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USER MANUAL, RSS-1000-CVSI

7000-5970

Rev.

A

page

359

of

396

INSTALLATION & USE OF FUME EXTRACTION & NITROGEN

The RSS-1000-CVSI is plumbed and ready for fume extraction, as well as nitrogen, although

both are sold separately. Metcal™ offers several fume extraction systems, which can be found at the
following web address:

http://www.okinternational.com/metcal/english/globalnavigation/products/fume-extraction

Nitrogen must be purchased from a reputable supplier.

FUME EXTRACTION

For the safety of the operators and working environment, Metcal offers a full line of solder fume

extractors. From volume to bench-top fume extraction, Metcal™ has systems to purify the air by
filtering harmful smoke and particulates from the working area. However, the RSS-1000-CVSI can be
used with any fume extraction device that attaches to the Extraction Hose (included.) The
dimensions of the Extraction Hose are shown below.

When a fume extraction device is connected, the tubing is routed at the rear of the gantry as

shown:

1380mm ± 10

56mm

75mm

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Summary of Contents for RSS-1000-CVSI

Page 1: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 1 of 396 Robotic Soldering System RSS 1000 CVSI User Manual ...

Page 2: ...ICE This document contains proprietary data of OK International Inc The receipt or possession of this document does not convey any rights to reproduce it disclose its contents or to manufacture the concepts and details disclosed by this document This document may not be copied or disclosed in whole or in part to anyone without written permission of an officer of OK International Inc All rights res...

Page 3: ...ROBOT GANTRY CONNECTIONS 22 ROBOT HEAD CONNECTION 22 CV POWER CABLE CONNECTION INSTRUCTIONS 23 SOFTWARE NAVIGATION 24 LOGIN SCREEN 24 MAIN SCREEN OVERVIEW 25 MAIN MENU BAR 26 HEADER BAR 28 PROFILE OPTIONS 31 ADVANCE PROFILE OPTIONS 33 SOLDER FEEDER OPTIONS 35 CAMERA TOOLS 37 CONNECTION VALIDATION DISPLAY 39 TOOLBAR 43 MOTION CONTROL 45 REMAINING MENUS BUTTONS 48 SYSTEM OPERATION 50 POWERING UP THE...

Page 4: ...G NEW USER 106 DELETING USER 112 VIEWING USER LOGIN HISTORY 116 CHANGING TIME ZONE 118 CLEAR PATTERN PARAMETERS 122 RESET TO FACTORY SETTINGS 126 IOT SETTINGS 129 PROFILE MANAGEMENT 130 PROFILE CREATION 130 SAVING A PROFILE 131 SAVING PROFILE TO EXTERNAL USB DEVICE 134 PROFILE REMOVAL 136 FOLDER CREATION 140 FOLDER REMOVAL 146 CONNECTION VALIDATION VS STANDARD SOLDERING 150 WHY USE CONNECTION VALI...

Page 5: ...ction 192 Editing Feeder Settings 197 Edit Order of Features Within a Profile 199 Remove a Feature from a Profile 200 MERGE PROFILE 201 COMPONENT BASED MERGE 201 PRINTED CIRCUIT BOARD ASSEMBLY BASED MERGE 208 GENERATE ARRAY 216 Examples of Generate Array Settings 218 Single Point Array 229 Multiple Pattern Array 232 SET GO TO LOCATION 238 OFFSET PROFILE 239 DRY RUN 243 TIP ALIGNMENT 245 TIP ALIGNM...

Page 6: ...STMENT OF COMPUTER VISION CAMERA 330 TIP CLEANING 332 OVERVIEW 332 TIP CLEANING PROFILE SET UP 333 ADVANCE TIP CLEANING PROFILE 336 IMPLEMENTATION OF TIP CLEANING PROFILE 341 TIP CLEANING TROUBLE SHOOTING 346 EDITING A CLEANING PROFILE 347 CUSTOM CLEANING LOCATIONS 354 BRUSH REPLACEMENT 356 INSTALLATION USE OF FUME EXTRACTION NITROGEN 359 FUME EXTRACTION 359 NITROGEN 360 TROUBLESHOOTING 362 MAINTE...

Page 7: ...S USE THE ROBOT WITHIN THE STANDARD REQUIREMENTS SUCH AS VOLTAGE AIR PRESSURE POWER FREQUENCY ETC AS DETAILED IN THE SPECIFICATIONS ON PAGE 9 CHANGES OR MODIFICATIONS MADE TO THIS PRODUCT WITHOUT EXPRESS CONSENT FROM OK INTERNATIONAL WILL VOID THE USERS AUTHORITY TO OPERATE THE EQUIPMENT DO NOT PLACE ANY MAGNETS ON THE CONTROLLER BOX OF THE ROBOT AS THIS WILL PRODUCE UNDESIREABLE EFFECTS ON THE SY...

Page 8: ...put in place to ship the unit securely Unplug the unit before cleaning or performing any maintenance Clean the exterior of the system with a damp cloth Do not use solvent based cleaners Slots and openings in the system are provided for ventilation and to ensure reliable operation as well as protection from overheating The openings should never be blocked or covered Do not overload power outlets an...

Page 9: ...re Flash Programming Header compatible with Dedi Prog programmer Board Dimensions 99 x 74mm 2 9 x 3 9in Temperature Range 0 40 C Power 5V min 2 5A DC Operating System Linux O S Language Unicode supported Motion Control 4 Axis Programming Methodology Icon Driven Graphical Programming Language Motion Interpolation 2D 3D and 4D Interface with Solder Iron Feeder Control Required File Importing DXF GER...

Page 10: ...ower Supply Weight 3 35 kg Certification Marking CE TUV Tip to Ground Potential 2 mV Resistance 2 Ohms Idle Temp Stability 1 1 C in Still Air Tip Temp Accuracy Meets or exceeds IPC J STD 001 Standard Soldering Iron Cable Length 183 cm 72 Burn Proof ESD Safe Soldering Iron Connectors Radio Freq Connector F type Power Connector Power Connector 6 pin DIN Touch Screen Monitor Diagonal Size 396 24 mm 1...

Page 11: ...on Protocol UART TTL Motor driver Integrated Motor Stepper Motor Encoder N A Resolution X Y Z 0 01 mm Theta 0 01 Operation Range X Y 400 mm x 400 mm 0 02 Z 100 mm 0 02 300 0 02 Speed Vector X Y Up to 100 mm s Max Z Up to 80 mm s Max Up to 100 s Max Interpolation X Y Up to 150 mm s Max Z Up to 150 mm s Max Up to 150 s Max Space X Y Up to 300 mm s Max Z Up to 300 mm s Max Up to 300 s Max Repeatabili...

Page 12: ... automated high precision soldering control system with soldering capabilities in 4 axes X Y Z R Coupled with Connection Validation the RSS 1000 CVSI takes the risk associated with the variables involved in soldering activity and removes the success and failure determination of a good solder joint out of the hands of the operator In addition to Connection Validation the RSS 1000 CVSI includes Smar...

Page 13: ...ss Camera 12 Solder Tip Cleaner 4 Solder Wire Feeder Tube Adjustment Assembly 13 Smart Interface Display 5 Power On LED 14 Fume Extraction Tube 6 CCD Camera Power Switch Lighting Controls 15 CCD Witness Camera Display 7 Main Power Switch 16 Nitrogen Outlet Tube 8 Camera Calibration Fixture 17 Solder Wire Feeder 9 End Effector Cartridge Lock 5 6 7 1 2 3 16 14 9 12 10 11 15 13 17 8 4 ...

Page 14: ... Screws 26 CCD Witness Camera 12V Power Connection 20 Controller Box Power Connection 27 Micro HDMI Connection 21 Solder Wire Feeder Connection 28 Ethernet Connection 22 CCD Witness Camera Connection 29 6x USB Connections 23 Inlet Power Connection 30 Communications Cable 24 Nitrogen Air Regulator 19 18 24 30 29 28 27 26 23 22 25 20 21 ...

Page 15: ... to operate this machine in a comfortable well spaced environment Every Selective Soldering Robot has been factory assembled and calibrated Recalibration is not necessary after initial setup Verifying calibration and product functionality is strongly recommended prior to initial use Power Up Sequence Plug in all harnesses provided with unit Plug in all all power cords provided with unit Once all h...

Page 16: ...per Personal Protection Equipment PPE use an 8mm 5 16 socket to remove all of the screws 16X at the bottom of the crate 2 With the assistance of a coworker or a mechanical lifting device carefully lift lid of crate vertically and evenly using proper lifting techniques 3 Remove accessory box ...

Page 17: ... mechanical lifting device carefully lift unit off pallet using proper lifting techniques 5 1 Warning Weight of unit is not evenly distributed The back of the unit is heavier than the front Please be mindful of this when lifting 6 Loosen nuts of unit s feet to remove shipping brackets 7 Remove shipping foam from the following locations 7 1 Top Plate ...

Page 18: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 18 of 396 7 2 Calibration Slider Block Assembly 7 3 End Effector 7 4 Head Gantry ...

Page 19: ...5 Connection Validation Housing 7 5 1 Warning Failure to remove foam from Connection Validation Housing may result in the overheating of the Connection Validation Power Supply 8 Replace Connection Validation Housing Cover once foam is removed Unboxing Complete ...

Page 20: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 20 of 396 CONTROLLER BOX CONNECTIONS Optional Optional Optional OPEN ...

Page 21: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 21 of 396 ROBOT BASE CONNECTIONS N ...

Page 22: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 22 of 396 ROBOT GANTRY CONNECTIONS ROBOT HEAD CONNECTION Plug into an external outlet see next page for instructions ...

Page 23: ...of the configuration please use an external outlet for powering the CV Power Supply at the rear of the unit Outlet of which the CV Power Supply is to be plugged in to will vary depending on region If unsure of what outlet to use please contact the facility s maintenance department of which the unit is to be installed in for assistance ...

Page 24: ... CVSI 7000 5970 Rev A page 24 of 396 SOFTWARE NAVIGATION LOGIN SCREEN Admin Login Engineer Login Operator Login Login Enter Main Power Button Power Off Controller Restart Controller Cancel Firmware Version Software Version ...

Page 25: ...70 Rev A page 25 of 396 MAIN SCREEN OVERVIEW Motion Controls Main Menu Bar Global Coordinate Display Status Bar Toolbar Profile Options Connection Validation Display Solder Feeder Options Camera Tools Header Bar Advance Profile Options ...

Page 26: ...70 Rev A page 26 of 396 MAIN MENU BAR Create New Profile Edit Profile Open Profile Save Profile Run Profile Pause Profile Available only after run profile is activated Stop Profile Global Settings Eject USB Emergency Stop Main Menu Bar ...

Page 27: ...t the profile active in the workspace This can be a profile saved on the onboard memory profile from an external memory device or an unsaved work in progress profile At any point in time the user may hit the pause button to stop all robot movement and maintain its position Upon clicking the pause button the icon will change to the play button again to be pressed to resume operation The Stop Profil...

Page 28: ...ames and or status of the profile will be displayed on the left of the header bar CV cartridge name and or status of the cartridge with respect to the profile will be displayed on the right of the header bar Name of Profile Active in Workspace CV Cartridge of Profile Header Bar ...

Page 29: ...ing profile is opened Upon completion of a run of the profile live or dry run the robot will return to the home position 0 0 0 0 in the X Y Z Θ axes respectively Appears when an existing profile is opened and changes have been made to the profile Upon completion of a run of the profile live or dry run the robot will remain in the X Y and Θ coordinates of the last programmed point but shall move to...

Page 30: ...ult state upon bootup or when the new profile button has been tapped Appears when RF has yet to be cycled On Off after a power down or reboot of the system The CV Cartridge that was used to program the profile will appear on the right hand side of the header bar to notify operators of the correct cartridge for the job If the installed cartridge does not match the programmed cartridge then the disp...

Page 31: ...396 PROFILE OPTIONS Merge Profile Waypoint Solder Point Toggled under Waypoint Solder Line Toggled under Waypoint Interpolation Move Space Move Toggled under Interpolation Record Point Undo Waypoint Pattern Line Redo Waypoint Pattern Line Profile Options ...

Page 32: ... another after the programmed retract has been completed Interpolation Move provides the ability to move in a straight line from the first point to the next In other words all axes will be move simultaneously during the movement Transition speed has a max velocity of 150 mm s When icon is active movement commands on workspace will be executed at this speed setting Space Move is the second of two t...

Page 33: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 33 of 396 ADVANCE PROFILE OPTIONS Set Go To Location Generate Array Advance Profile Options ...

