Page 1 HR 600/2 Hybride-Rework-System Translation of the original operating manual: 3BA00207_01 | Serial No.: .......... Ersa GmbH Leonhard-Karl-Str. 24 97877 Wertheim Phone +49 9342/800-136 www.ersa.de Fax +49 9342/800-132 Rev. 3 Mobile +49 171 241 846 8 Printing date: 06/08/2019 service-ersa@kurtzersa.de...
Page 3: Table Of Contents
Table of contents Table of contents Introduction .............................. 7 Product information............................ 8 1.1.1 General information about the product ..................... 8 1.1.2 The optional Voidless Rework system .................... 8 1.1.3 Intended use............................ 8 1.1.4 Retrofitting, changes .......................... 8 1.1.5 Warranty............................. 8 Information about this manual ......................... 9 1.2.1 Pictogram and symbol explanations.................... 10 1.2.1.1...
Page 4 Target readers group ........................ 50 6.1.2 Supplementary documents ...................... 50 6.1.3 ESD-hazardous components ...................... 51 Overview of the machine parts........................ 52 Switching on the HR 600/2 and starting HRSoft ..................... 54 The user interface ............................ 55 6.4.1 Menu bar ............................ 56 6.4.1.1 The [Start] tab......................... 57 6.4.1.2...
Page 5 Table of contents Turning off the HR 600/2 unit ........................ 141 Updating the HRSoft program........................ 142 Spare and wear parts............................ 143 Read this first! ............................... 144 7.1.1 Nameplate and serial number ...................... 144 7.1.2 Target readers, permitted spare parts ................... 144 Spare parts .............................. 145 Treatment of messages and malfunctions....................... 147...
Page 7: Introduction
1 | Introduction 1 Introduction Product information............................ 8 1.1.1 General information about the product ..................... 8 1.1.2 The optional Voidless Rework system .................... 8 1.1.3 Intended use............................ 8 1.1.4 Retrofitting, changes .......................... 8 1.1.5 Warranty............................. 8 Information about this manual ......................... 9 1.2.1 Pictogram and symbol explanations.................... 10 1.2.1.1 Prevailing term definitions in this instruction manual............ 11 1.2.1.2...
Page 8: Product Information
HR 600 series. 1.1.2 The optional Voidless Rework system The HR 600/2 Rework System is also available as an optional voidless rework sys- tem. The Voidless Rework System can reduce gas entrapments in soldered joints. For this purpose, the PCB is set into sinusoidal vibrations by means of piezoelectric actuators, and the voids under the components are reduced in liquid solder.
Page 9: Information About This Manual
1 | Introduction Information about this manual 1.2 Information about this manual For your safety ERSA products are developed, manufactured and tested in compliance with the ba- sic safety requirements. Nevertheless, residual risks still exist! For this reason, please read these operating instructions before operating the ma- chine for the first time.
Page 10: Pictogram And Symbol Explanations
1 | Introduction Information about this manual 1.2.1 Pictogram and symbol explanations Pictograms are used to identify dangers, both in this instruction manual and on the machine. Specific information or requirements and prohibitions for the prevention of per- sonal injury or property damage are shown in the manual with a pictogram, and are complemented in the text by hierarchically graded, signal words in bold print: DANGER It describes an immediately threatening danger...
Page 11: Prevailing Term Definitions In This Instruction Manual
1 | Introduction Information about this manual 1.2.1.1 Prevailing term definitions in this instruction manual In addition to the pictograms described above, we use the following symbols and notations: Safety instructions ü This symbol means: Prerequisite to avert a danger. a) This symbol means: Measures to avert a danger. An example: NOTE Machine malfunctions caused by improper maintenance!
Page 12: Warnings
1 | Introduction Information about this manual 1.2.1.2 Warnings We use the following pictograms for warnings: WARNING Dangerous electrical voltage! Danger of electrocution! WARNING Hot surfaces, hot gases! Burn hazard! WARNING Laser beam! Risk of retinal burns! WARNING Risk of injury! Hand injury risk! Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev.
Page 13: Rule Notices
1 | Introduction Information about this manual 1.2.1.3 Rule notices NOTE Read the operating instructions! Prior to working in areas that are marked with the symbol shown, the corresponding operating instructions must be read! NOTE Wear protective goggles! When working in areas which are marked with the symbol shown, suitable protective goggles must be worn! NOTE Use hearing protection!
Page 14: Prohibition Notices
1 | Introduction Information about this manual 1.2.1.4 Prohibition notices We use the following pictograms for prohibition notices: Prohibition, in general! Do not touch! No fire and naked light! Eating and drinking prohibited! No smoking!! Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 14 / 169...
Page 15: Target Readers Group
1 | Introduction Information about this manual 1.2.2 Target readers group These instructions are intended for people who use, adjust, operate or service the machine. DANGER Personal injury or material damage due to inadequate maintenance and improper operation of the machine! ü...
Page 16 1 | Introduction Information about this manual Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 16 / 169...
Page 17: Technical Data
2 | Technical data 2 Technical data Printed circuit boards and components...................... 18 General data.............................. 18 PC system requirements .......................... 18 Pneumatics.............................. 19 Connection data.............................. 19 Ambient conditions............................ 19 Heating system.............................. 19 Axis system.............................. 20 Cameras ................................ 20 2.10 Available options............................. 21 Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev.
Page 18: Printed Circuit Boards And Components
2 | Technical data Printed circuit boards and components 2.1 Printed circuit boards and components Description PCB top cooling Hybrid fans PCB bottom cooling Compressed air with blow pipe Max. PCB size (width x depth, mm) 390 x 285 Extended PCB size (width x depth, mm)* 390 x ca. 500 Max.
Page 19: Pneumatics
2 | Technical data Pneumatics 2.4 Pneumatics Designation Maximum inlet pressure (bar, oil-free) Minimum inlet pressure (bar, oil-free) Required connector (quick coupling) ¼ inch 2.5 Connection data Description Mains voltage 3-wire system N / PE (V) 1 x 230 V Voltage tolerance (%) ±...
