RPS ODYSSEY LEAD TINNING SYSTEM User Manual

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DYSSEY

EAD

INNING

YSTEM

™

USER GUIDE

VERSION 1.1

EXPLICITLY AUTHORIZED BY RPS. UNAUTHORIZED USAGE IS PROHIBITED.

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Page 1 DYSSEY INNING YSTEM ™ USER GUIDE VERSION 1.1 © 2004 - 2011 RPS AUTOMATION LLC. INFORMATION CONTAINED HEREIN IS CONFIDENTIAL AND INTENDED ONLY FOR USE BY INDIVIDUALS EXPLICITLY AUTHORIZED BY RPS. UNAUTHORIZED USAGE IS PROHIBITED.
Page 2: About This Guide
ODYSSEY USER GUIDE ABOUT THIS GUIDE The information contained in this User's Guide is the property of RPS Automation LLC (“RPS”) and shall not be reproduced or published in whole or in part without the prior express written approval of RPS.
Page 3: Declaration Of Manufacturer
EN61326 (Group 1 Class A) harmonized and published standard. DECLARATION RPS Automation LLC confirms that all regulations and legislation is complied with under European machinery directives noted below. RPS Automation LLC declares that the products listed are of sound, safe and good technical construction and fit for purpose.
Page 4: Table Of Contents
ODYSSEY USER GUIDE CONTENTS INTRODUCTION How to Use This Guide RPS Warranty Protection RPS Support Services 2 SYSTEM OVERVIEW System Functional Components Tinning Process Components Service Access Point | Rear 2.4 Side Right Programming and Operating Software 3 HEALTH & SAFETY...
Page 5 4.6 Computer & Software 5 OPERATION X Y Z Axis Overview Front Panel Operating Controls About The Flow of Solder in an RPS System 5.4 The RPS Solder Pot | Load Solder Solder Temperature Control 5.6 When to Add Solder Solder Pump Assembly &...
Page 6 ODYSSEY USER GUIDE 6 CALIBRATION & OFFSETS About the Home Position 6.2 Validate | Set the Home Position 7 LEAD TINNING OPERATION LOAD/UNLOAD STATION Dynamic Flux Station Preheat/Dry Station (option) 7.4 Static Solder Station (Solder Removal) Dynamic Solder Station (Solder Application) 7.6 Dynamic Wash Station (Option) Nitrogen and Lead Tinning 7.8 Nitrogen Generators...
Page 7 ODYSSEY USER GUIDE 9 TROUBLESHOOTING General 9.2 Solder Safety 9.3 Soldering Process 10 EXTRAS 10.1 Advanced Techniques 10.2 Tips & Tricks 10.3 Continuing Selective Soldering Education 7 of 55...
Page 8: Introduction
ODYSSEY USER GUIDE 1 INTRODUCTION Welcome to the RPS Odyssey Lead Tinning System™ The Odyssey is a powerful system for high precision automated lead tinning. This system is an excellent choice for high mix, and when properly configured, high volume lead tinning production.
Page 9: How To Use This Guide
UPPORT ERVICES You are a valued RPS customer— if you have any needs at any time, please do not hesitate to contact us. We have many resources dedicated to help you resolve process, system, system, maintenance or programming needs that may arise. Please use these resources as and when needed.
Page 10: System Overview
ODYSSEY USER GUIDE 2 SYSTEM OVERVIEW 2.1 S YSTEM UNCTIONAL OMPONENTS Main Control Panel System Monitor, Keyboard, and Process Area Mouse Flux, Water, and Flux Pump Storage Storage for Tools, Spares, User Guides 2.2 T INNING ROCESS OMPONENTS Auto Load Dynamic Wash Station Tooling Gantry Unload...
Page 11: Service Access Point | Rear
ODYSSEY USER GUIDE Static Solder (Strip) Station Dynamic Flux Station Dynamic Solder (Dip) Station 2.3 S ERVICE CCESS OINT Main Power Switch Signal Generator / PC Access Secure Lock-Out Electrical Panel Electrical Panel Cooling Fans 11 of 55...
Page 12: Side Right
ODYSSEY USER GUIDE 2.4 S IGHT Nitrogen Flow Control Electrical, Air, and N2 Inlet 12 of 55...
Page 13: Programming And Operating Software
PERATING OFTWARE RPS MaestroLite™ is the robotic control software that controls the operation of the Odyssey Lead Tinning System. Equipped with intuitive controls, the software package allows the operator to quickly refine programs and easily monitor and control all robotic operations.
Page 14: Health & Safety
ODYSSEY USER GUIDE 3 HEALTH & SAFETY 3.1 S AFETY ARNING YMBOLS This manual contains safety instructions wherever required. These instructions are divided into two categories as follows: WARNING combined with the yellow symbol: Warning is used to indicate the following: RECOMMENDATION NOTE combined with the blue symbol: A note is used to indicate the following: 3.2 S...