Page 34: ...within the working envelope as a location for the robot to go to after each profile is complete Every subsequent profile will start from this location as well The Generate Array function allows users to instantly create an array of solder points lines and waypoints This function is fully customizable to allow establishment of array direction path type and instance skipping ...

Page 35: ...000 CVSI 7000 5970 Rev A page 35 of 396 SOLDER FEEDER OPTIONS Pulse Solder Feeder Forward Pulse Solder Feeder Backward Test Solder Feed Solder Feeder Settings Dry Run Toggled Off Dry Run Toggled On Solder Feeder Options ...

Page 36: ...e desired volume and the system automatically calculates the equivalent solder feed length This length can then be entered within the solder feed parameter window In addition users can select the ratio of solder between pre tin and the solder event the solder feed delay and the speed at which the solder is fed Although not directly related to solder feeding Dry Run is a very useful tool that not o...

Page 37: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 37 of 396 CAMERA TOOLS Enable Disable Camera Take Screenshot Open Image DXF Gerber Pattern Recognition Camera Tools ...

Page 38: ...he teal icon signifies when the function is available camera in an enabled state the grey icon signifies when the function is not available camera is in its disabled state Opens various file types such as PNG DXF and Gerber files ART file extension DXF and Gerber files must be imported whereas PNG files can either be created from a screenshot of the workspace or imported from another unit With the...

Page 39: ... CV Settings Toggle CV RF On Off Connection Validation Display Tip Cartridge Installed on Robot Active Temperature Display Connection Validation Power Meter Watts Connection Validation Status Proper Grounding Indicator Connection Validation Time Out Counter Connection Validation Time Out Counter ...

Page 40: ...and the Power Graph screen The graph displays the amount of power in watts used over a given time period in seconds Information displayed includes number of joints soldered with installed cartridge peak power usage current temperature cartridge serial number and cartridge lot code see example below The graph must be toggled on by an engineer or admin prior to a profile being run by an operator Tog...

Page 41: ...idation Settings Celsius Toggled On Fahrenheit Toggled On Exit CV Audio Toggled On CV Audio Toggled Off Solder Station Link Toggled On Solder Station Link Toggled Off Number of Joints Soldered with Installed Cartridge Peak Power on Joint Current Temperature of Solder Tip Cartridge Serial Number Cartridge Production Lot Code ...

Page 42: ... can program a delay before any movement commands are executed Typically used for tips with a larger geometry this feature allows for full and even heat distribution to the soldering tip as well as allowing it to reach its maximum temperature The delays can be programmed from 0 10 seconds A programmed delay of 0 allows for the system to automatically turn on the iron at the beginning of a profile ...

Page 43: ...R MANUAL RSS 1000 CVSI 7000 5970 Rev A page 43 of 396 TOOLBAR Motion Control Fine Coarse Adjustment Toggle Absolute Position Home Speed Settings Offset Tip Cleaning Parameters Camera Zoom Nitrogen Toolbar ...

Page 44: ...ze speeds for each axis 1 100 mm s for the X Y axes and 1 200 mm s for the Transition speed The Z axis to a maximum of 1 80 mm s Θ can be adjusted from 1 100 s The icon will become gold when the menu is active grey when another menu is active If the system does not detect any mouse movement for 10 seconds the system will default to the motion control main menu Offset allows users to offset any pre...

Page 45: ...ON CONTROL Jog Head Left Jog Head Right Jog Top Plate Down Jog Top Plate Up Rotate Clockwise Rotate Counter Clockwise Jog End Effector Up Jog End Effector Up Θ Quick Snap 0 Θ Quick Snap 90 Θ Quick Snap 180 Θ Quick Snap 270 Z Limit Up Z Limit Down Motion Controls ...

Page 46: ... a button press occurs Rotates end effector clockwise This is a coarse adjustment and the distance travelled is dependent on the speed settings and how long of a button press occurs Rotates end effector counter clockwise This is a coarse adjustment and the distance travelled is dependent on the speed settings and how long of a button press occurs Jog end effector up This is a coarse adjustment and...

Page 47: ...e 90 position is counterclockwise to the 0 position This is an absolute command or in other words will automatically rotate to the 90 position regardless of its current position Θ Quick Snap rotates end effector to the 180 position The 180 position is counterclockwise to the 0 position This is an absolute command or in other words will automatically rotate to the 180 position regardless of its cur...

Page 48: ...6 REMAINING MENUS BUTTONS Status Bar Global Coordinate Display X Axis Position Y Axis Position Θ Position Z Axis Position Unit Status Sticky Note Time Software Version Firmware Version Loading Icon Log Out Current User Manual Permission Level Programmed Pts ...

Page 49: ...operator that the unit is being accessed remotely or simply a safety reminder from management to the operator When not in use the icon resides in the bottom right of the screen To access the Sticky Note tool simply tap on the icon within the Status Bar to bring up the Sticky Note pad This same action can be used to hide the Sticky Note when not in use Tap on the enlarged Sticky Note pad to bring u...

Page 50: ...rence specifications 2 Verify all cables have been plugged into the appropriate locations 2 1 Reference System Architecture Controller Box Connections and Robot Base Connections for cable routing locations 3 Follow all safety and regulatory information 4 Plug in IEC 60320 C 13 connector into its corresponding receptacle 5 Toggle the power switch to the ON position ON ...

Page 51: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 51 of 396 POWERING OFF THE UNIT 1 Tap the Logout button ...

Page 52: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 52 of 396 2 Tap the Power Button ...

Page 53: ... MANUAL RSS 1000 CVSI 7000 5970 Rev A page 53 of 396 3 Tap the Power Off Button 4 Once the screen has gone black signaling that the system has shut down toggle the main power switch to the OFF position OFF ...

Page 54: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 54 of 396 REBOOTING SOFTWARE 1 Tap the Logout button ...

Page 55: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 55 of 396 2 Tap the Power Button ...

Page 56: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 56 of 396 3 Tap the Restart button The system will reboot returning to this screen upon completion ...

Page 57: ...login history change system time zone reset factory settings and revert to factory settings 2 2 2 Note Only one admin allowed per system 2 3 Engineer 2 3 1 Unlimited access to all features with the exception of admin privileges see 2 2 1 2 3 2 Can create a custom password change password 2 4 Operator 2 4 1 Can open start and stop a profile In addition operator can open manual press the emergency s...

Page 58: ...p the keyboard to type in the password 4 Upon initial startup there will only be an Admin Login available The Password for the Admin Login is 1000 This password can be changed after initial Log in Note In the event the Admin forgets their password contact the Metcal Technical Service Department for a password reset ...

Page 59: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 59 of 396 5 After the password has been entered tap to complete log in ...

Page 60: ...m metcal english globalnavigation resources software download Complete the following steps to successfully update the Smart Interface Software to the latest revision 1 Navigate to the Solder Robot Section of the Software Download Page at the link previously provided 2 Download the software 2 1 The file is downloaded within a Zip File 3 Extract the file okirobot 4 Copy the file to the Main Director...

Page 61: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 61 of 396 6 Insert flash drive into an available USB port on the rear of the controller box at the rear of the unit 7 Tap the Global Settings Button ...

Page 62: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 62 of 396 8 Tap the Software Update Menu 9 Tap the USB icon next to Update Application USB to update the software ...

Page 63: ...000 CVSI 7000 5970 Rev A page 63 of 396 9 1 Tap Yes on the Prompt 9 2 Note the screen will turn white and the system reboot 10 Upon bootup confirm the version number displayed matches that which is shown on the website ...

Page 64: ...NUAL RSS 1000 CVSI 7000 5970 Rev A page 64 of 396 11 Tap on the appropriate permission and enter password After password has been entered tap to proceed with log in 12 Tap to eject USB Software Update Complete ...

Page 65: ...ound at the following link http www okinternational com metcal english globalnavigation resources user manuals Although not required the user manual can then be uploaded to the unit for an environmentally friendly way to access the manual Complete the following steps to successfully update the User Manual for the Smart Interface Software to the latest revision 1 Navigate to the Solder Robot Sectio...

Page 66: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 66 of 396 6 Insert flash drive into an available USB port on the rear of the controller box at the rear of the unit 7 Tap the Global Settings Button ...

Page 67: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 67 of 396 8 Tap the Software Update Menu 9 Tap the USB icon to next to User Manual Update USB ...

Page 68: ...6 10 Tap Yes on the Prompt 10 1 Tap the user manual button to confirm the update has taken place 10 2 If the following message displays check to make sure the USB is completed seated within the controller box and redo steps 7 10 User Manual Update Complete ...

Page 69: ...ty function will prevent the user from using any of the motion controls to go beyond this point The default setting is for 100mm or in other words the full range of travel in the Z Axis Values are calculated from the home position The home position for the Z Axis is the location when the end effector is fully retracted into the head Therefore any measurements should be with respect to the home pos...

Page 70: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 70 of 396 2 Tap the System Settings Menu 3 In the last row of the menu tap the yellow box next to Z Limit ...

Page 71: ...ev A page 71 of 396 4 Input the value in millimeters 4 1 In this example the value was set at 45 mm This means that the software will prevent any travel that is greater than 45 mm in the Z Axis from the home position see diagram below 45mm ...

Page 72: ...of 396 4 2 This in turn would mean there is a 55mm clearance from the board 4 3 If unsure of what height to set for the Z Limit safety complete the following steps Otherwise skip to step 5 4 3 1 Install PCBA fixture onto top plate in a desired location ...

Page 73: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 73 of 396 4 3 2 Install PCBA onto fixture 4 3 3 Using the jog controls jog to an open location on the PCBA clear of any leads ...

Page 74: ... the PCBA switch from coarse to fine movement by tapping the motion controls button once to toggle to fine movement 4 3 5 Adjust the value of each fine adjustment movement to 0 10mm in the X Y and Z directions by tapping the box in between the arrows to bring up the keypad and entering the value ...

Page 75: ...96 4 3 5 1 Please note that these values are not required and can be adjusted as needed They will however minimize the chance of inadvertent crashing of the board 4 3 6 Carefully drive the end effector down to the board until the tip slightly contacts PCB ...

Page 76: ...cy of this information is dependent on the fixture that is used in these steps and can vary due to machining tolerances variations in board height flatness of the fixture surface among other factors Please consult ASME Y14 43 2003 when designing a fixture for design rules and assigning the appropriate tolerances For design constraints of fixture design associated with the RSS 1000 CVSI please refe...

Page 77: ...nce the desired value has been entered tap the Enter button to clear the keypad 6 Tap the Close button to save the new Z Limit value and exit the global settings menu Z Limit set This value can be changed at any time at the Admin and Engineer permissions levels ...

Page 78: ...own to a desired height Please note that values are calculated from the home position The home position for the Z Axis is the location when the end effector is fully retracted into the head Therefore any measurements should be with respect to the home position Values set DO NOT correlate to a given height off the board In addition please note that this feature will only prevent collisions resultin...

Page 79: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 79 of 396 2 Tap the System Settings Menu 3 In the second to last row of the menu tap the yellow box next to Clearance Height Touch Screen ...

Page 80: ...e in millimeters 4 1 The default Z Limit is 0mm or in other words the end effector fully retracted up into the head 5 Once the desired value has been entered tap the Enter button to clear the keypad 6 Tap the Close button to save this value and close the Global Settings menu ...

Page 81: ...MANUAL RSS 1000 CVSI 7000 5970 Rev A page 81 of 396 6 1 In the event one wishes to turn this feature off one may do so by tapping the check mark 6 2 Followed by tapping the Close button Clearance Height Set ...

Page 82: ...s shown below When the iron is active the CV display brightly and boldly displays that the RF button is illuminated in an eye catching green signifying RF is in the ON position the Power Bar meter is displayed as well as the current temperature as shown below This will let users know from a distance that the iron is hot and to take the necessary precautions PPE avoiding hot surfaces etc when opera...

Page 83: ...In addition the Smart Interface System will automatically deactivate RF when any of the following functions are utilized by the user Home New Profile Stop Emergency Stop Furthermore upon logging out of the software the system will automatically deactivate RF ...

Page 84: ...always active When this beam is broken all motion will be stopped immediately This would be similar to the behavior of activating the emergency stop button The system will remain in this suspended mode until the beam is no longer broken and the emergency stop pop up message is cleared In addition the bottom of the rear panel is open for cable routing access Lastly there is an access hole on the ri...