Page 20: Axis System
2 | Technical data Axis system Temperature sensors Designation Sensor type Non-contact infrared sensor (pyro- meter), digital Additional inputs for K-type thermo- couples* *An AccuTC is included in delivery. 2.8 Axis system Description Type Precision guide with stepper motors Axes X, Y, Z and rotation Placement accuracy (µm) ±...
Page 21: Available Options
PCB frame, XL 0HR635 Voidless module to reduce bubbles 0HR-VL1 The following devices can be connected to the HR 600/2 unit. They can be con- trolled using the HR 600/2 unit. Description Item number Fume extraction Ersa EASY ARM 1...
Page 22: Available Options
2 | Technical data Available options Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 22 / 169...
Page 23: For Your Safety
3 | For your safety 3 For your safety General safety instructions .......................... 24 3.1.1 Nationally valid safety and accident prevention regulations ............ 24 3.1.2 Fire protection .......................... 24 Subject-related safety instructions ......................... 25 3.2.1 Dealing with electrical equipment.................... 25 3.2.2 Dealing with process materials and substances ................ 25 Safety instructions for certain operating phases ....................
Page 24: General Safety Instructions
3 | For your safety General safety instructions 3.1 General safety instructions 3.1.1 Nationally valid safety and accident prevention regulations For any work performed on the machine itself or on its electric or pneumatic equip- ment, the locally applicable accident prevention, safety and environmental protec- tion regulations are to be observed.
Page 25: Subject-Related Safety Instructions
3 | For your safety Subject-related safety instructions 3.2 Subject-related safety instructions 3.2.1 Dealing with electrical equipment DANGER Dangerous electrical voltage! Serious injury or death from electric shock! ü Work on the electrical system or the machine electrical devices must be under- taken only by a skilled electrician or by properly trained people under the supervi- sion and guidance of a skilled electrician in accordance with the electro-technical rules.
Page 26: Safety Instructions For Certain Operating Phases
3 | For your safety Safety instructions for certain operating phases CAUTION toxic fumes! Risk of poisoning by inhalation! a) During soldering, gas emissions arise from the module or from the solder paste used. These gas emissions are harmful. b) With respect to respiratory protection, the operator must observe the processing instructions specified in the safety data sheets of the solder pastes and fluxes used! 3.3 Safety instructions for certain operating phases...
Page 27: Safety Instructions For Certain Machine And System Parts
3 | For your safety Safety instructions for certain machine and system parts 3.5 Safety instructions for certain machine and system parts 3.5.1 Hot device CAUTION Risk of burns from hot surfaces! a) Touching the device surfaces may cause burns! All heated machine parts, the surrounding housing parts and insertion frame, the PCB and the components will become hot even during warm-up to the process temperature [Tinit]! Parts become strongly heated during the soldering process!
Page 28 3 | For your safety Retrofitting and changes Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 28 / 169...
Page 29: Transport, Installation, Storage, Disposal
4 | Transport, installation, storage, disposal 4 Transport, installation, storage, disposal Setting up the rework system ......................... 30 Information concerning machine transport and storage................ 32 Unpacking the machine .......................... 32 Scope of delivery............................. 33 Unpacking the Rework System ........................ 33 Setting up the rework system ......................... 35 Connecting the Rework System ........................
Page 30: Setting Up The Rework System
4 | Transport, installation, storage, disposal Setting up the rework system 4.1 Setting up the rework system WARNING Fire hazard, hazard due to heat accumulation! Personal or material damage is possible! a) Above, behind and next to the machine there must be no furniture (shelves, cab- inets) or flammable products! b) The distance to the walls must be at least 10 cm.
Page 31 4 | Transport, installation, storage, disposal Setting up the rework system Fig. 2: Setting up the HR 600/2 unit ü To align the machine: a) To align, use a spirit level. With the levelling feet (2), align the machine hori- zontally. b) Observe the following points: ð...
Page 32: Information Concerning Machine Transport And Storage
4 | Transport, installation, storage, disposal Information concerning machine transport and storage 4.2 Information concerning machine transport and storage CAUTION Material damage is possible! ü The machine is supplied in a sturdy carton on a pallet. Damage caused by im- proper storage or improper transportation is not covered by warranty! a) Always transport or store the machine in a box on a pallet! b) During the machine transport, avoid any jerky movement, abrupt setting-down or bumping!
Page 33: Scope Of Delivery
3HR600-06-022 Adaptor for suction device 0IR5500-45 Vacuum cup, 5 mm, silicone 0IR4520-02 USB flash drive Rework 3BA00149 Operating instruction HR 600/2 3BA00225 Compressed-air hose, 3 m, 6 mm Ø 98943 USB cable A-B 3ET00241 Available options: With regard to this, please read Chapter Available options.
Page 34 We recommend keeping the packaging materials for later use. ð Only with this packaging material can the HR 600/2 unit be safely packed, stored and transported! The possible presence of tempering colours on the heating head is due to manufac- turing reasons.
Page 35: Setting Up The Rework System
4 | Transport, installation, storage, disposal Setting up the rework system 4.6 Setting up the rework system WARNING Fire hazard, hazard due to heat accumulation! Personal or material damage is possible! a) Above, behind and next to the machine there must be no furniture (shelves, cab- inets) or flammable products! b) The distance to the walls must be at least 10 cm.
Page 36 4 | Transport, installation, storage, disposal Setting up the rework system Fig. 5: Setting up the HR 600/2 unit ü To align the machine: a) To align, use a spirit level. With the levelling feet (2), align the machine hori- zontally. b) Observe the following points: ð...
Page 37: Connecting The Rework System
ü To connect the machine: a) Remove all the accessories from the packaging, unwrap them and lay them out. Fig. 6: The back side of the HR 600/2 unit 1 Power cable 7 Connection of the optional RPC camera lighting 2 Main fuse...
Page 38: Assembling The Accu-Tc Holder And Air Deflector
4 | Transport, installation, storage, disposal Assembling the Accu-TC holder and air deflector NOTE Use the soldering fume extraction system! Solder fumes are hazardous to health. For this reason, a soldering fume extraction sys- tem should always be used. As regards the type of soldering fume extraction system, we recommend using the Ersa “Easy Arm”...