Page 15: Solder And Dross
ODYSSEY USER GUIDE 3.3 S OLDER AND ROSS This is a robotic platform that uses molten solder to solder through hole connectors to printed circuit boards. Solder is hot, molten and capable of spilling, splattering or otherwise. Some solder contains lead material that can be hazardous. Care should be taken around all solder. !!"...
Page 16: Installation
ODYSSEY USER GUIDE 4 INSTALLATION These procedures are intended for the use of those staff members adequately trained in the installation of capital equipment. No procedure should be executed which appears to the installers to be hazardous or present a significant risk to the equipment or personnel. )* $!! 4.1 I NSTALLATION...
Page 17: Functional Specifications
<20 PPM O KEY FEATURES & OPTIONS • Steel Welded Frame • Admin Access Control • Lifetime Solder Pot Warranty • Non Proprietary Spare Parts All specifications subject to change without notice. RPS not responsible for typographical errors. 17 of 55...
Page 18: Unpack & Place
ODYSSEY USER GUIDE 4.3 U & P NPACK LACE The system is shipped fully crated. To uncrate and place: 1. Remove the top and sides of the main crate and inspect for damage. 2. The system is attached to the crate skid with 4 clamps.
Page 19: Initial Setup
ODYSSEY USER GUIDE 4.5 I NITIAL ETUP ELECTRICAL Electrical connections shall be made to the disconnect box in accordance with the codes and regulations in place in your location. As defined above in the facilities requirements section, the disconnect box has been wired for 3 wire, single phase, 208/240 VAC power.
Page 20: Computer & Software
4.6 C & S OMPUTER OFTWARE All RPS systems come standard with computer, computer screen, mouse and Microsoft Windows® operating software. Pre-installed on every computer will be the RPS MaestroLite™ Operating Software, and Adobe Reader for PDF review. MPORTANT ILES MaestroLite files on the C drive contains all the factory default systems settings (sub- utilities) and finished and refined final selective soldering programs.
Page 21: Operation
ODYSSEY USER GUIDE 5 OPERATION 5.1 X Y Z A VERVIEW Three axes on the Odyssey comprise the core robotic motion. Vertical motion is controlled by the Z axis. Gripper (clamp) motion is controlled by the Y-axis, and the left to right motion is controlled by the X-axis.
Page 22: About The Flow Of Solder In An Rps System
OLDER IN AN YSTEM The RPS solder pot is a unique station that employs the re-circulation of molten solder to an inner process tank. The solder is pumped through a solder-duct and up a solder-riser. Mounted on top of the riser is the solder nozzle through which the solder is pumped.
Page 23: Solder Temperature Control
5. Save & Exit: Pressing the Setup key again to save and exit to operation state. 6. Rotate Key: this key is used to change default factory settings. Do not use this key without contacting RPS. Actual Temp Set Temp...
Page 24: When To Add Solder
ODYSSEY USER GUIDE 5.6 W HEN TO OLDER OLDER 1. Turn Off the Pump (if equipped) Add Solder 2. Add solder to the molten solder bath. 5.7 S & C OLDER SSEMBLY OMPONENTS In order to understand and effectively utilize the Solder Pump Assembly you must be familiar with its general description, purpose of components, controls settings and process parameters, the assembly breakdown, and proper maintenance.
Page 25: Solder Pump Operation
The pump motor RPM’s are adjusted from the MaestroLite control panel “Spindle RPM” or from the script of the PCB subroutine. From the Spindle RPM window (below), use the slide bar OR enter an RPS speed to adjust the pump impeller (i.e., spindle) speed.
Page 26 ODYSSEY USER GUIDE MaestroLite Control Panel: Change MaestroLite Control Panel: Change the slider to adjust pump speed this value to adjust pump speed ETERMINING THE ORRECT EIGHT When adjusted correctly, the solder will be flowing consistently off of one edge of the nozzle.
Page 27 ODYSSEY USER GUIDE $ $ $ $ *! 27 of 55...
Page 28: Calibration & Offsets
This switch will indicate to the system that it has reached its home position. Because RPS uses closed-loop servo motors for X, Y, and Z axis control, a return to home is not required during board processing. However, the home state position must be calibrated into the system as a universal reference point for all robotic moves.