Page 85: ...mitter 3 USB Extension 4 Locking Bar 5 Light Curtain Receiver 6 Splice Box 7 3 RCA Extension Cable 8 DC Power 2 1MM Barrel Plug Extension 9 Monitor Mounting Hardware 10 Solder Tip Cleaner Tray Access Hole 11 Extension Cable Access Hole 12 Light Curtain Relay 13 Solder Wire Feeder Access Door 7 8 1 2 5 4 9 13 11 12 6 10 3 ...

Page 86: ... SAFETY COVER INSTALLATION 1 Power down both monitors 2 Unplug all wires from both monitors 3 Cut all cable ties at the base in the back of the unit WARNING Do NOT attempt to install cover alone Ask a coworker for assistance and use proper lifting techniques ...

Page 87: ...MI cable from spiral wrap 5 With one hand securing the monitor assembly in place at the bottom of the monitor arm mount remove the bottom M5 socket head cap screw from the monitor arm mount 5 1 Warning The monitor arm mount may swing depending on the weight distribution ...

Page 88: ...00 CVSI 7000 5970 Rev A page 88 of 396 6 Loosen the thumb screw of the touch screen monitor and carefully slide the arm toward the bottom of the monitor arm mount 7 Repeat this process for the CCD Witness Camera Display ...

Page 89: ... to the side 9 Unbox the AC RSS 1KSC 9 1 When choosing an install location it is best to choose a location in which there is limited to no access to the rear of the unit such as against a wall This is a safety precaution to prevent operators from bypassing the safety cover and accessing the robot 10 Install the USB Extension Cable Item 3 using the two 4 40 x 3 16 long screws provided ...

Page 90: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 90 of 396 11 Unplug the Controller Box Power Cable from the back of the unit 12 Plug the Splice Box in its place ...

Page 91: ... 7000 5970 Rev A page 91 of 396 13 Plug the Power Cable that was removed in Step 8 into one of the two DIN connectors on the Splice Box 14 Remove screws and cable clamps from the rear of the left gantry arm when facing the rear ...

Page 92: ...page 92 of 396 15 With the assistance of a coworker and or a crane lift the cover over the unit with the opening towards the front of the unit 15 1 The opening is designated by the side with the two light curtains mounted to the left and right ...

Page 93: ...ame locking bar and slide rail forward This crossbar is used as a method from preventing operators from sliding the cover forward to access the unit For this reason limit the amount of adjustment in the crossbar as much as possible 16 Plug in Safety Cover cable to the remaining DIN connector of the Splice Box ...

Page 94: ...les from Step 11 through mouse hole on the right side of the safety cover 18 Connect the RCA and DC Power extensions to their respective cables 19 Adjust Monitor Mounting Hardware to the desired height with a distance between fasteners to be about 245mm 9 65 apart 245mm ...

Page 95: ...5970 Rev A page 95 of 396 20 Remove fasteners and mount the aluminum extrusion to the top spring nut 21 With one hand securing the extrusion slide the CCD Monitor Arm into the extrusion twisting the thumbscrew clockwise once in place ...

Page 96: ...ER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 96 of 396 22 Use the same process in the previous step for the touch screen monitor arm 23 Replace fastener for the bottom spring nut and torque once in place ...

Page 97: ...v A page 97 of 396 24 Route the cables through the monitor cable clips 25 Reconnect all cables 26 Plug in USB extension Safety Cover Installation Complete Note Safety Cover Activation MUST be completed for Safety Cover to become functional ...

Page 98: ... Cover has been installed please use the following steps to activate the safety cover within the software 1 Once the Safety Cover has been installed turn on system 2 Log In Under Either Admin or Engineer 2 1 Operators do not have access to the Safety Cover activation for safety purposes 3 Tap to enter ...

Page 99: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 99 of 396 4 Tap the Global Settings menu 5 Tap the System Settings menu ...

Page 100: ... is activated with no Safety Cover connected the following message will appear Administrators and Engineers will be able to navigate to the menu to turn off the message but Operators will not have access If an operator is logged in they must reboot the system and an Administrator or Engineer must then log in and disable the Safety Cover ...

Page 101: ...e Safety Curtain has now been activated If the Light Curtain s infrared beam is ever broken the system will cease movement and a pop up message will appear as shown below Once the beam is cleared the message may then be cleared by tapping OK and the system will can now resume ...

Page 102: ...SSWORD Note This procedure will apply to all permissions levels 1 After logging in tap the Permissions Identifier Icon in the bottom right corner 1 1 In this example a user with Admin permission will be used 2 Tap on the white space to the right of Enter Current Password ...

Page 103: ... RSS 1000 CVSI 7000 5970 Rev A page 103 of 396 3 A keyboard will pop up at the bottom of the screen Type in the current password 4 Tap on the white space to the right of Enter New Password and enter a new password ...

Page 104: ... 4 1 Passwords must be 4 10 characters in length 4 2 Passwords are case sensitive 4 3 It is recommended to include numbers lowercase and uppercase letters 5 Tap on the white space to the right of Confirm New Password and re type the password entered in step 4 ...

Page 105: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 105 of 396 6 Tap the button to save the password change 7 A confirmation message will appear if the password change was successful ...

Page 106: ... 7000 5970 Rev A page 106 of 396 ADDING NEW USER Note This function can only be completed at the Admin permission level 1 After logging in under admin tap on the admin icon in the bottom right corner 2 Tap on the Add User menu ...

Page 107: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 107 of 396 3 Tap on the white space to the right of User ID 4 Enter User ID 4 1 User ID must be between 3 7 characters including spaces ...

Page 108: ...Tap on the white space to the right of Password to create the user s password 5 1 User s password must be between 4 10 characters in length 5 2 Passwords are case sensitive 6 Retype password in the white space to the right of Confirm Password to confirm password ...

Page 109: ...f 396 7 Tap on the yellow box to the right of Class Type to open the dropdown menu 7 1 The two choices for Class Type are 7 1 1 Engineer 7 1 2 Operator 7 1 3 Permissions for each class type are described in the Software Navigation section of this manual ...

Page 110: ... 1000 CVSI 7000 5970 Rev A page 110 of 396 8 After the Class Type is selected tap on the button to complete the addition of the New User 8 1 If the rules for user password is violated the following message will appear ...

Page 111: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 111 of 396 8 2 For passwords that do not match the following screen will appear 8 3 A successful addition of a new user will yield the following message ...

Page 112: ...00 CVSI 7000 5970 Rev A page 112 of 396 DELETING USER Note This can only be done at the admin permission level 1 After logging in under admin tap on the admin icon in the bottom right corner 2 Tap on the Delete User menu ...

Page 113: ... 5970 Rev A page 113 of 396 3 Tap on the white box next to User ID 4 Type in the User ID that is to be deleted 4 1 The User ID must be typed in EXACTLY as it is listed within the software otherwise the following message will appear ...

Page 114: ...age 114 of 396 4 1 1 To verify a User ID s exact characters tap on the List Users Menu 4 1 2 Tap on the yellow box to the right of the type of User Permission level to open the drop down menu listing all users under the desired permission level ...

Page 115: ...R MANUAL RSS 1000 CVSI 7000 5970 Rev A page 115 of 396 5 Return to the Delete User menu and tap the to confirm deletion of user 5 1 A confirmation message will appear when the User is successfully deleted ...

Page 116: ...7000 5970 Rev A page 116 of 396 VIEWING USER LOGIN HISTORY Note This can only be done at the admin permission level 1 After logging in under admin tap on the admin icon in the bottom right corner 2 Tap on the Login History menu ...

Page 117: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 117 of 396 3 Login History will display the User ID Login Time and Logout Time for the last 5 users ...

Page 118: ...ANUAL RSS 1000 CVSI 7000 5970 Rev A page 118 of 396 CHANGING TIME ZONE Notes This can only be done at the admin permission level This will affect the unit s clocks on both the home screen and operating screen ...

Page 119: ...UAL RSS 1000 CVSI 7000 5970 Rev A page 119 of 396 Time is adjusted via Coordinated Universal Time UTC 1 After logging in under admin tap on the admin icon in the bottom right corner 2 Tap on the Time Zone menu ...

Page 120: ...ER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 120 of 396 3 Tap on the Yellow Box to the right of Select Time Zone to expand the dropdown menu 4 Select the time zone that corresponds to the unit s location ...

Page 121: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 121 of 396 4 1 Consult a UTC chart for the appropriate UTC setting 5 Tap the button to register the time zone change 6 Tap Close to complete ...

Page 122: ...7000 5970 Rev A page 122 of 396 CLEAR PATTERN PARAMETERS Note This can only be done at the admin permission level 1 After logging in under admin tap on the admin icon in the bottom right corner 2 Tap on the Factory Settings menu ...

Page 123: ...R MANUAL RSS 1000 CVSI 7000 5970 Rev A page 123 of 396 3 Tap on the button next to Reset Pattern Parameters 4 Tap Yes to Proceed with resetting unit back to factory default parameters 4 1 Tap No to cancel ...

Page 124: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 124 of 396 5 Tap on the Logout button 6 Tap the Power button ...

Page 125: ...00 CVSI 7000 5970 Rev A page 125 of 396 7 Tap the Restart button 8 Once the system has rebooted it will have cleared all parameters created by the user leaving only the default pattern parameters Parameter Reset Complete ...

Page 126: ...000 5970 Rev A page 126 of 396 RESET TO FACTORY SETTINGS Note This can only be done at the admin permission level 1 After logging in under admin tap on the admin icon in the bottom right corner 2 Tap on the Factory Settings menu ...

Page 127: ...ER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 127 of 396 3 Tap on the button next to Reset Pattern Parameters 4 Tap Yes to Proceed with resetting unit back to factory default settings 4 1 Tap No to cancel ...

Page 128: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 128 of 396 5 Tap on the Logout button 6 Tap the Power button ...

Page 129: ...sical devices embedded with electronics software sensors actuators and connectivity which allows for these devices to connect and exchange data Metcal is excited to announce that it will be rolling out more and more products integrated with IOT to allow for better Process Control Traceability Training Purposes and Troubleshooting Unfortunately this is still under development at this time but pleas...

Page 130: ...p the Create New Profile button on the Main Menu Bar The system will automatically clear the workspace of any previously programmed points and drive to the Home Position head driven to the left of the gantry top plate driven closest to the user end effector retracted into the head and with the iron facing left Main Menu Bar ...

Page 131: ...ystem is not equipped with an auto save function and therefore it is a good idea to save one s work periodically throughout the programming process Complete the following steps to save a profile 1 Tap the Save icon to open the file management system 2 Type out the desired File Name ...

Page 132: ...00 CVSI 7000 5970 Rev A page 132 of 396 3 Tap the Save Profile icon Profile Saved 1 In cases in which the user is saving progression use the following steps 1 1 Tap the name of the active profile to highlight the profile ...

Page 133: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 133 of 396 1 2 Tap the Save Profile icon 1 3 Tap Yes to Proceed with the Changes 1 3 1 Tap No to cancel Progression Saved ...

Page 134: ... space For this reason the system is equipped with several extra USB ports that can be used for expandable memory among other devices Complete the following steps to save the profile to an external device 1 Plug in the external USB device into an available USB port on the rear of the controller box at the rear of the unit 2 Wait around 5 seconds for the system to recognize the device 3 Tap the Sav...

Page 135: ...le Name 5 Tap the USB icon to indicate to the system that the file is to be saved to the external USB device 6 If the profile is to be saved to a particular directory within the external device tap the directory in which the profile is to be saved otherwise proceed to the next step ...

Page 136: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 136 of 396 7 Tap the Save icon Profile Saved to an External Device PROFILE REMOVAL 1 Tap the Save icon to open the file management system ...

Page 137: ... CVSI 7000 5970 Rev A page 137 of 396 1 1 The one of the two following Pop up Menus will appear Without External Memory Main Directory Available Folders Internal Cancel Delete Folder Image Create Folder Save Image Profiles ...

Page 138: ...page 138 of 396 With External Memory Available Files External Main Directory of Robot Available Folders Internal File Transfer Button To USB Cancel Delete Folder Image Create Folder Save Image Main Directory of USB File Transfer Button From USB ...

Page 139: ...e name of the profile that is to be removed 2 1 The name will become highlighted with a blue ribbon once selected 3 Tap the Delete Icon to permanently remove the profile 3 1 WARNING This action CANNOT BE UNDONE Please take careful consideration before removing a profile ...

Page 140: ...ce System allows for the creation of folders to better assist user in organizing their profiles per the job customer operator type etc Pro Tip Although not required Metcal recommends adding the following folders for frequently used file types Solder Profiles Templates Layouts TCP o TCP stands for Tip Cleaning Profiles Complete the steps on the next page to create a new folder ...