Page 39 4 | Transport, installation, storage, disposal Assembling an RPC camera Fig. 9: Assembling an RPC camera, example picture. Run the camera cables under the Re- work System backwards. a) Fit the RPC camera to the rail (8) using two knurled screws. With regard to this, please read document [3BA00222 Connecting RPC camera].
Page 40: Disposal
4 | Transport, installation, storage, disposal Disposal 4.10 Disposal CAUTION Disposal ü Solder waste is hazardous waste and must not be disposed of together with do- mestic waste. a) Provide safe and environmentally friendly disposal of packaging materials! b) Make sure that all process materials and replacement parts are disposed of in a safe and environmentally friendly way! In accordance with Directive 2008/98/EC on waste and Directive 2002/96/EC on waste electrical and electronic equipment, we recommend the following proced-...
Page 41: Commissioning
5 | Commissioning 5 Commissioning Setting up the PC............................. 42 Starting HRSoft and setting up the database connection manager .............. 45 Initialisation of motors and axis limits ...................... 48 Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 41 / 169...
Page 42: Setting Up The Pc
– The PC user must have administrator rights. – Devices must be assembled and connected as described in the previous chapters. – Do not connect the HR 600/2 unit and the PC yet. – Do not use a network cable or wireless LAN yet. Preparing the PC a) Switch on the PC and wait for the operating system to start.
Page 43 Connect the PC with the supplied USB cable to the HR 600/2 unit. With regard to this, please also read Chapter Connecting the Rework System [} 37]. b) Use the main switch to turn on the HR 600/2 unit. With regard to this, please also read Chapter Overview of the machine parts [} 52].
Page 44 5 | Commissioning Setting up the PC a) Open the [HR600-0XXX] removable data carrier. b) Holding down the shift key, select the [Calibration Data] folder and the [Spe- cific Control Settings] file. c) Select the [Copy] command. d) Open the [C: \ ProgramData \ ERSA GmbH \ HRControl] directory. e) Copy the files to this directory with the [Paste] command.
Page 45: Starting Hrsoft And Setting Up The Database Connection Manager
It is possible to use an SQL server on a network drive and store the database there. This database can then be used simultaneously by multiple users of the HR 600/2 unit. For any questions about the regular backup of the database, contact your net- work administrator.
Page 46 5 | Commissioning Starting HRSoft and setting up the database connection manager Database assistant Server name: Update Information Host Data-location: Product: Level: Edition Version: Login on server Windows-Authentification SQL-Server Authentification (recomm.) SQL-Server user name: Password Connect server Database selection Database on server ErsaHrData Test connection Create HR database...
Page 47 5 | Commissioning Starting HRSoft and setting up the database connection manager For any questions about the regular backup of the database, contact your network administrator. You can also back up the database manually. With regard to this, please read Chapter Database administration and maintenance manager [} 98]. Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev.
Page 48: Initialisation Of Motors And Axis Limits
Then a message appears. Now power cycle the HR 600/2. ð [Initialize axis limits]: This button allows you to initialise the limit switching of the X, Y and Z axles.
Page 49: Function Description
Target readers group ........................ 50 6.1.2 Supplementary documents ...................... 50 6.1.3 ESD-hazardous components ...................... 51 Overview of the machine parts........................ 52 Switching on the HR 600/2 and starting HRSoft ..................... 54 The user interface ............................ 55 6.4.1 Menu bar ............................ 56 6.4.1.1 The [Start] tab......................... 57 6.4.1.2...
Page 50: Read This First
6 | Function description Read this first! 6.1 Read this first! 6.1.1 Target readers group These instructions are intended for people who use, adjust, operate or service the machine. DANGER Personal injury or material damage due to inadequate maintenance and improper operation of the machine! ü...
Page 51: Esd-Hazardous Components
The HR 600/2 can be smoothly integrated in such an environment. Using one of the buttons on the front, the user can for example connect an ESD strap. The housing of the HR 600/2 is connected to the earth wire of the voltage supply network via the kettle plug.
Page 52: Overview Of The Machine Parts
6 | Function description Overview of the machine parts 6.2 Overview of the machine parts Fig. 11: Overview of the machine parts 1 Connection socket thermocouple 1 (TE1) 12 Connection socket thermocouple 2 (TE2) 2 X axle 13 Glass plate, component support and component identification 3 Telescopic holder for the thermocouple 14 Connection for the ESD strap...
Page 53 6 | Function description Overview of the machine parts Fig. 12: HR 600 block diagram Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 53 / 169...
Page 54: Switching On The Hr 600/2 And Starting Hrsoft
Wait until the HR 600/2 has performed its own self-diagnoses and has been referenced. ð The head will remain in the start position and the HR 600/2 will be ready for operation. Note: In Chapter Tutorial, the working steps of the processes Desoldering a com- ponent [} 122] and Soldering a component [} 132] are described.
Page 55: The User Interface
6 | Function description The user interface 6.4 The user interface After starting HRSoft, the user interface to control the HR 600/2 unit will be dis- played. The start dialog is divided into the following areas: Style Start Camera and light...
Page 56: Menu Bar
6 | Function description The user interface 3 The tabs to display windows 7 The parameter windows Actual parameters, Data table, System settings and System info See Chapter The parameter windows [} 79] 4 For the work area, 8 The status bar also see No.
Page 57: The [Start] Tab
Record processes Analysis functions Menu area [Control]: Manually connection of the HR 600/2 unit to the axle control, and user change. – [Connect]: This button restores the connection between HR 600/2 and PC in case it was lost. – [Change user]: Switch to other users with other access rights by entering the password.
Page 58 6 | Function description The user interface Menu area [Analysis functions]: To analyse recorded processes. This function is possible during process recording, or after invoking an already archived process. With regard to this, please read Chapter Record, archive and analyse processes [} 138]. –...