Page 29: Validate | Set The Home Position
ODYSSEY USER GUIDE 6.2 V ALIDATE ET THE OSITION To adjust the home position: This process should take no more than 5 minutes. 1. MOVE HOME: Home all the axes using the MaestroLite controls. Home All Axes 2. ZERO ALL AXES: In the main screen window of MaestroLite, insure the “Program” and “Machine”...
Page 30: Lead Tinning Operation
7 LEAD TINNING OPERATION 7.1 LOAD/UNLOAD STATION The Odyssey Lead Tinning System is equipped with a Load/Unload station located at the left side of the machine near the gantry home position. Components will each have a corresponding matrix tray (tooling) that is populated with components and located on the load station using the installed guide pins.
Page 31: Dynamic Flux Station
The dynamic flux system is controlled through the use of a peristaltic pump located in the lower right cabinet. The pump RPM will be set by the RPS technician during system installation. Flux Reservoir Flux and Water...
Page 32: Tatic Older
RPS systems require high purity nitrogen (99.999% or less than 20 ppm oxygen) at 80 psi delivered to the system at a flow rate of 250 CFH.
Page 33 To repeat, what is important is how much oxygen is present. As an example: 99.998% = 20ppm of impurities = recommended by RPS 99.997% = 30ppm of impurities = not recommended by RPS (too much oxygen) 99.99% = 100ppm of impurities = not useful for inertion It would be ideal to have 99.999%.
Page 34: Nitrogen Generators
ODYSSEY USER GUIDE 7.8 N ITROGEN ENERATORS Nitrogen generators are a great means to provide a constant supply or high purity nitrogen. If funding is available, nitrogen generators will remove the headache of transporting, ordering and purging the line for tank changeovers. When production increases to multiple systems or multiple shifts, an N2 generator is essential.
Page 35: Rear Electrical Panel | Power Issue Resolution
ODYSSEY USER GUIDE 7.9 R LECTRICAL ANEL OWER SSUE ESOLUTION If the system is experiencing a power issue and a circuit failure is suspected, then access the circuit breakers via the back access panel. & R HECK ESET IRCUIT REAKERS 1.
Page 36: Maintenance Procedures
Regularly inspect the system’s components for wear or damage. Pay particular attention to the items on the list below. Note that many of the components are obtained by RPS Automation LLC from other OEMs and have maintenance procedures within their own manuals.
Page 37: Schedule | Quick Guide
ODYSSEY USER GUIDE 8.3 S CHEDULE UICK UIDE RPS Maintenance Daily Annual INSTRUCTIONS Item Hours Basic wipe down / cleaning. Remove System Wipe Down flux (if any). Wipe lenses. Remove dross from below N2 Dross Removal shroud Tin nozzle surface with a heavily...
Page 38: System Wipe Down | Daily
ODYSSEY USER GUIDE 8.4 S YSTEM AILY Daily maintenance and cleaning should take just 10-15 minutes per day. This minor investment will result in superior soldering results, lower long term maintenance costs and greater satisfaction among operators, programmers and owners. 1.
Page 39: Solder Pump Service | 240 Hours
ODYSSEY USER GUIDE 8.6 S | 240 H OLDER ERVICE OURS The rotation of the impeller will produce oxide particles (known as dross) that build up over time and restrict flow. It is very important to remove the dross in order to maintain a proper head height at the nozzle.
Page 40 RHYTHM SLIDE USER GUIDE 3. Remove Solder Pump Fasteners Next, the operator must remove the solder pump fasteners. This will be accomplished by removing the 4 screws holding the solder pump in place. 40 of 55...
Page 41 ODYSSEY USER GUIDE 4. Lift the Pump From the Pot Handle pump assembly carefully tilt the riser end up to drain as much solder out of the pump housing as you can. CAUTION: The riser and solder pot can be very hot. Carefully bring the pump assembly to a metal cart. Put on a table with cardboard, cookie sheet, or wood underneath it.
Page 42 RHYTHM SLIDE USER GUIDE 6. Clean Solder Pot of Dross Before re-installing the pump, now is a good time to skim dross off the solder bath. Before removing nozzle, use a spatula to clear away any oxidized solder or burned flux floating on top of the solder bath. 7.