Page 141: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 141 of 396 1 Tap the Save icon to open the file management system 2 Enter the name of the folder that is to be created ...

Page 142: ...I 7000 5970 Rev A page 142 of 396 3 Tap the Create Folder icon 3 1 Note Folders cannot have the same name as any previously created folder at the same level within the directory If this occurs the following message will appear ...

Page 143: ...UAL RSS 1000 CVSI 7000 5970 Rev A page 143 of 396 4 Repeat Steps 2 3 until all desired folders have been created 4 1 To create a subdirectory tap the arrow to the left of the folder icon to expand its contents ...

Page 144: ...000 5970 Rev A page 144 of 396 4 1 1 Note If the directory is empty the arrow will face down and the folder will appear in an opened state but no file names will appear beneath it 4 2 Tap the folder to ensure it has been selected ...

Page 145: ... MANUAL RSS 1000 CVSI 7000 5970 Rev A page 145 of 396 4 3 Enter the name of the subdirectory and tap the Create New Folder icon 5 Once all files have been created Tap the Exit icon Folder Creation Complete ...

Page 146: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 146 of 396 FOLDER REMOVAL 1 Tap the Save icon to open the file management system ...

Page 147: ... name of the folder that is to be removed 2 1 The name will become highlighted with a blue ribbon once selected 3 Clear all contents within the folder 3 1 Note This action CANNOT BE UNDONE Please take careful consideration before removing any profile or subdirectories ...

Page 148: ...of 396 4 Once all contents have been removed tap the Delete Icon to permanently remove the icon 4 1 If any profiles or subdirectories remain the following error message will appear This is done as a safeguard of accidentally an entire folder s contents ...

Page 149: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 149 of 396 5 Tap the Exit icon to leave the file management screen Profile Successfully Removed ...

Page 150: ...joint defects and lead to an improvement in quality while also mitigating risk In addition the Chip in Cartridge technology precisely calculates and displays tip temperature on a large color display improving audit compliance FLOW CHARTS OF SOLDERING PROCESSES When determining which process CV or Standard Soldering is best for a given application it is best to understand the process flow for each ...

Page 151: ...west temperature cartridge that will accomplish the task Doing so will minimize the potential for thermal damage CV STATE CODES To better assist users in understanding what is occurring during each solder joint process codes are provided in the top right corner of the CV display as indicated by the arrow Please note that when CV is deactivated the code displayed is OFF Below are the definitions fo...

Page 152: ...t the CV calculation could not be performed due to an issue with thermal efficiency In other words the tip chosen for the job cannot provide enough of a thermal load to provide a sufficient IMC TO CV Timeout Failure TO indicates that the iron has remained on the joint for at the programmed CV timeout setting and will result in an abort ER Unexpected Error ER indicates a catastrophic error with the...

Page 153: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 153 of 396 SOLDER PARAMETERS AND SETTINGS SOLDER POINT 1 Tap on the Waypoint button once to toggle to Solder Point ...

Page 154: ...he differences between Transition Move and Space Move please refer to the Profile Options section of the manual Once selected the setting will be used for programming and any subsequent points programmed will follow suit until the setting is changed The system allows for profiles to have a mixture of Interpolation and Space moves Use of one or another is application dependent 3 1 Pro Tip Programmi...

Page 155: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 155 of 396 4 To create a new Solder Point parameter tap the Parameter Table Button otherwise skip to Step 5 4 1 To add a new parameter tap the Add button ...

Page 156: ...ange for profile names 4 4 2 Style 4 4 2 1 Defines whether the parameter under editing is a Dot Solder Point or Line Solder Line 4 4 3 Start Delay 4 4 3 1 Defines how long the soldering iron is to remain on a joint before a pre feed of solder takes place This is done to warm up the lead or object to be soldered 4 4 3 2 Used when Connection Validation is turned off 4 4 3 3 Unit of measurement is in...

Page 157: ... soldering iron will retract in the Z Axis before moving in the X Y or Θ axes 4 4 7 2 Used to clear any obstacles of nearby components or other features that may lead to crashing of the soldering iron end effector 4 4 7 3 Unit of measurement is in millimeters 4 4 8 Save 4 4 8 1 Saves all values within the Parameter Edit screen 4 4 9 Copy 4 4 9 1 Function creates a new parameter duplicating all the...

Page 158: ...will appear on the screen to signify that a point has been recorded Programming a Point Complete SOLDER LINE Note When programming a solder line the settings for the solder wire feeder will slightly change The solder feeder feed rate will dictate the amount of solder that is dispensed for the programmed line instead of a fixed length The higher the speed the greater the volume of solder that is di...

Page 159: ...ces between Transition Move and Space Move please refer to the Profile Options section of the manual Once selected the setting will be used for programming and any subsequent points programmed will follow suit until the setting is changed The system allows for profiles to have a mixture of Interpolation and Space moves Use of one or another is application dependent 3 1 Pro Tip Programming with Spa...

Page 160: ... 1000 CVSI 7000 5970 Rev A page 160 of 396 4 To create a new Solder Line Parameter tap the Parameter Table Button and complete the following steps otherwise skip to step 5 4 1 To add a new parameter tap the Add button ...

Page 161: ...ange for profile names 4 4 2 Style 4 4 2 1 Defines whether the parameter under editing is a Dot Solder Point or Line Solder Line 4 4 3 Start Delay 4 4 3 1 Defines how long the soldering iron is to remain on a joint before a pre feed of solder takes place This is done to warm up the lead or object to be soldered 4 4 3 2 Used when Connection Validation is turned off 4 4 3 3 Unit of measurement is in...

Page 162: ...oldering iron will retract in the Z Axis before moving in the X Y or Theta axes 4 4 7 2 Used to clear any obstacles of nearby components or other features that may lead to crashing of the soldering iron end effector 4 4 7 3 Unit of measurement is in millimeters 4 4 8 Save 4 4 8 1 Saves all values within the Parameter Edit screen 4 4 9 Copy 4 4 9 1 Function creates a new parameter duplicating all t...

Page 163: ...ote that the robot uses vector movements i e will move in all three directional Axes and rotation about the Z Axis simultaneously Therefore this factor should be considered when programming the second point to create the line For this reason the directional jog controls should be used rather than touching on the work space to jog to prevent a change in height when producing a solder line 10 Tap th...

Page 164: ...r Feeder Parameter button the following menu will be displayed By toggling the Feed by Length button the following Feed by Volume converter menu appears Feed by Length Pre Tin Length Feed Rate Solder Feed Feed Delay Speed mm s Feed by Volume Pre Tin Length Feed Rate Solder Feed Feed Delay Speed mm s Solder Diameter mm Desired Solder Volume Solder Feed Length Fine Adjust Fine Adjust Fine Adjust Fin...

Page 165: ... tapping the sign to increase the value or the sign to decrease the value The green slide bar allows the operator to select the velocity at which the solder is dispensed This is done by simply sliding the circular icon left and right until the desired speed appears in the green box WAY POINTS Waypoints are programmed locations within a solder program that allow operators to send the end effector t...

Page 166: ... is a diagram showing the Solder Wire Feeder assembly mounted to the unit along with the direction of each adjustment Once the adjustment has been dialed in to the user s preferred location the user can use the locking nuts to hold the position of the adjustment Front View Up Down Adjustment Assembly Toward Away Adjustment SWF Tube Left Right Adjustment Assembly Locking Nuts Rotational Adjustment ...

Page 167: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 167 of 396 Rear View Rotational Adjustment Assembly Rotational Adjustment 2 SWF Tube ...

Page 168: ...s This allows the user to adapt any profile in a fraction of the time than it would with the traditional teach pendant The display will update with new positions so the user can see how their changes will look before they are implemented within the profile Users even have the option to quickly identify and remove any point within a profile Please note that only Admins and Engineers will have acces...

Page 169: ...e within the editing screen Proceed with changes made to the profile These changes can then be test run to ensure they were programmed as intended If satisfied the user will still need to save the overall profile to complete the changes Cancels all changes made to the profile Stops all motors and prompts user that the E Stop has been engaged Upon clearing of the message the unit will home itself C...

Page 170: ...meter type Dot Line or Waypoint Name of Parameter In the event the user needs to alter the settings within the Parameter and a new name is desired the name can be changed by tapping on the box If a name change is desired the confirms the name change has taken place If this button is not tapped the name change will not take place Creates an exact copy of a Parameter and all its settings The copy au...

Page 171: ...Copy button 2 1 Although not required it s always best to make a copy as to not affect other programmed points within the profile of which the original parameter is used and works well 3 If a new name for the parameter is desired tap the name of the parameter 3 1 A keyboard will automatically pop up at the bottom of the work space 3 2 Tap the Confirm Parameter Rename button once the name has been ...

Page 172: ...nged 4 1 Both the Solder Parameter setting and the numeric box will illuminate green to signify the setting and value that is under edit 5 Tap the Delete key on the numeric keypad to clear the value 6 Use the keypad to enter the new value 7 Tap on the next numeric box to the right of the parameter setting that is to be changed ...

Page 173: ...green to signify the Profile Edit screen is active 9 Swipe up down on the parameters listed to scroll until the desired feature with the parameter that is to be edited is highlighted by the yellow band 9 1 Note Parameters are listed in the following format 10 Tap on the Parameter Name to open the List of Parameters Selected Parameter Program Order Parameter Name Parameter Type ...

Page 174: ...proceed with the changes made to the profile 15 In the left half of the header bar the profile name will appear with a message as follows 15 1 This is to indicate that the profile has been changed but has not been permanently stored to the system This allows for the user to test the parameters and make any changes if needed before committing to saving the profile If satisfied tap the Save icon to ...

Page 175: ...rview of the Profile Edit Screen Features Within Profile Diagram Features w in Profile Programmed Transition Speed Parameter Details Coordinates of Feature Solder Feeder Settings Position of End Effector Feature Manipulation Options Selected Parameter Program Order Parameter Name Parameter Type ...

Page 176: ...polation or Space move can be changed by tapping on the displayed movement to toggle from one to the other For details on Interpolation and Space Moves refer to the Profile Options section o The speed will automatically update when toggling from Space Move to Interpolation Move if set for a value greater than 150 mm s Parameter Details The Parameter Details section displays the information regardi...

Page 177: ... the coordinates would be to utilize the axis corresponding record button or utilizing the Offset All and Apply to All Functions Feeder Settings Feeder settings displayed in the edit menu mirror the solder feeder settings on the main screen Whether the point was programmed using length or volume the edit menu will only display the equivalent length when programming by volume Any setting can be cha...

Page 178: ...s the Z Value based of the current coordinates of the end effector The Record R function auto populates the R Value based of the current coordinates of the end effector Reorders a programmed feature toward the start of the profile This may be done as many times as is necessary until the feature has been ordered to the number 1 position of the profile Reorders a programmed feature toward the end of...

Page 179: ...R MANUAL RSS 1000 CVSI 7000 5970 Rev A page 179 of 396 To edit the points within a profile use the steps below to navigate to the Profile Edit screen 1 Tap the Profile Edit button 2 Tap Profile Edit Screen ...

Page 180: ...escription of the setting with a few exceptions Specific instructions pertaining to each parameter are detailed in the following sections Edit Transition Speed 1 Swipe up down on the features listed to scroll until the desired feature that is to be edited is highlighted by the yellow band 2 Tap the blue box labeled Space to toggle between Space Move and Interpolation Move ...

Page 181: ... edit 4 Tap the Delete key on the keypad to clear the existing value 5 Using the keypad enter the new value for the desired speed o 1 150 mm s for Interpolation Move o 1 300 mm s for Space Move 6 Repeat steps 1 4 for all values that are to be edited 6 1 If a desired speed is to be set for all features the Apply to All function can be used to quickly set the speed to all features within the profile...

Page 182: ... 5970 Rev A page 182 of 396 Edit Parameter 1 Swipe up down on the features listed to scroll until the desired feature that is to be edited is highlighted by the yellow band 2 Tap on the Parameter Name to open the List of Parameters ...

Page 183: ...ange 5 Tap to confirm changes and return to the profile for testing 5 1 Note If satisfied with the changes don t forget to save Editing a Point Coordinate 1 Swipe up down on the features listed to scroll until the desired feature that is to be edited is highlighted by the yellow band 2 Tap the numerical box to the right of the coordinate that is be changed ...