Page 59: The [Camera And Light] Tab
6 | Function description The user interface 6.4.1.2 The [Camera and light] tab Current image Style Start Camera and light Placement View Extras Zoom Transparency Top LED light Bottom LED light RPC light Camera Save Switch on/off Dismiss Open selection Live video Image-functions RPC AOI External viewer...
Page 60 6 | Function description The user interface ð The detail image will be displayed in high definition. In this way you can for ex- ample observe the solder melting process. Bildbearbeitung Fig. 14: Ersa LiveViewer Double-clicking in the LiveViewer top bar enlarges the window to screen size. You can zoom the camera image via the mouse wheel.
Page 61: The [Positioning] Tab
6 | Function description The user interface 6.4.1.3 The [Positioning] tab Current image Start Camera and light Placement View Extras Style Heating Heating Save in Reference Reference Pixel to Switch Move to Save Move to Save Light Mode head head Component position profile cameras...
Page 62 6 | Function description The user interface – Too bright workplace lighting will adversely affect the camera proper oper- ation. – The glass plate is very dirty. – The positions of the cameras are not set up correctly. With regard to this, please read document [HR600 Setup instructions.pdf] on the data carrier [USB flash drive Rework] [3BA00149].
Page 63: The [View] Tab
6 | Function description The user interface 6.4.1.4 The [View] tab In this menu you can set various preferences. With regard to this, please read the chapter Customizing the presentation of charts and windows [} 87]. Current image Style Start Camera and light Placement View Extras...
Page 64: The [Extras] Tab
The [Extras] tab is reduced to the [Options ] and [Help ] buttons if you are not logged in as [Administrator]. All settings contained in the [Extras] tab have already been made when commissioning the HR 600/2 unit. These settings must only be changed by trained, qualified staff!
Page 65 6 | Function description The user interface Menu area [Online help]: – [Help]: Opens [Online help]. Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 65 / 169...
Page 66: The Automation Bar
6 | Function description The user interface 6.4.2 The automation bar The four left-hand buttons of the automation bar control the process, while the six right-hand buttons control the single process steps. Fig. 15: The automation bar To use a profile, select it in the profile table and enable it in the [Profile library] work area by clicking on the [Activate] button.
Page 67 6 | Function description The user interface – [Go to target position ]: If it is marked in yellow, the target position on the PCB is approached with the camera. – [Run pin detection ]: If it is marked in yellow, the pins (connections) of the component on the glass plate are detected.
Page 68: Work Areas
6 | Function description The user interface 6.4.3 Work areas Style Start Camera and light Placement View Extras Change Diagram Delete Delete Setpoint Connect Open Delete Archiving Cursor Save Print Recording curve all dots user settings Export Control Data accesses Record processes Analysis functions Archive Profiles...
Page 69: The Work Area [Soldering]
6 | Function description The user interface 6.4.3.1 The work area [Soldering] Style Start Camera and light Placement View Extras Change Diagram Delete Delete Setpoint Connect Open Delete Archiving Cursor Save Print Recording curve all dots user settings Export Control Data accesses Record processes Analysis functions Archive...
Page 70 6 | Function description The user interface travel path of the axles clear! During the desoldering process, the button is displayed as a stop button [Stop desoldering process] stop button. It terminates the soldering and desoldering process. The component is stored or the head moves to the parking position. With respect to this, please read the chapter Profiles [} 102].
Page 71 6 | Function description The user interface DANGER Laser beam! Risk of injury due to retinal burns a) Do not stare into the laser beam! b) Do not point the laser beam at other people! Reflecting surfaces under the laser generate reflections! c) Class 2 laser according to DIN EN 60825-1:2008-5, P <...
Page 72: The Work Area [Placement]
6 | Function description The user interface 6.4.3.2 The work area [Placement] Current image Style Start Camera and light Placement View Extras Zoom Transparency Top LED light Bottom LED light RPC light Switch Camera Save Dismiss Open ON/OFF selection Live video Image-functions RPC AOI External viewer...
Page 73 6 | Function description The user interface – [Move axis backward]: It allows moving the heads manually backward. This is also possible with the key combination [Ctrl] + [Top arrow key]. By pressing the scroll wheel while holding down the mouse button, the move- ment can be sped up or slowed down.
Page 74 6 | Function description The user interface – Second status indication: Shows whether errors have turned up during pro- cessing. If the display panel is green, there are no errors. If the display panel is red, you can read the current error message. Also see 2 Performing the positioning process [} 135] Ersa GmbH...
Page 75: The Work Area [Profile Library]
6 | Function description The user interface 6.4.3.3 The work area [Profile library] Library Profile library Online-HR 600 Current image Archive Profiles Search for profiles Profile definitions Specifications Profile name Sensor Show template profiles Board Adaptor (head) Profile parameters Component Head position Delete Profile automation PCB positioning...
Page 76 6 | Function description The user interface – [Activate]: Enables the profile you have selected in your profile table. You can then work with this profile. – [Search term]: Displays a comment belonging to the profile, if there is one stored. –...
Page 77: The [Archive] Work Area
6 | Function description The user interface 6.4.3.4 The [Archive] work area Profiles Online-HR 600 Current image Archive Archive Search period of time Comments to this process Year Month Number from: Combined search User Show profile parameters Tracking code Show profile Profile Duration [s] Imag Date...
Page 78 6 | Function description The user interface [Search options] frame: By clicking on the [Precise search], [LIKE search], [Combine AND] and [Combine OR] button, you can refine the search for profiles. If the square inside the button is shown in orange, the corresponding option is active. The system is not case-sensit- ive.
Page 79: The Parameter Windows
6 | Function description The user interface 6.4.4 The parameter windows Style Start Camera and light Placement View Extras Change Diagram Delete Delete Setpoint Connect Open Delete Archiving Cursor Save Print Recording curve all dots user settings Export Control Data accesses Record processes Analysis functions Archive...
Page 80: The Parameter Window [Actual Parameters]
6 | Function description The user interface 6.4.4.1 The parameter window [Actual parameters] The [Profile parameters] of the currently active profile are displayed in this win- dow. ü To display the [Actual parameters] parameter window: a) Enable the [Actual parameters] tab. Actual parameters Profiles Board...