Page 43: Nitrogen Shroud Cleaning | 240 Hours
5. Torch if Needed: Use a hand held propane torch burn off the contamination on the surface of the sintered metal, followed by the wire brushing process. 6. If Shroud is Not Functioning Properly— RPS recommends immediate replacement for proper soldering performance. 43 of 55...
Page 44: Solder Pump Belt Inspection | 240 Hours
Monthly or every 250 hours of continuous service, apply a small amount of multi-purpose synthetic lubricant with Syncolon (PTFE) to all the axes rails. Since these bearings have been properly lubricated from RPS, a small amount goes a long way. RPS suggested method of lubricating the shafts and bearings is to apply lubricant directly to the shafts.
Page 45: Extended Storage & Non-Operation | Annual
ODYSSEY USER GUIDE 8.10 E & N XTENDED TORAGE PERATION NNUAL Even if the machine is not going to be used for an extended period it still needs to be lubricated. All axes should be exercised at least once every 2 weeks. This will prevent freeze-ups and potential equipment degradation due to inactivity. 45 of 55...
Page 46: Change Solder Pots
RHYTHM SLIDE USER GUIDE 8.11 C HANGE OLDER Allow the solder to solidify before moving. The solder pot may be in a warm, but solid state prior to moving to or from the system. A period of 20-30 minutes of NO HEAT is recommended to allow the solder to achieve a solid state for safe transport. 1.
Page 47: Replace Solder Pump Belt
4. Connect New Tank: Remove the pressure regulator from old tank and place it on the gas output of the new tank. 5. Turn On Sequence: open the lines back up starting from the tank and working your way back to the RPS system.
Page 48: Inspect / Replace Solder Pot Thermocouple
RHYTHM SLIDE USER GUIDE 6. Purge: Sometimes oxygen enters the lines during tank change over, this will be evident by a poorly inerted solder wave. To purge the lines, just let the N2 run until it runs pure or conditions improve. 8.14 I NSPECT EPLACE...
Page 49: Solder Alloy Maintenance
RPS has found that as much as 30% of new solder bars include oxides that can be removed by this method, and our belief is that the oxides present in the new bar act as a nucleation point to attract more dross. To this you add burned flux and copper, and you have a mess to deal with when soldering.
Page 50: Troubleshooting
RHYTHM SLIDE USER GUIDE 9 TROUBLESHOOTING 9.1 G ENERAL PROBLEM POSSIBLE CAUSE & SOLUTION No Main Power Disconnect on wall OFF Machine disconnect OFF Main breaker/fuse is tripped, blown No air Check main air supply disconnect No motion MaestroLite offline Obstruction or jam Reset Motion Control On No or Low Solder Temperature...
Page 51: Solder Safety
ODYSSEY USER GUIDE OLDER AFETY PROBLEM POSSIBLE CAUSE & SOLUTION During maintenance solder spills Always drain impeller before removing pump from solder pot by holding at an angle to drain from impeller inlet onto solder into tank floor/shoes etc. Wear safety clothing, eye protection, thermal gloves, and correct shoes Solder explosion when placing Pumps can acquire moisture when sitting outside of the solder pot.
Page 52: Soldering Process
RHYTHM SLIDE USER GUIDE 9.3 S OLDERING ROCESS PROBLEM POSSIBLE CAUSE & SOLUTION Excessive dross See solder maintenance Nitrogen inertion not satisfactory Solder bridging Solder Dip Depth too low Solder pre-dwell time too short Leads too short if dip solder process Nitrogen inertion not satisfactory Nitrogen leaks •...
Page 53 ODYSSEY USER GUIDE Check N2 Pressure • Check N2 Flow Rate • Nitrogen manifold needs cleaning Solder level too low, pump speed too high 53 of 55...
Page 54: Extras
& T RICKS Don’t hesitate to call RPS or your field technician with questions regarding your process and programming needs. We are always happy to share our strategies and approaches to make the most of your RPS Selective Soldering System.
Page 55 Witness Vision, VisionCorrect, Harmony Selective Soldering System, Opus Selective Soldering System, Rhythm SLIDE Selective Soldering System, and Rhythm Selective Soldering System and the RPS logo are trademarks of RPS Automation LLC. INFORMATION CONTAINED HEREIN IS CONFIDENTIAL AND INTENDED ONLY FOR USERS EXPLICITLY AUTHORIZED BY RPS.