Page 184: ...p the Delete key on the keypad to clear the existing value 4 Use the keypad to enter the new coordinate value 5 Tap the numerical box to the right of the next coordinate that is to be changed 6 Repeat this process until all desired values have been changed 6 1 The refresh button may be used in order to view the changes made 6 2 A new green dot will appear at the location of the programmed coordina...

Page 185: ...onfirm changes and return to the profile for testing 7 1 Upon the return to the profile the old solder point location will have been removed from the profile 7 2 Note If satisfied with the changes don t forget to save Editing Line Coordinates 1 Swipe up down on the features listed to scroll until the desired feature that is to be edited is highlighted by the yellow band ...

Page 186: ...Value coordinate will be adjusted first 2 2 Once selected the coordinate and Point 1 boxes will illuminate green 3 Tap the Delete key on the keypad to clear the existing value 4 Use the keypad to enter the new coordinate value 5 To ensure the horizontal line is retained the Y Value of Point 2 will need to be adjusted to the same value that was set in Step 4 ...

Page 187: ...n may be used in order to view the changes made 6 2 A new green line will appear at the location of the programmed coordinates 6 3 Note The line location will remain displayed until the user taps to proceed with the changes 7 Tap to confirm changes and return to the profile for testing 7 1 Upon the return to the profile the old solder line location will have been removed from the profile 7 2 Note ...

Page 188: ...e profile under edit 2 Swipe up down on the features listed to scroll until the desired feature that is to be edited is highlighted by the yellow band 3 Tap the Snap To button to automatically send the end effector to the solder point selected 4 Once the end effector arrives at the programmed solder point tap the Motion Control button to toggle to the motion controls ...

Page 189: ...tion controls 5 Tap the box underneath Snap 6 Once the box is selected use the keypad to enter the desired increment for controlled movement 6 1 This increment is highly application dependent Use good judgement when selecting this value 6 1 1 For densely populated boards 0 1 mm is highly recommended as the Snap increment ...

Page 190: ...gle to Jog 6 3 1 The jog controls function identically to the coarse movement controls on the main screen 6 3 2 Please note that the jog speed will be that of which is selected within the global parameters Use with caution 7 Using the motion controls jog the end effector to the desired location 8 Once in the desired location begin tapping the Record Coordinates of all axes that changed in order to...

Page 191: ...illuminate green and the box will automatically be populated to match the global coordinate 9 Repeat this process for any other points within the profile 10 Tap to confirm changes and return to the profile for testing 10 1 Note If satisfied with the changes don t forget to save Editing a Coordinate Using the Record Coordinate Function Complete ...

Page 192: ...hin the program This can especially be problematic when there are multiple orientations or heights within a program For example say a given program included half of the programmed points at an orientation of 0 and the other half at 180 If a 45 rotation was used during the offset the values of the new coordinates would then be changed to 45 and 225 respectively Please take careful consideration whe...

Page 193: ...e end effector to the starting point of the solder line 4 Once the end effector arrives at the starting point of the soldering line tap the Motion Control button to toggle to the motion controls 5 Use the motion controls to jog to the new location of the feature and or components that are to be line soldered ...

Page 194: ...Use the following steps to jog using the main screen controls 5 1 1 Tap the Absolute Move button 5 1 2 Enter new the coordinates of a feature and tap Move to execute the command 5 1 2 1 Note In cases in which the coordinates are unknown the coarse and fine movement motion controls may be used 5 1 3 Tap the Edit Profile icon to open the editing screen 5 1 4 Tap the Profile Edit button ...

Page 195: ...ffset reference 5 1 6 Proceed to Step 6 6 Once the end effector is in the new location of the desired feature tap the Offset All button 6 1 The feature highlighted will be repositioned to the new location and the coordinates are automatically populated 7 Tap to confirm changes and return to the profile for testing ...

Page 196: ...ates for various positions of individual PCBA s within an array of PCBA s This in turn can be used in conjunction with the Merge Profile function to create one massive program to exponentially decrease programming time For more details on how to use the Merge Profile function for Printed Circuit Board Assemblies refer to Printed Circuit Board Assembly Based Merge of the Merge Profile section Don t...

Page 197: ...lationship between solder feeder settings within the Profile Edit Screen and the Main Solder Feeder Settings Menu Note Feed ratio is the percentage of the pre tin vs the overall length fed 5mm of 25 is 20 1 Swipe up down on the features listed to scroll until the desired feature that is to be edited is highlighted by the yellow band ...

Page 198: ...n the keypad to clear the existing value 4 Use the keypad to enter the new coordinate value 5 Repeat this process for all solder feeder settings that are to be edited 5 1 Don t forget to use the Apply to All function if the setting is to be used throughout the entire profile 6 Tap to confirm the changes and return to the profile for testing 6 1 Note If satisfied with the changes don t forget to sa...

Page 199: ...ipe up down on the features listed to scroll until the desired feature that is to be edited is highlighted by the yellow band 2 Tap the or to change the feature s order 2 1 Note In this example the feature chosen was the final feature of the profile Therefore only the function can be used in such a case ...

Page 200: ...d from the profile 3 2 Note If satisfied with the changes don t forget to save Reordering of Features Within Profile Complete Remove a Feature from a Profile 1 Swipe up down on the features listed to scroll until the desired feature that is to be edited is highlighted by the yellow band 2 Tap the to remove the feature 2 1 Note the feature will turn black to indicate it is to be deleted shown on th...

Page 201: ... can also use this function to create multiple instances of a pattern that is not practical or possible with an evenly distributed array The following procedures will provide instructions on how to merge profiles for different scenarios COMPONENT BASED MERGE This is typically used in applications in which the component pattern to be merged is used quite frequently as multiple random instances with...

Page 202: ...tions and tap the waypoint icon once to toggle to solder point 3 Swipe Up or Down to scroll to the desired dot parameter that is to be used 4 When programming the following points one must consider the geometry of the component its orientation and critical dimensions For this example the following Operational Amplifier will be used in the orientation shown below ...

Page 203: ...ed within a program Please see the Edit Profile section for more details 6 Tap the record button 7 Jog the end effector in the X direction in 2 54mm increments for the next three pins recording a point at each pin 8 To navigate to pin 5 in the correct orientation for the ideal application with no obstacles or prohibiting geometry the following values would be used 8 1 From the global coordinate pe...

Page 204: ... application skip to step 11 However Metcal follows the IPC J STD 001 and IPC A 610 standards when soldering Therefore in this example the component will be soldered with alternating pins on alternating sides to be compliant 10 2 Tap to enter the Edit Profile Screen 10 3 Tap to reach the Edit Segment Screen 10 4 Swipe up down on the program order until DOT 7 is highlighted 10 5 Tap to reorder the ...

Page 205: ... 396 10 8 Repeat this process until the points are programmed in the order shown below 10 9 Tap to save the changes 11 Tap to save the template 11 1 Pro Tip Save the Template with the name of Component Solder Parameter Template to aid with identification ...

Page 206: ...te the save 13 Tap to open profile the component is to be merged with 14 Tap the name of the profile and tap to open the profile 15 Jog end effector to the location in which the component is to be inserted with reference to pin 8 16 Tap on the Merge button 16 1 The following menu will appear 17 Tap Select File ...

Page 207: ...70 Rev A page 207 of 396 18 Tap the name of the component template that was created in the previous steps and tap to continue 19 Tap Insert to merge the template with the profile 19 1 The component will then be merged into the profile ...

Page 208: ...ond with a multi PCBA fixture for use in production This procedure will describe how to produce multiple instances of a profile after it has been perfected The fixture in this example will house four PCBA s at 200mm apart in both directions 1 Tap New Profile to ensure that the workspace is clear of all programmed points 2 Tap the Merge button 2 1 Note If the profile that is to be used was programm...

Page 209: ...96 4 Tap the name of the profile template that is to be used and tap to continue 5 Tap Insert to merge the template with the profile 5 1 The profile for the single board should now appear in the workspace 6 Tap to toggle to the fine adjustment jog controls ...

Page 210: ... used as well 7 Enter the X Axis Coordinate ONLY for the location of the next board 7 1 In this example the location of the next board is 200mm to the right of the first programmed board 8 Tap the Merge button 9 Tap Select File 10 Tap the name of the profile template that was selected in Step 1 and tap to continue ...

Page 211: ...Insert to merge the template with the profile 11 1 The 2nd profile will appear in the work space 11 2 The location of the next board is 200mm in the Y Axis To save travel time from board to board the PCBA directly the one programmed in step 10 will be programmed next ...

Page 212: ...Coordinate ONLY for the location of the next board 12 1 In this example the location of the next board is 200mm below the second programmed board 13 Tap the Merge button 14 Tap Select File 15 Tap the name of the profile that was selected in the previous steps and tap to continue ...

Page 213: ...00 5970 Rev A page 213 of 396 16 Tap Insert to merge the template with the profile 16 1 The template will now appear in the bottom right section of the fixture 17 Enter the Y Axis Coordinate ONLY for the location of the next board ...

Page 214: ... 214 of 396 17 1 In this example the location of the next board is 200mm to the left of the first programmed board 18 Tap the Merge button 19 Tap Select File 20 Tap the name of the profile that was selected in the previous steps and tap to continue ...

Page 215: ...merge the template with the profile 21 1 The template will now appear in the bottom right section of the fixture 22 Test the profile and make the necessary tweaks with the Edit function 23 If satisfied tap to save the profile Printed Circuit Board Assembly Based Merge Complete ...

Page 216: ...l appear 1 Number of Rows and Columns Within Array 1 1 Rows 1 2 Columns 1 3 Any number that is entered as a decimal will automatically be rounded to the nearest whole number 2 Row Offset 2 1 In millimeters mm 3 Column Offset 3 1 In millimeters mm 4 Skip Instance s 4 1 Tap the to activate 4 1 1 A will appear along with a text box 4 2 Instances which are to be skipped are entered with a space in bet...

Page 217: ...hich the features within the array are executed 6 Direction of Array 6 1 Toggle X Left Right 6 2 Toggle Y Up Down 6 3 Settings determine which direction the array will be programmed 7 Run Generate Array 7 1 Proceed with Creation of Array 8 Cancel Generate Array 8 1 Cancel the Creation of Array 1 2 1 1 3 2 5 7 4 8 6 1 6 2 1 ...

Page 218: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 218 of 396 Examples of Generate Array Settings 1 Number of Rows and Columns Within Array 2 Row Offset 3 Column Offset Offset 50mm Offset 50mm Columns Rows ...

Page 219: ...5970 Rev A page 219 of 396 4 Skip Instance s Note Order in which skipped instances are entered does not matter Pattern Type Direction of Array will determine which value an instance is assigned 1 2 3 4 8 7 6 5 9 10 11 12 16 15 14 13 ...

Page 220: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 220 of 396 5 Array Path Pattern 5 1 Vertical Zig Zag 1 4 7 2 5 8 3 6 9 ...

Page 221: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 221 of 396 5 2 Horizontal Zig Zag 1 2 3 4 5 6 7 8 9 ...

Page 222: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 222 of 396 5 3 Vertical Square Zig Zag 1 6 7 2 5 8 3 4 9 ...

Page 223: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 223 of 396 5 4 Horizontal Square Zig Zag 1 2 3 6 5 4 7 8 9 ...

Page 224: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 224 of 396 5 5 Spiral 1 2 3 8 9 4 7 6 5 ...

Page 225: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 225 of 396 6 Direction of Array 6 1 Right Down The first point programmed will be at the top left of the array ...

Page 226: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 226 of 396 6 2 Right Up The first point programmed will be at the bottom left of the array ...

Page 227: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 227 of 396 6 3 Left Down The first point programmed will be at the top right of the array ...

Page 228: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 228 of 396 6 4 Left Up The first point programmed will be at the bottom right of the array ...

Page 229: ...sired dot parameter that is to be used is highlighted by the yellow band 4 Position the end effector at the location of the top left corner of where the array is to be programmed 5 Tap the Generate Array button 5 1 The button will illuminate gold to signify the array function is active 6 Tap the Record button to designate the first point of the array 7 Tap the Generate Array button once again to s...

Page 230: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 230 of 396 8 Enter the desired values in the respective fields 9 After all the values have been filled tap Run ...

Page 231: ...array will appear in the workspace programmed to the settings previously specified 10 Test the program to ensure complete satisfaction 10 1 Enter the Edit Screen to make any necessary changes 11 Save profile once satisfied with the results Single Point Array Complete ...