Page 81: The Parameter Window [Data Table]
6 | Function description The user interface 6.4.4.2 The parameter window [Data table] In the parameter window [Data table] you can specify which values to display in the window [Online-HR 600]. The display of the diagram itself may be adjusted to your requirements in the [Display properties] dialog.
Page 82: The Parameter Window [System Settings]
6 | Function description The user interface 6.4.4.3 The parameter window [System settings] In the [System settings] parameter window, you can set the requirements to auto- matically record and cool the soldering process at the end of the process. With re- gard to this, please read the chapter [The window [Online HR 600] [} 85]].
Page 83: The Parameter Window [System Info]
Angle of rotation Save target position Fig. 25: The [System info] parameter window Information: – [System parameters]: Shows information on the HR 600/2 unit. – [Expert data]: Displays information on the operational data. Note: OSTR = Upper radiator Status indications: The status indications are displayed in red or green.
Page 84: The Status Bar
6 | Function description The user interface 6.4.5 The status bar Save target position X-Axis Y-Axis Z-Axis Angle of rotation The status bar at the bottom of the screen contains the Save target position button on the left and shows the current position of the X and Y axles on the right, as well as the Z axle and the rotation angle of the pick-and-place nozzle.
Page 85: The Window [Online Hr 600]
6 | Function description The user interface 6.4.6 The window [Online HR 600] This window appears when you click on the [Soldering] button in the functional area. The window graphically represents an active soldering process: Archive Profiles Online-HR 600 Current image Top heat Bot heat Head...
Page 86 6 | Function description The user interface The graphical representation of the measurements in the diagram can be changed. With respect to this, please read Chapter The parameter window [Data table] [} 81]. To edit the process display: ü You can adjust the graphic display of the [Online-HR 600] window to your re- quirements.
Page 87: Working With The Hr 600/2 Unit
6 | Function description Working with the HR 600/2 unit 6.5 Working with the HR 600/2 unit 6.5.1 Presets 6.5.1.1 Customizing the presentation of charts and windows You can customise the user interface to suit your way of working. You may want to hide some windows permanently, because you do not need them for your work.
Page 88 6 | Function description Working with the HR 600/2 unit To show tabs: You can show and hide the tabs [Actual parameters], [Data table], [System settings] or [System info] in the lower section of the parameter window. ü To show and hide the tabs: a) In the menu area [View], click the drop-down menu and select an entry [Actual parameters].
Page 89: Creating A User
6 | Function description Working with the HR 600/2 unit 6.5.1.2 Creating a user You can lock or unlock individual sections of the machine control system for a cer- tain group of people. To this purpose, the dialog box [User administration] is used.
Page 90 6 | Function description Working with the HR 600/2 unit To add a user: ü To add a user: a) Click on the [Create new user] button. b) Enter a name into the entry field [Username]. ð It is differentiated between capital and small letters.
Page 91 6 | Function description Working with the HR 600/2 unit To delete users: ü Deleting a user means deleting the user name with its rights. You can perform this process only if you have logged in as [Administrator]: a) Select a user in the window [List of actual users]. The selection highlights with colour.
Page 92: Click On The Button [Options]
6 | Function description Working with the HR 600/2 unit 6.5.1.3 Click on the button [Options] Clicking on the [Options] button in the [Extras] will open the [HRSoft options] dia- log. The [Options] button will only be visible if you are logged in as [Administrator] or as [Power user].
Page 93 6 | Function description Working with the HR 600/2 unit – [Tracking is active (input is optional)]: The [Tracking code] window will open. It is necessary to enter a tracking code. The [Tracking code] window remains opened. – [Tracking is active (system forces input)]: The [Tracking code] window will open.
Page 94 For this purpose, the PCB is set into sinusoidal vibrations by means of piezoelectric actuators, and the voids under the components are reduced in li- quid solder. The HR 600/2 Rework System can be retrofitted with a voidless module.
Page 95: Database Assistant
All server and database settings have already been made w hen commissioning the HR 600/2 unit; with regard to this, please read the chapter Starting HRSoft and set- ting up the database connection manager [} 45]. Should it be necessary to make changes to these settings, you can use the [Database assistant].
Page 96 6 | Function description Working with the HR 600/2 unit Selecting a new server: ü To select a new server: a) [Server name:]: Select a server from the drop-down menu. b) Click on the [Update] button. ð The data in the [Information] frame is updated.
Page 97 6 | Function description Working with the HR 600/2 unit To select a database: ü To select a database on the server if it already exists on the server: a) Select the [ErsaHrData] database from the drop-down menu [Database selec- tion] in the [Database on server] frame.
Page 98: Database Administration And Maintenance Manager
6 | Function description Working with the HR 600/2 unit 6.5.1.5 Database administration and maintenance manager In these menus you can view the computer/server settings. You can also create a backup of the [ErsaHrData] database, load a backup and optimize the database.
Page 99 6 | Function description Working with the HR 600/2 unit ð A window is opened. b) Select a file in [.scr] format. c) Confirm with [OK]. ð The profile templates have been imported. In the frame [Backup]: The [Last Backup] display panel has no functions.
Page 100: Firmware Update
6 | Function description Working with the HR 600/2 unit 6.5.1.6 Firmware update The following operations must be performed by trained, qualified staff only. You must be logged in as an administrator. Firmware is the control software of the elec- tronic assemblies in the Rework System.
Page 101 6 | Function description Working with the HR 600/2 unit ð If the version level of the selected file is equal to or lower than the current firmware version level, an error message is displayed. In this case, you can- not update the firmware with this file.
Page 102: Profiles
6 | Function description Working with the HR 600/2 unit 6.5.2 Profiles What are profiles? A profile is a file that contains all relevant data and settings for the rework process. You can create profiles, save them and enable them at a later time.
Page 103: Enabling A Profile Template
6 | Function description Working with the HR 600/2 unit 6.5.2.1 Enabling a profile template Some [Template profiles] are deposited in the factory. These templates already contain useful settings for the most common rework processes. You can choose a template, customize it to your needs, as well as rename and save it. To do this, first select a template and then save it in your own [Profile library].
