage designed weights and a special jig. To calibrate, proceed as follows: DS80Kg (For Use with the Zone Shear Table only) Fit the 80kg calibration jig so that the weight hangs at the front of the machine. - Page 67 BS5KGHS load cell calibration using the high speed XY table. Hang the weight, which is asked for by the software here Shear tool shear point Fixing Holes Front of calibration jig BS5KGHS load cell calibration using the zone shear XY table. The adapter plate can only be installed in one orientation.
- Page 68 To fit the calibration jig in order to calibrate the BS5KgHS it is necessary to remove the existing work holder and stand by removing the three or four screws as described in section 5.3. At the time of press the BS5KGHS has only one range so only one weight (500g) is required for BS5KgHS load cell calibration.
- Page 69 The machine will then ask for the correct weight to be aligned. To prevent any damage to the tool tip calibrating the BS5Kg is only performed using a 500g weight. To cover the full range of possible forces the results are scaled. Place the weight over the pulley pulley See section 7.2 Shear Cartridge...
- Page 70 Ensure that the ceramic tip is in good condition and not damaged (chipped). Set the tool above the landing surface, behind the round pin. Landing surface Round pin Press <OK> and the machine will automatically lift the weight at least two times (the first time is to centralise the weight).
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Page 71: Getting Data From Another Machine
GETTING DATA FROM ANOTHER MACHINE It is possible to collect data from other Dage machines. It is possible to enable this feature for a free 30-day trial. See your line engineer. ELECTING A REMOTE MACHINE The second machine will have been connected to the Series 4000, 4000HS or 5000, and a test group configured by your engineer to expect test results from it. -
Page 72: Question And Answers
QUESTION AND ANSWERS 10.1 D ATA STORAGE 10.1.1 What is a sample If a measuring instrument can remember results of tests, it is then possible to compare the results today with those last week or last month. In this way gradual changes in the quality of bonds or wires can be investigated. - Page 73 You must select the correct 'Test Group’; a list of those available can be displayed using the arrow. The correct group for your test will be advised by your engineer. Selecting a group sets the machine test parameters, and defines which 'group' the results should be saved in.
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Page 74: Calibration
10.2 C ALIBRATION 10.2.1 How does the calibration work Calibration is performed by lifting a known weight equal to the maximum that can be measured on the range selected. The machine will tell you which weight is required see section 7. The cold bump pull cartridge uses a special hook designed to lift the weight on the centre-line of the transducer. -
Page 75: Jogging Problems
10.3 OGGING PROBLEMS 10.3.1 The cartridge will not drive up or moves in one direction only It is possible that the cartridge is not balanced (nulled), due to tool changes or occasionally cartridge warm-up. Press the or the button For cold bump pull cartridges, a lower limit can be set, the machine will not drive below this point.