Page 232: ...ample with the five transistors programmed at the dimensions shown 1 Tap New Profile to ensure that the workspace is clear of all programmed points 2 In this example a waypoint will be programmed before each solder point to ensure that iron approaches the lead of the transistor in a desired path 3 Jog to the location of the first waypoint 4 Tap the Generate Array button 4 1 The button will illumin...

Page 233: ...r Down to scroll through the dot parameters until the desired dot parameter that is to be used is highlighted by the yellow band 9 Jog to the first pad of the transistor 10 Tap the Record Button 11 Repeat this process for the next two points of the transistor 11 1 Note If in any case an error is made use the Undo Redo buttons ...

Page 234: ...he design of the printed circuit board there are five transistors total in two rows that are offset from one another To program all transistors in one sweep the values within the Generate Array function must be programmed using logic and reasoning The following sub steps will describe which values were chosen and why they were chosen 13 1 Rows and Columns 13 1 1 The array can be visualized as 2 ro...

Page 235: ...n be inferred that transistor R2C2 lies at the midpoint of transistor R1C1 and R1C3 13 4 Array Path Pattern 13 4 1 The Vertical Square Zig Zag was chosen as this would have the least amount of travel time from transistor to transistor The Vertical Zig Zag could also apply as the next two instances would be skipped However the Vertical Square Zig Zag makes for a simpler Instance Skip programming se...

Page 236: ...ransistor in the top left corner of the board in the orientation in the fixture 13 6 Instances Skipped 13 6 1 With the chosen Array Path Pattern and Direction of Array the following order is programmed The numbers in gold designate the points in which will programmed in the array and the numbers in black designate the instances that will be skipped 1 4 5 9 8 2 3 6 10 7 ...

Page 237: ...ev A page 237 of 396 14 Tap the Run Button 15 The programmed points will now appear in the workspace in the correct spacing Pro Tip This program can be saved and used as a template for multi board soldering Multiple Pattern Array Complete ...

Page 238: ... one should consider obstacles between the last solder point and the desired Go To Location as the Smart Interface System will complete a vector move to reach the Go To Location In addition one should also consider other aspects such as accessibility to the PCBA fixture and tip cartridge as these are frequently replaced items The Go To Location is a global setting and therefore will affect all pro...

Page 239: ...r time and the programmed points appear to have shifted This can also be used to compensate for the mechanical tolerances when changing solder cartridges The offset will continue to take effect until the user removes them or programs a new offset WARNING The Offset Profile function is a Global Setting or in other words will affect ALL profiles Please be mindful of this when programming any offset ...

Page 240: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 240 of 396 3 1 The following menu will appear 4 Tap the Record button to automatically record the position of the end effector in the X Y and Z axes ...

Page 241: ... proceed with the offset 5 1 Tap cancel to cancel the changes Programming an Offset Complete To Remove the Offset 1 Tap the Offset button 2 Tap the green box on the left 2 1 The green box represents the offset in the X Axis 2 2 Upon tapping the green box the numeric keyboard pops up ...

Page 242: ...button to clear the value 4 Tap on the next green box representing the Y Axis and repeat step 3 5 Tap on the yellow box representing the Z Axis and repeat step 3 6 Tap the Save button to proceed with restoring the original profile without an offset Removing an Offset Complete ...

Page 243: ...ings will be disabled RF will automatically shut off without the ability to turn it on until the Dry Run is either completed or toggled off o In other words the iron will remain cool preventing any damage to the PCBA under testing No solder will dispense on any joint All time delays start delay feed delay and dwell are disabled for the duration of the run o The system defaults to a one second paus...

Page 244: ...he system will execute the X Y Θ movement commands to position the end effector above the first cleaning zone point as the cleaning zone is the first point for all profiles The end effector will remain in this position until the user taps the Run Profile Continue button after which the end effector drives down to the programmed height of the cleaning zone s starting point This allows users to pin ...

Page 245: ...nsure that the cartridge is placed within the End Effector Cartridge Lock in the exact same position every time The Fixture Tip Alignment Fixture comes preassembled with the 2 5mm chisel insert but inserts for other geometries will be made available sold separately For further ease of alignment Metcal offers the Center Point Tool sold separately to ensure that the axis of rotation of tip is aligne...

Page 246: ... page 246 of 396 2 Slide End Effector Cartridge Lock over the CV cartridge from the connector side down as shown 3 Insert End Effector Cartridge Lock into Tip Alignment Fixture Assembly 7059 9160 with the set screw facing the rear of the unit ...

Page 247: ... Rev A page 247 of 396 4 Rotate the CV cartridge as necessary until the tip fits within the groove of the fixture 5 Torque the set screw in the End Effector Cartridge Lock 1 5 in lbs once in the correct orientation Tip Alignment Complete ...

Page 248: ...TER POINT ALIGNMENT 1 If not already Log In to Robotic Soldering System using 1000 for the password and tapping once entered 2 Tap the button to toggle to the fine adjustment jog controls 3 Drive end effector down in the Z Axis by 20mm using the highlighted icon ...

Page 249: ...accessory bracket and rotate accessories Solder Wire Feeder Tube Assembly and CCD Camera out of the way Before After 5 Remove the CV Cartridge assembly from the Tip Alignment Fixture 6 Loosen set screw of Soldering Robot CV H8 AV Note Loosening of set screw is only required if a different tip geometry is inserted ...

Page 250: ...Spring Retainer down toward the cartridge until there is a reasonable amount of spring force applied to the cartridge assembly Once in place hand tighten the set screw into place 9 1 To test if there is a reasonable amount of spring force applied to the cartridge assembly rotate the cartridge assembly counter clockwise and remove it from the End Effector Then try reinserting the cartridge assembly...

Page 251: ...etainer up and away from the cartridge 9 1 2 If the spring force is too weak loosen the set screw and adjust the End Effector Spring Retainer down and toward the cartridge 9 2 Once in the correct location torque the set screw into place 10 Attach the Center Point Tool Assembly 7059 9150 to the End Effector with the thumb screw facing the rear of the unit ...

Page 252: ... thumb screw to the right of the end effector to adjust the cartridge closer or further away from the alignment pin The objective is to position the solder tip such that the reaches the alignment pin 13 1 Rotate the thumbscrew clockwise to raise the cartridge assembly up and the tip away from the alignment pin 13 2 Rotate the thumbscrew counter clockwise to lower the cartridge assembly down and th...

Page 253: ...s out of position Out of alignment use step 13 1 Perfectly Aligned Out of alignment use step 13 2 13 4 Once in position rotate the locking nut clockwise to lock in position 13 5 Note If thumbscrew is adjusted to the maximum limit readjust to lower limit and loosen the entire assembly via the M5 SHC screw to move the cartridge into position ...

Page 254: ...ool Assembly to the circular feature on the calibration fixture 14 1 Carefully jog the end effector down in the Z Axis in small increments to confirm alignment has been achieved 14 1 1 If the alignment tip is out of alignment with the circular feature use the fine adjustment jog controls to carefully jog it into place Out of Alignment Aligned ...

Page 255: ...he event the robot needs to be homed there will be no need to realign the alignment pin The X Y values can be entered in the Absolute Move feature and the robot will return to the previously aligned location 16 Carefully jog the end effector down in the Z Axis until the tip is around 5mm away from the fixture Then slide the Calibration Fixture vertically until it contacts the solder tip 16 1 Once ...

Page 256: ...pective sections The unit will be factory calibrated for a board height of 38 1mm However design of any fixture that deviates from this height will require re calibration of the camera at the new height Correct calibration of the Computer Vision Camera is essential to the several functions of the RSS 1000 CVSI It is imperative that this procedure be followed step by step line by line Failure to do...

Page 257: ...ion Validation Power Supply after installation of cartridge 4 Use the jog controls to position the cartridge point over the PCBA 5 Slowly jog end effector down in the Z Axis until the cartridge is 5mm above an open area of PCBA free of components 6 Use the Fine Adjustment jog controls to slowly jog end effector down until cartridge first contacts PCBA substrate 6 1 Record the Z Axis value in the G...

Page 258: ... 396 8 Loosen the Z Axis thumb screw indicated by the arrow and verify the Calibration Slider Block assembly is in the lowest position 9 Tap the Absolute Position button 10 Enter the value recorded in step 6 1 in the yellow box to the right of Z Position ...

Page 259: ... height of PCBA 12 Raise Calibration Slider Block assembly until the black raised feature of the Scaling Block contacts the cartridge tip as shown in Figure 12 12 1 Lock into place by turning clockwise on the thumb screw directly beneath the Height Adjustment Block as indicated by the arrow Figure 12 ...

Page 260: ... Block shown in Figure 12 2 13 Tighten thumb screw once in the correct location 14 Tap the Home button 15 OPTIONAL Some find it useful to set Z Limit safety height to the height recorded in step 6 1 to reduce programming time However doing so may introduce the risk of collisions with components mounted to the working surface of PCBA Use with Caution 16 Tap the Camera button to turn on the camera F...

Page 261: ...e 261 of 396 16 1 Note The Camera button will illuminate blue and an image will appear in the workspace area 17 Tap the Global Settings Button 18 Tap the Camera Settings Menu 19 Tap Start next to Camera Calibration to start the camera calibration ...

Page 262: ...unctions used for camera calibration Record Camera Offset Coarse Jog Speed Value mm s Fine Adjustment Increment mm Fine Adjustment Direction Camera Offset X Y values Reset Calibration Coarse Jog Speed Slide Bar Coarse Jog Direction Fine Adjustment Slide Bar Cancel Calibration Continue to Next Step ...

Page 263: ...usly resizes the image to fill the complete work space with camera stream 20 2 Warning Resetting calibration without completing the entire calibration will result inaccurate movement when using the workspace to jog to a location 21 Using coarse jog controls fine adjustment align the origin top left corner of Scaling block to the origin of the work space on the screen top left corner of displayed c...

Page 264: ... 0 0 point of the workspace which is the origin 22 Once the two origins have been aligned tap the Record Camera Offset button 22 1 Note This action will populate the X Y fields with the initial offset 22 2 Note II The live video is now converted to a still image 23 Tap next to advance to the scaling page 24 Adjust the camera scale slide bar to 100mm 24 1 For fine adjustment of the slide bar in the...

Page 265: ...e Use the fine adjustment slide bar to increase decrease movement as needed The units are in mm 27 Once in position tap the Set Camera Scale button to save this scaling size and tap the next button to proceed to the next step 27 1 Note Upon tapping the next button the image reverts to live video and the image is now scaled to size relative to the work area the robot will automatically return to th...

Page 266: ...cation 1X 2X or 3X However in any of the three magnification cases the operator would be able to position the end effector over one component tap on the other component and the system would travel 10mm 28 To determine if fine tuning is required inspect along the edges of the raised surface of the scaling block displayed in the workspace The newly scaled image should not have any gap to the left or...

Page 267: ...ocation at the scaled image size one last time before the calibration is complete 29 Once the image has been repositioned tap the check mark to complete the calibration 29 1 It is highly recommended that a Position Verification Test be conducted detailed in the next section in order to verify that calibration was successfully completed ...

Page 268: ...s successful 1 Using the jog controls position the crosshair over the circular feature of the Scaling Block 2 Slowly drive end effector down to Scaling Block 2 1 If the calibration was performed successfully the tip should land at the centroid of the circular feature tangent to the circular feature or somewhere in between dependent on the offset calibrated The location may vary dependent on angle ...

Page 269: ...If position of solder tip is unsatisfactory skip to the Fine Adjustment After Calibration section 4 Jog end effector over to installed PCBA 5 Locate a feature on the board such as a pin to be soldered 6 Use the fine adjustment to position the crosshair directly on the centroid of feature 7 Slowly jog end effector down until solder tip has reached location at which soldering would take place contac...

Page 270: ... pin or pad after an invalid Camera calibration or after failure of the position verification test WARNING If the height has changed since the last Camera calibration a full calibration MUST be performed This procedure should not be used as a shortcut to calibrate the camera Doing so may have undesired results and or may cause damage to workpiece or unit 1 Tap the Home Button to ensure you are at ...

Page 271: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 271 of 396 4 Tap Start button next to Camera Calibration 5 Tap the Next button 5 1 Do NOT touch any of the other controls or buttons ...

Page 272: ...Do NOT touch any of the other controls or buttons 7 Once in the Fine Adjustment section input the X Y offset if known by adjusting the fine adjustment slide bar to the desired value and moving in the correct location 7 1 Use the Diagram below to enter the values with the appropriate sign positive or negative when entering the fine adjustment X Y X Y X Y X Y ...