Page 104: Deleting A Profile
6 | Function description Working with the HR 600/2 unit e) Select a template and confirm your selection with [OK]. ð The template will be copied and displayed in the [Profiles] tab. f) In the directory tree under [Library], click on the directory in which the profile should be saved.
Page 105 6 | Function description Working with the HR 600/2 unit b) Click on the [Profile parameters] button in the [Delete] frame. ð A query dialog is displayed. c) Confirm with [OK]. ð The profile has been deleted. Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3...
Page 106: Searching For A Profile
6 | Function description Working with the HR 600/2 unit 6.5.2.3 Searching for a profile If many profiles are already available in your [Profile library], you can use the [Search for profiles] to search for an existing profile. a) Enable the [Profiles] tab in the [Common settings] window.
Page 107: Customizing A Profile
In most cases, it makes sense to adapt an existing profile to your own require- ments. To do so, use the [Template profiles] which were delivered together with the HR 600/2 unit. You can also customise a profile from your own [Profile library]. As a standard user you cannot edit profiles.
Page 108 6 | Function description Working with the HR 600/2 unit Save: ü To save the profile: a) Click on the [Profile parameters] button in the [Overwrite] frame. ð Changes are saved in the profile. Also see 2 The [Archive] work area [} 77] Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev.
Page 109 6 | Function description Working with the HR 600/2 unit 6.5.2.4.2 Customizing a profile in the [Common settings] tab. In this and in the following chapters you will find a description of the tabs in which the profile parameters are defined. Open the tabs one after another and adjust the profile.
Page 110 6 | Function description Working with the HR 600/2 unit ð Thermocouples TE1 and TE2 measure the temperature at the tip of the thermocouple. With respect to this, please read the chapter Positioning a thermocouple [} 125]. The infrared sensor (IRS) measures the surface tem- perature and, depending on the PCB and components, this value may differ from that measured with the thermocouple.
Page 111 6 | Function description Working with the HR 600/2 unit Fig. 44: Read PCB placement on the scales To save changes in the profile: a) Click on the [Profile parameters] button in the [Overwrite] frame. ð Changes are saved in the profile.
Page 112 During setting, observe how the gradient changes. The green Kelvin values are displayed in red when the HR 600/2 is unable to reach the requested temperatures in the requested time. Please note that the components should not be heated as quickly as pos- sible;...
Page 113 6 | Function description Working with the HR 600/2 unit e) In the [Differing solder parameters] frame, in case of profiles including both soldering and desoldering, the desoldering process can be set individually. The gradient of the desoldering process is displayed in yellow in the graph display.
Page 114 6 | Function description Working with the HR 600/2 unit 6.5.2.4.4 Adjusting the radiator configuration in the [Configuration] tab Now adjust the radiator configuration to your requirements. For [time 1], [time 2], [time 3] and [time 4] you can determine each time a radiator configuration.
Page 115 6 | Function description Working with the HR 600/2 unit Configuration Fan: Heater balance TOP-based balanced BOT-based Default Cancel Help Fig. 47: Configuration window To adjust the output of a convection fan to an area: a) Move the slider [Fan:] to the left or right.
Page 116 6 | Function description Working with the HR 600/2 unit To customize the control ratio between upper radiator/lower radiator: You can change the power ratio: – [TOP-based] (100%, heat only the upper radiator) – [balanced] (50%, heat upper and lower radiators equally) –...
Page 117 6 | Function description Working with the HR 600/2 unit 6.5.2.4.5 Customizing the placement process in the [Placement] tab The placement process involves picking up the component from the glass plate or dip module and putting it down onto the PCB.
Page 118 6 | Function description Working with the HR 600/2 unit – The pick-and-place nozzle places the component onto the landing surface. [Auto. Dip]: in this case, the Dip station must be incorporated and the component lie on the glass plate. The following steps are performed automatically: –...
Page 119 6 | Function description Working with the HR 600/2 unit c) Save the change. Placement mode ü To position a component: a) Enable the [Setting down and move until it touches] radio button in the [Place- ment mode] frame. ð The component is placed onto the landing position, until it comes into contact with the circuit board.
Page 120 6 | Function description Working with the HR 600/2 unit 6.5.2.4.6 Entering information into the [Image and document] tab You can store further information for your profile such as working instructions, documents or pictures. All information can be saved in the profile.
Page 121 6 | Function description Working with the HR 600/2 unit To paste a Search term: a) Enter any text into the [Image comment] frame. b) Click on the [Profile parameters] button in the [Overwrite] frame. ð The comment will be shown in the window in the [Image and document] tab as soon as you select the profile.
Page 122: Soldering Instruction Manual
The HR 600/2 can be smoothly integrated in such an environment. Using one of the buttons on the front, the user can for example connect an ESD strap. The housing of the HR 600/2 is connected to the earth wire of the voltage supply network via the kettle plug.
Page 123 6 | Function description Working with the HR 600/2 unit Fig. 50: Inserting the circuit board ü To insert the circuit board: a) Activate the tab [Start] in the menu bar. b) In the work area, click on the button. ð The heads will move to the park position. Keep the travel path of the axles clear! c) Loosen all six knurled screws (1) and (3).
Page 124 6 | Function description Working with the HR 600/2 unit ð The pipette is lowered completely. e) In case of larger pipettes: Pull the clear silicone nozzle downwards. f) Attaching a new silicone nozzle g) In case of smaller pipettes: Remove the pipette. The pipette is held magnetic- ally.
Page 125 6 | Function description Working with the HR 600/2 unit 6.5.3.1.2 Positioning a thermocouple Fig. 51: Positioning the thermocouple a) Insert the holder (5) into one of the holes (4). b) Clamp the holder with the lever (2) in a clockwise direction.
Page 126 6 | Function description Working with the HR 600/2 unit 6.5.3.1.3 Shielding heat sensitive components Fig. 52: Shielding heat sensitive components a) Use reflector tape and/or a suitable air deflector for shielding. b) To do this, slide the air deflector (1) along the rail under the heating head (2).
Page 127 6 | Function description Working with the HR 600/2 unit 6.5.3.1.4 Enabling a profile template Some [Template profiles] are deposited in the factory. These templates already contain useful settings for the most common rework processes. You can choose a template, customize it to your needs, as well as rename and save it. To do this, first select a template and then save it in your own [Profile library].
Page 128 6 | Function description Working with the HR 600/2 unit e) Select a template and confirm your selection with [OK]. ð The template will be copied and displayed in the [Profiles] tab. f) In the directory tree under [Library], click on the directory in which the profile should be saved.
Page 129 6 | Function description Working with the HR 600/2 unit Version 1: ü Position the head using the laser: a) In the functional area, enable the [Placement] button. ð In the work area, the buttons and the visual displays for the placement process appear.
Page 130 6 | Function description Working with the HR 600/2 unit Style Start Camera and light Placement View Extras Change Diagram Delete Delete Setpoint Connect Open Delete Archiving Cursor Save Print Recording curve all dots user settings Export Control Data accesses Record processes...
Page 131 6 | Function description Working with the HR 600/2 unit ð The process has now been completed. The component is unsoldered and the solder joint is ready to receive the new device. If you want to solder a compon- ent in the next step, you must first search for a profile of the [Soldering] type and enable it.
Page 132: Soldering A Component
The step-by-step sequence of the soldering process is described below. 6.5.3.2.1 Preparing the soldering operation ü Set up the HR 600/2 and the PCB as described in the chapter Desoldering a component [} 122]: a) Insert the PCB into the support frame as described in the chapter Inserting the PCB.
Page 133 6 | Function description Working with the HR 600/2 unit 6.5.3.2.2 Enabling a profile template Some [Template profiles] are deposited in the factory. These templates already contain useful settings for the most common rework processes. You can choose a template, customize it to your needs, as well as rename and save it. To do this, first select a template and then save it in your own [Profile library].
Page 134 6 | Function description Working with the HR 600/2 unit e) Select a template and confirm your selection with [OK]. ð The template will be copied and displayed in the [Profiles] tab. f) In the directory tree under [Library], click on the directory in which the profile should be saved.
Page 135 6 | Function description Working with the HR 600/2 unit ð Proper polarity means: If Pin 1 is for example located top left in the solder- ing position, also PIN 1 of the prepared component must be arranged on the top left.
Page 136 6 | Function description Working with the HR 600/2 unit ð The lower camera detects the connections of the component with differ- ent brightness degrees. The connections of the component are shown with a coloured border. ð The process is stopped. If not all connections are recognized:...
Page 137 6 | Function description Working with the HR 600/2 unit ð The contours of the component are identified and displayed as a red area. ð The lower camera detects the connections of the component with differ- ent brightness degrees. The connections of the component are shown with a coloured border.
Page 138: Record, Archive And Analyse Processes
6 | Function description Working with the HR 600/2 unit 6.5.3.3 Record, archive and analyse processes To record and analyse a process: ü Soldering and desoldering processes can be recorded automatically by pressing the [Record] button. With respect to this, please read the chapter The para- meter window [System settings] [} 82]:...
Page 139 6 | Function description Working with the HR 600/2 unit Automatically archiving a process When the process is finished, the recording process can be automatically archived. The soldering and desoldering processes have been archived. ü To enable automatic archiving: a) In the [Extras] tab from the [Parameters and settings] menu area, click on the [Options] button.
Page 140 6 | Function description Working with the HR 600/2 unit a) In the [Start] tab from the [Record processes] menu area, select the [Diagram settings] button. b) The dialog [Display properties] is displayed. It includes the three [Layout], [Status bars] and [Reference lines] areas.
Page 141: Turning Off The Hr 600/2 Unit
ð If the process file (*.HRS) has been edited, you will be asked if you want to save the changes. b) Wait for 10 seconds for the program to close. c) Use the main switch to turn off the HR 600/2 unit. d) If necessary, shut down the PC. Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev.
Page 142: Updating The Hrsoft Program
6 | Function description Updating the HRSoft program 6.7 Updating the HRSoft program The number of the installed HRSoft version can be found in the program informa- tion window. a) Call it up via the Ersa icon button in the top right corner. b) Make sure that the same Windows user is used as the one the previous version was installed with.
Page 143: Spare And Wear Parts
7 | Spare and wear parts 7 Spare and wear parts Read this first! ............................... 144 7.1.1 Nameplate and serial number ...................... 144 7.1.2 Target readers, permitted spare parts ................... 144 Spare parts .............................. 145 Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 143 / 169...
Page 144: Read This First
7 | Spare and wear parts Read this first! 7.1 Read this first! 7.1.1 Nameplate and serial number Fig. 59: Example of the nameplate of a machine. The details are not identical to those specified on the nameplate of your machine! NOTE Important note When ordering spare parts always specify the machine number.
Page 145: Spare Parts
7 | Spare and wear parts Spare parts 7.2 Spare parts Description Item number Controller for stepper motor 3ET00339 Motherboard MMC-01 259581 Control board 0HR605 USB cable A-B 3ET00241 USB cable A - B mini 5 pin 3ET00347 USB stick 0HR630 Operating instructions HR 600 3BA00207 USB Hub, 7-fold...
Page 146 7 | Spare and wear parts Spare parts Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 146 / 169...
Page 147: Treatment Of Messages And Malfunctions
8 | Treatment of messages and malfunctions 8 Treatment of messages and malfunctions Stiff control of the pick-and-place nozzle ..................... 148 Pin pad overlay incorrect .......................... 148 Contours are not correctly recognized...................... 148 Positions are approached improperly...................... 148 Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 147 / 169...
Page 148: Stiff Control Of The Pick-And-Place Nozzle
End HRSoft. Use the main switch to turn off the HR 600/2 unit. b) Wait 10 seconds. Use the main switch to turn on the HR 600/2 unit. c) Start HRSoft. ð The message [Cameras and axes will be referenced now] appears.