Page 273: ...hin the software such as establishing Fiducial Points future feature Pattern Recognition or simply using an image to create a program Please be mindful of the lighting when screenshots are taken The objective is to maintain consistent lighting from when screenshots are taken to machine operation Therefore it is good practice to keep the unit in a stationary location in which the lighting is contro...

Page 274: ...ck theta snaps to rotate the end effector 90 to clear any bracketry of end effector from obscuring view 3 Tap the Take Screenshot icon 3 1 The following Pop up Menu appears Without External Memory Main Directory Available Files Internal Cancel Delete Folder Image Create Folder Save Image ...

Page 275: ...e 275 of 396 With External Memory Available Files Folders External Main Directory Available Files Folders Internal File Transfer Button To USB Cancel Delete Folder Image Create Folder Save Image Main Directory of USB File Transfer Button From USB ...

Page 276: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 276 of 396 4 Highlight the folder in which the screenshot is to be saved in by tapping on the folder 5 Enter name for the screenshot ...

Page 277: ... scale the camera was calibrated at Before importing any DXF or ART file types please make sure they created with a 1 1 scale as unscaled images will either appear extremely large or possibly not at all Please note that PNG files that are to be imported shall come from another RSS 1000 CVSI with a fixture of EXACT height and scaling Failure to do so will lead to programming errors on the imported ...

Page 278: ...e by tapping on the file name 4 Tap the open icon 4 1 Image will appear in the workspace located where the picture was taken Opening an Image Complete IMAGE ZOOM 1 Verify that the camera is turned off 1 1 Icon should be grey in color 2 Tap the Open Image icon 3 Highlight the desired image by tapping on the file name ...

Page 279: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 279 of 396 4 Tap the open icon 4 1 Image will appear in the workspace located where the picture was taken 5 Tap on The Zoom icon ...

Page 280: ...ptions are 1X 2X and 3X Zoom In the event the zoom is insufficient for the application at hand the camera may be adjusted mechanically to lower the camera to the workspace Please note that this action WILL REQUIRE RE CALIBRATION Please see Mechanically Lower Camera section for instructions Zoom Slide Bar Reset to 1X Zoom Scrolls Image Down Scrolls Image Left Scrolls Image Up Scrolls Image Right ...

Page 281: ...ge 281 of 396 7 Use the directional arrows to reposition the still image into the desired location using the following motion See example below 8 In the example on the previous page the operator will need to use the and icons to center the image ...

Page 282: ... in which the lighting is controlled In addition do not crowd around the unit or stand in front of a light source when taking a screenshot The simple act of hovering over the unit while the screenshot is taken can have negative effects as this will cast a shadow over the unit Avoid casting shadows that will not be present during normal operation WARNING Failure to adhere to this recommendation can...

Page 283: ...0 Rev A page 283 of 396 6 1 Icon should be grey in color 7 Tap the Open Image icon 8 Highlight the desired image by tapping on the file name 9 Tap the open icon 9 1 Image will appear in the workspace located where the picture was taken ...

Page 284: ...ox around a location on the image as the first fiducial point 11 1 Pro Tip Select an object or feature that is unique and distinct from any other feature on the board 11 1 1 Examples of good objects to select for fiducial points are drilled holes for mounting or holes drilled specifically for fiducial points of computer vision systems 11 1 2 Examples of bad objects to select for fiducial points in...

Page 285: ...Select an object that is located diagonally and at a considerable distance from the first fiducial point 12 2 Examples of good and objects provided in the previous step are still applicable to this step as well 13 Upon releasing finger from touch screen a dialogue box will appear as follows 13 1 The image on the left depicting the first point established the image on the right depicting the second...

Page 286: ...system to search for and letting the Smart Interface System find other instances of the defined pattern The user can then apply the desired predefined program to each desired instance Please be mindful of the lighting when using pattern recognition The objective is to maintain even lighting throughout the working envelope Therefore it is good practice to keep the unit in a stationary location in w...

Page 287: ...sert specific soldering parameters into a pattern once patterns features have been recognized by the Smart Interface System Please note that due to physical limitations 1 Tap to ensure that the workspace is clear of all programmed points 2 Tap once to toggle to solder point 3 Swipe Up or Down to scroll to the desired Dot Parameter that is to be inserted on each pattern identified ...

Page 288: ...8 of 396 4 Once the desired Dot Parameter is highlighted yellow tap the Absolute Move icon 4 1 Enter the following values 4 2 Tap Move to execute the command 4 3 The end effector will be positioned dead center to the work space 5 Tap the Record button ...

Page 289: ...CBA with designated fixture at the current calibrated height 2 Verify the Connection Validation Power Supply or RF is in the OFF position 3 Install desired Connection Validation cartridge 3 1 Verification of cartridge at the correct pivot position can be completed by referring to the Tip Alignment section 3 2 WARNING Do NOT turn on the Connection Validation Power Supply after installation of cartr...

Page 290: ... the Global Coordinate Display on a piece of paper 7 Tap the Camera Icon to enable the Computer Vision Camera 7 1 Note The icon will illuminate blue when active and an image should appear in the workspace 8 Use the jog controls to move to the desired location for screenshot 8 1 If necessary use the quick theta snaps to rotate the end effector 90 to clear any bracketry of end effector from obscurin...

Page 291: ... the image consistent with the profile to be programmed For example if an Engineer were to program Metcal s I O PCBA the name Metcal I O PCBA should be used when taking a screenshot and when saving the programmed pattern 11 Turn off the Camera 11 1 Icon will return to grey in color 12 Tap the Open Image icon 13 Highlight the desired image by tapping on the file name ...

Page 292: ...l appear in the workspace located where the picture was taken 15 Tap the Pattern Recognition button 15 1 The button will illuminate blue when active 15 2 In addition the Pattern Recognition Window will appear Insert Pattern Coarse Adjust Filter Adjust Neg Filter Adjust Pos Delete Pattern Filter ...

Page 293: ...ection for magnification instructions 16 Select the pattern to be recognized by tapping the top left corner of the object to be recognized and swipe diagonally until a yellow box is formed around the desired pattern 16 1 If unsatisfied with the area selected a new box may be created using the same method previously mentioned ...

Page 294: ...Rev A page 294 of 396 16 2 The system will automatically detect the number of identical patterns per previously established filter percentage 16 3 If needed adjust the Computer Vision increase the filter until all patterns are recognized ...

Page 295: ...00 5970 Rev A page 295 of 396 16 4 In the event the filter is too large and unintended objects are identified decrease the filter percentage 17 Tap the Insert Pattern button 18 With Template highlighted by default tap Select File ...

Page 296: ...CVSI 7000 5970 Rev A page 296 of 396 19 Select the desired template to be inserted 20 Tap the Open Icon 20 1 The template name will now be displayed 20 2 Tap Cancel if incorrect template was selected 20 3 Tap Ok to continue ...

Page 297: ...tically insert the template onto all recognized patterns 22 In the event certain patterns are to be omitted complete the following steps otherwise continue to Step 23 22 1 Tap the Delete Pattern button 22 1 1 The icon will illuminate blue signaling that the Delete Pattern function has been activated ...

Page 298: ...tap the patterns that are to be removed 22 2 1 In the event a pattern was deleted on accident repeat steps 16 21 22 2 2 Once all desired patterns have been removed tap the Pattern Recognition button to turn the feature off 22 2 3 The Icon will return to its original grey color ...

Page 299: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 299 of 396 23 Tap to enter the Edit Profile Screen 24 Tap to reach the Profile Edit Screen ...

Page 300: ...elected the box will illuminate to a neon green 26 Use the keypad to enter the height of the PCBA 26 1 If the height of the fixture is unknown use the following steps otherwise skip to Step 28 26 2 Tap the Motion Control icon to access the motion controls 26 2 1 The motion controls will now appear in place of the scroll wheel ...

Page 301: ...SER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 301 of 396 26 3 Tap the numerical box below the Snap button 26 3 1 The box will become highlighted once selected 26 4 Use the keypad to enter a value of 5mm ...

Page 302: ...the Z Axis down button to begin jogging the end effector down toward the PCBA in 5mm increments 26 6 Once the Solder Tip has reached 5mm above the PCBA change the snap value to 0 2mm and carefully continue to jog down until the tip contacts the surface of the substrate ...

Page 303: ...000 CVSI 7000 5970 Rev A page 303 of 396 26 7 Tap the Record Z button 26 7 1 The numerical box to the right of Z Value will automatically be populated with the current height of the end effector 26 8 Proceed to Step 28 ...

Page 304: ... profile before going into production In some cases patterns may be recognized close to the corners of the camera viewing area where the curvature of the camera combined with parallax error may give the false impression of the actual distance of objects In such cases points on an image may appear in the programmed location but physically may be in another location altogether For this reason it is ...

Page 305: ...imensions from a manufacturer Complete the following steps to create a layout 1 Install a bare if possible PCB with the hole pattern that the Layout is being created for Make sure to use the designated fixture at the current calibrated height 2 Verify the Connection Validation Power Supply or RF is in the OFF position 3 Install desired Connection Validation cartridge 3 1 Verification of cartridge ...

Page 306: ... 7000 5970 Rev A page 306 of 396 7 Swipe Up or Down to scroll to the desired Dot Parameter that is to be inserted on each pattern identified 8 Use the jog controls to position the camera image centered over the area of the PCB ...

Page 307: ...d practice to keep the name of the image consistent with the profile to be programmed For example if an Engineer were to program Metcal s I O PCBA the name Metcal I O PCBA should be used when taking a screenshot and when saving the programmed pattern 11 Tap the camera icon once more to turn off the Camera 11 1 Icon will return to grey in color 12 Tap the Open Image icon 13 Highlight the desired im...

Page 308: ... 396 14 Jog the head to the position X Y where the first joint of the layout is to be soldered 14 1 The zoom function may be utilized to locate the first joint 15 Slowly jog end effector down in the Z Axis until the cartridge is 5mm above the Layout area ...

Page 309: ...emaining joints of the transistor 18 1 Include any orientation changes that may be required as the application dictates 18 2 Note If unsure of the orientation when programming do not panic The Profile Edit tool allows for quick and painless edits to several points in a snap even after the layout is used More details on the Profile Edit tool can be found in the Profile Edit section of the manual 19...

Page 310: ...v A page 310 of 396 19 1 Pro Tip Save the Layout with the name of Solder Parameter Layout to aid in identification of the parameters used and to distinguish from normal solder profiles 20 Tap the Save Profile button Layout Creation Complete ...

Page 311: ...s to set up once a library of components is saved future printed circuit boards can be programmed with the greatest of ease 1 Tap New Profile to ensure that the workspace is clear of all programmed points 2 Navigate to Profile Options and tap the waypoint icon once to toggle to solder point 3 Swipe Up or Down to scroll to the desired dot parameter that is to be used 4 Tap on an arbitrary location ...

Page 312: ...thin a program Please see the Edit Profile section for more details 9 To navigate to pin 5 in the correct orientation the following values would be used 10 Tap the record button 11 Jog the end effector in the X direction in 2 54mm increments for the next three pins recording a point at each pin 11 1 Dependent on the geometry of the component programmed this may be sufficient for the program If thi...

Page 313: ...rofile Edit Screen 11 4 Swipe up down on the program order until DOT 7 is highlighted 11 5 Tap to reorder the point to position 2 11 6 Swipe up on the Program Order until DOT 4 is highlighted 11 7 Tap to reorder point to position 3 11 8 Repeat this process until the points are programmed in the order shown on the next page ...

Page 314: ...te 12 1 Pro Tip Save the Layout with the name of Solder Parameter Layout to aid in identification of the parameters used and to distinguish from normal solder profiles 13 Once the file name has been entered tap to complete the save 14 Tap the Save button to save the layout Component Based Layout Complete 1 2 3 4 5 6 7 8 ...

Page 315: ...re to do so may produce unfavorable results 31 Verify the Connection Validation Power Supply or RF is in the OFF position 32 Install desired Connection Validation cartridge 32 1 Verification of cartridge at the correct pivot position can be completed by referring to the Tip Alignment section 32 2 WARNING Do NOT turn ON the Connection Validation Power Supply RF after installation of cartridge 33 Ta...

Page 316: ... be soldered centered within Computer Vision viewing area 34 2 If necessary use the quick theta snaps to rotate the end effector 90 to clear any bracketry of end effector from obscuring view 35 Tap the Take Screenshot icon 36 Save the image 36 1 Pro Tip It is good practice to keep the name of the image consistent with the profile to be programmed For example if an Engineer were to program Metcal s...