Page 149: Service And Maintenance
9 | Service and maintenance 9 Service and maintenance Service table.............................. 150 Maintenance work to be performed daily .................... 151 9.2.1 Checking the pipette for smooth running and cleaning it .............. 151 Maintenance work to be performed weekly .................... 157 9.3.1 Cleaning the control of the pick-and-place nozzle ................. 158 Maintenance work to be performed monthly ....................
Page 150: Service Table
9 | Service and maintenance Service table 9.1 Service table Duration Further information Daily 15 Min 9.2.1 Checking the pipette for smooth running and cleaning it Weekly 5 Min 9.3.1 Cleaning the control of the pick- and-place nozzle Monthly 5 Min 9.4.1 Checking the vacuum filter of the pipette air supply and repla-...
Page 151: Maintenance Work To Be Performed Daily
9 | Service and maintenance Maintenance work to be performed daily 9.2 Maintenance work to be performed daily 9.2.1 Checking the pipette for smooth running and cleaning it Check the pipette for smooth running every day after switch-on. The pipette in the heating head is exposed to flux smoke. Depending on the intens- ity of smoke exposure, the pipette requires regular cleaning.
Page 152 9 | Service and maintenance Maintenance work to be performed daily c) Wipe dry with a dry, lint-free cloth. d) Check the pipette for smooth running again. e) If the pipette still does not run smoothly, continue with the step [Removing the pipette and cleaning it completely].
Page 153 9 | Service and maintenance Maintenance work to be performed daily h) Leave the protective conductor cable attached to the heating head cover. In a different series of HR 600 rework systems, the cover of the pipette should not be opened with an Allen key, but with an open-end wrench. You will see this look- ing inside through the grid above the heating head.
Page 154 9 | Service and maintenance Maintenance work to be performed daily c) Push the pipette upwards and pull it out of the heating head from above; see the picture on the right. If necessary, use a gripping tool, e.g. tweezers. d) Clean the whole pipette. Use a flux remover or rubbing alcohol recommended by the flux manufacturer.
Page 155 9 | Service and maintenance Maintenance work to be performed daily b) Check whether the vacuum filter of the air supply of the pipette is discoloured or clogged. If this is the case, replace the vacuum filter. For more information, please refer to the following Chapter Checking the vacuum filter of the pipette air supply and replacing it [} 160].
Page 156 9 | Service and maintenance Maintenance work to be performed daily h) Remove the pipette from the heating head; see the picture on the right. If ne- cessary, use a gripping tool, e.g. tweezers. i) Clean the whole pipette. Use a flux remover or rubbing alcohol recommended by the flux manufacturer.
Page 157: Maintenance Work To Be Performed Weekly
9 | Service and maintenance Maintenance work to be performed weekly 9.3 Maintenance work to be performed weekly Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 157 / 169...
Page 158: Cleaning The Control Of The Pick-And-Place Nozzle
9.3.1 Cleaning the control of the pick-and-place nozzle The control of the pick-and-place nozzle needs to be cleaned at least once a week. With intensive use of the HR 600/2 unit, daily. The pick-and-place nozzle is exposed to flux smoke. Depending on the intensity of smoke exposure, the pick-and-place nozzle requires regular cleaning.
Page 159: Maintenance Work To Be Performed Monthly
9 | Service and maintenance Maintenance work to be performed monthly 9.4 Maintenance work to be performed monthly Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 159 / 169...
Page 160: Checking The Vacuum Filter Of The Pipette Air Supply And Replacing It
9 | Service and maintenance Maintenance work to be performed monthly 9.4.1 Checking the vacuum filter of the pipette air supply and replacing it Every month, the vacuum filter of the pipette air supply must be checked for dirt or clogging. The vacuum filter is located at the back of the heating head. ü...
Page 161: Maintenance Work To Be Performed Quarterly
9 | Service and maintenance Maintenance work to be performed quarterly 9.5 Maintenance work to be performed quarterly 9.5.1 Visual inspection and lubrication of the X and Y axles If dirty, or at least every three months, lubricate the two guide rails of the X and Y axles.
Page 162: Service Work To Be Performed Annually
9 | Service and maintenance Service work to be performed annually 9.6 Service work to be performed annually 9.6.1 Visual inspection and lubrication of the X and Y axles If dirty, or at least every three months, lubricate the two guide rails of the X and Y axles.
Page 163: Service Work To Be Performed When Required
9 | Service and maintenance Service work to be performed when required 9.7 Service work to be performed when required 9.7.1 Cleaning the glass plate. If the glass plate is dirty, components and pins will not be detected. ü To clean the glass plate: a) Let the machine cool down to a safe temperature.
Page 164: Re-Memorising The Pipette Position
9 | Service and maintenance Service work to be performed when required 9.7.2 Re-memorising the pipette position After a heating head change, the Rework System must memorise the pipette posi- tion again. You need a pen to mark a PCB. Perform the following steps: Use the smallest pick-and-place nozzle for this procedure.
Page 165 9 | Service and maintenance Service work to be performed when required ð The pipette position has been memorised. Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 165 / 169...
Page 166 9 | Service and maintenance Service work to be performed when required Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 166 / 169...
Page 167: Annex
10 | Annex 10 Annex 10.1 EC Declaration of Conformity........................ 168 Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 167 / 169...
Page 168: Ec Declaration Of Conformity
10 | Annex EC Declaration of Conformity 10.1 EC Declaration of Conformity Also see 2 CE Declaration of Conformity HR 600 [} 169] Ersa GmbH 3BA00207_01 Operating Instructions HR 600_2 | Rev. 3 168 / 169...

Kurtz Ersa HR 600/2 Translation Of The Original Operating Manual

1 Introduction

2 Technical Data

3 For Your Safety

4 Transport, Installation, Storage, Disposal

5 Commissioning

6 Function Description

7 Spare and Wear Parts

8 Treatment of Messages and Malfunctions

9 Service and Maintenance

10 Annex

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Summary of Contents for Kurtz Ersa HR 600/2

Table of Contents