Page 317: ... O PCBA should be used when taking a screenshot and when saving the programmed pattern 37 Tap the camera icon once more to turn off the Camera 37 1 Icon will return to grey in color 38 Tap the Open Image icon 39 Highlight the desired image by tapping on the file name ...

Page 318: ...cated where the picture was taken 41 Use the jog controls to jog the crosshairs over the first joint that is to be soldered 41 1 Note This must be identical to the first joint within the programmed layout Selecting any other joint will result in Layout insertion off the intended pads 42 Tap the Pattern Recognition button ...

Page 319: ...ermitted 42 3 1 See Image Zoom section for magnification instructions 43 Select the pattern to be recognized by tapping the top left corner of the object to be recognized and swipe diagonally until a yellow box is formed around the desired pattern 43 1 Note Pattern selection MUST occur around component in which the crosshairs are located Insert Pattern Coarse Adjust Filter Adjust Neg Filter Adjust...

Page 320: ...a selected a new box may be created using the same method previously mentioned 43 3 The system will automatically detect the number of identical patterns per previously established filter percentage 44 If needed adjust the Computer Vision increase the filter until all patterns are recognized ...

Page 321: ...RSS 1000 CVSI 7000 5970 Rev A page 321 of 396 44 1 In the event the filter is too large and unintended objects are identified decrease the filter percentage 45 Tap the Insert Pattern button 46 Tap the Layout button ...

Page 322: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 322 of 396 47 Once the Layout button is highlighted tap Select File 48 Select the desired template to be inserted ...

Page 323: ...49 Tap the Open Icon 49 1 The Layout name will now be displayed within the green box below Select File 49 2 Tap to cancel 49 3 Tap to proceed with Layout insertion 50 The Smart Interface System will automatically insert the Layout onto all recognized patterns ...

Page 324: ... will illuminate blue signaling that the Delete Pattern function has been activated 51 2 Once active tap the patterns that are to be removed 51 2 1 In the event a pattern was deleted on accident repeat steps 16 21 51 3 Once all desired patterns have been removed tap the Pattern Recognition button to turn the feature off 51 3 1 The Icon will return to its original grey color 52 Tap to enter the Edi...

Page 325: ...3 If any changes are to be made to the Parameter proceed with any changes otherwise skip to the next step 54 Tap to reach the Profile Edit Screen 55 Tap the box to the right of Z Value and below Point 1 55 1 Once selected the box will illuminate to a neon green ...

Page 326: ... height of the fixture is unknown use the following steps otherwise skip to Step 28 56 2 Tap the Motion Control icon to access the motion controls 56 2 1 The motion controls will now appear in place of the scroll wheel 56 3 Tap the numerical box below the Snap button 56 3 1 The box will become highlighted once selected ...

Page 327: ...value of 5mm 56 5 Tap the Z Axis down button to begin jogging the end effector down toward the PCBA in 5mm increments 56 6 Once the Solder Tip has reached 5mm above the PCBA change the snap value to 0 2mm and carefully continue to jog down until the tip contacts the surface of the substrate ...

Page 328: ...000 CVSI 7000 5970 Rev A page 328 of 396 56 7 Tap the Record Z button 56 7 1 The numerical box to the right of Z Value will automatically be populated with the current height of the end effector 56 8 Proceed to Step 28 ...

Page 329: ...profile before going into production In some cases patterns may be recognized close to the corners of the camera viewing area where the curvature of the camera combined with parallax error may give the false impression of the actual distance of objects In such cases points on an image may appear in the programmed location but physically may be in another location altogether For this reason it is b...

Page 330: ...iously taken will no longer have the correct scaling factor thus making jog commands using images inaccurate This option should only be used as a last resort or prior to creation of any profiles 1 Tap the Camera Icon to enable the Computer Vision Camera 1 1 Note The icon will illuminate blue when active and an image should appear in the workspace 2 Jog to a position where the fixtured printed circ...

Page 331: ... Loosen the bottom locking thumb screw to allow for focal adjustment 4 1 2 1 If needed remove the thumb screw focus the lens and place into an alternative locking screw hole 4 1 3 Once in focus tighten thumb screw 5 If satisfied with the image and focus torque the socket head cap screws to 4 5 in lbs Mechanical Adjustment Complete Thumb Screw Alt Hole ...

Page 332: ...p Cleaner assembly consists of two large stainless steel brushes 1 for maximum tip cleaning coverage The properties of the stainless steel minimize the amount of solder fusion to the bristles increasing the life of the brushes As the solder tip enters the Tip Cleaner assembly residual solder on the tip will be brushed onto the Cleaning Tray 2 The tray is held in place with a magnetic catch so remo...

Page 333: ...ns Section 3 1 WARNING Programming a Tip Cleaning Profile with Space Move may result in a collision depending on where the next programmed point of the profile is located Best practice is to program the Tip Cleaning Profile with Interpolation move 4 Jog the end effector in the X Axis to the entrance of the Tip Cleaning assembly 5 Tap the Record Button to establish the first point of the cleaning z...

Page 334: ... effector until the end of the cleaning zone is reached 7 Tap the Record Button once at the end of travel 8 Return to the entrance of the Tip Cleaning assembly 9 Tap the Record Button to establish the exit point 10 Tap the Save Icon on the Main Menu Bar to Save the Profile ...

Page 335: ...n of TCP at the beginning of the name to designate the profile as a cleaning profile to easily identify it when the time comes to select a cleaning profile covered later in this section In the example below TCP 1 was given as the name of the profile 11 Tap the Save icon Tip Cleaning Profile Setup Complete ...

Page 336: ...ify the Waypoint Icon is Active in the Profile Options Section 3 Verify the Interpolation Icon is active in the Profile Options Section 3 1 WARNING Programming a Tip Cleaning Profile with Space Move may result in a collision depending on where the next programmed point of the profile is located Best practice is to program the Tip Cleaning Profile with Interpolation move 4 Jog the end effector in t...

Page 337: ... was chosen merely for instructional purposes 6 3 To program the path above use the following steps 6 3 1 Tap the Motion Control Icon to toggle to the Fine Adjustment motion controls 6 3 1 1 The following menu should be visible 6 3 2 Enter 8mm in the Z Axis and tap the Up Icon 6 3 3 Tap the Record Button 6 3 4 Enter the following values tap their respective directions 8mm 3mm 16mm 8mm 90 Visual Re...

Page 338: ... 338 of 396 6 3 5 Tap the Record Button 6 3 6 Enter 8mm in the Y Axis and 5mm in the Z Axis fine adjustment 6 3 7 Tap the Record Button 6 3 8 Enter 8mm in the Z Axis and tap the Down Button 6 3 9 Tap the Record Button Visual Representation of Path ...

Page 339: ...3 1 5 3 9 6 3 13 Tap the Save Icon on the Main Menu Bar to Save the Profile 6 3 14 Pro Tip Give the profile name a designation of TCP at the beginning of the name to designate the profile as a cleaning profile to easily identify it when the time comes to select a cleaning profile covered later in this section In the example below TCP SAE was given as the name of the profile Visual Representation o...

Page 340: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 340 of 396 6 3 15 Tap the Save icon Advanced Tip Cleaning Profile Complete ...

Page 341: ...main as the cleaning profile until a new profile is selected Therefore it is imperative that the user be diligent when programming the cleaning profile and verify that cleaning profile implemented will be compatible with the solder profile selected Cleaning will occur at the beginning of every profile as well as the programmed frequency for solder points and solder lines In addition for every tran...

Page 342: ... for the user to establish the start location of the TCP The start location can be established at any point within the working envelope 400mm x 400mm x 100mm x 300 X Y Z Θ The coordinates of the current TCP start location are displayed directly beneath the icon Establishes length of solder that is to be retracted back into feeder tube during tip cleaning Depending on the position of the feeder tub...

Page 343: ... 3 1 In this example TCP Mr Clean rbt is used as the Tip Cleaning Profile 4 Tap the Open Profile Icon to proceed with loading of the Tip Cleaning Profile 4 1 WARNING Tapping of the Open Profile Icon will immediately send the robot to the home position Please clear the working envelope of any obstructions or limbs before sending the command ...

Page 344: ...ition the end effector at the start of the cleaning profile by entering the coordinates recorded from either step 4 1 from either the basic or advanced tip cleaning profile setup procedures in their respective locations in the Absolute Move menu 6 Tap the Record Tip Cleaning Profile Start Location button to establish the start location of the Tip Cleaning Profile ...

Page 345: ...d into the solder tube assembly during the cleaning zone 9 1 This information will only be known once the solder feeder tube assembly is adjusted in the desired location 9 2 With the iron hot solder should be fed until the solder wire contacts the tip 9 3 After contact is made use a pair of calipers to measure the length from the solder feeder tube to the tip of the un melted solder wire 9 4 Enter...

Page 346: ...cur when one of two events happens 1 The programmed Tip Cleaning Profile Start Location is incompatible with the selected Tip Cleaning Profile 2 The selected Tip Cleaning Profile is incompatible with the programmed Tip Cleaning Profile Start Location At first glance it appears that the two events are one in the same which is partially true The main cause is that a point or multiple points from the...

Page 347: ...ice between one or the other should be based off the application Use the following table to help decide whether to change the start location or the TCP Reprogramming Decision Guide Changing the TCP Start Location Changing the Points Within TCP 3 Points Are Out of Bounds 3 Points Are Out of Bounds TCP is very complex Obstructions Prevent New Start Location TCP Provides Ideal Cleaning TCP Contains E...

Page 348: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 348 of 396 3 Tap the Tip Cleaning Profile in question 4 Tap the File Open Icon to open the TCP ...

Page 349: ...p the Edit Profile Icon 5 1 The Edit Screen will appear as shown below 6 Tap the Point Edit button 7 Swipe up or down to scroll to first point in question 7 1 Note Waypoints will be identified as MOVE 7 2 The point under edit will be highlighted with a yellow band ...

Page 350: ...this would imply that the Tip Cleaning Profile Start Location was programmed at 390mm in the X Axis This is because the programmed point is at 390 007 in the X Axis but identified as out of bounds at 400 007 There is a 10mm shift to the right in the X Axis A shift can only occur if the TCP Start Location is programmed in a location differing from the start location of the TCP In this case it was p...

Page 351: ...ev A page 351 of 396 11 Swipe up to scroll to the next point 12 Using the same logic in step 12 the next X Value selected would be 384 5 13 Tap the Confirm Changes icon to proceed with the modifications 14 Tap the Save Icon to save changes ...

Page 352: ...isting Tip Cleaning Profile and tap Save to overwrite the previous Tip Cleaning Profile 16 Tap Open Profile icon on the Main Menu Bar to open the desired Solder Profile 17 Navigate to the Toolbar and select the Tip Cleaning Settings Icon 18 Tap the Open Tip Clean Profile button ...

Page 353: ...pen Icon to open the TCP 21 Tap the Confirmation button to proceed with the changes made 22 Tap the Run Icon to test the TCP and verify that all points were re programmed correctly and that the tip cleaning is sufficient for the intended application 22 1 If the profile is not to the operator s satisfaction repeat the steps listed within this procedure until the desired TCP is achieved Editing a Cl...

Page 354: ...lf Therefore this procedure will solely describe how to set a custom cleaning start location Please take careful consideration when selecting the new cleaning profile location Failure to do so may result in damage to the unit Below is the setup that will be used in this example 1 After the desired Tip Cleaning Profile is created and loaded tap the Absolute Move icon to position the end effector at...

Page 355: ...olbar tap the Motion Control icon once to toggle to Fine Adjustment 4 Enter 65mm in the Z Axis controls and tap the down arrow 5 Tap on the Tip Cleaning Settings Icon 6 Tap the Record Tip Cleaning Profile Start Location button to establish the start location of the Tip Cleaning Profile Custom Cleaning Location Programming Complete ...

Page 356: ...it is best to inspect the brushes after every shift and use good judgement to determine whether they should be replaced When the time comes for replacing brushes use the following steps 1 Put on PPE 1 1 Puncture Resistant Safety Gloves 1 2 Safety Glasses 2 Remove Tip Cleaning Assembly cover 3 Grasping from the back side of the bristles as indicated by the arrow slide the brushes toward the front o...

Page 357: ...page 357 of 396 4 Repeat for the other side 5 Insert the new stainless steel brush with the bristles facing inward and brush backing fitting within the holding feature of the Tip Cleaning Assembly base 6 Push until each brush contacts the stop ...

Page 358: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 358 of 396 7 Repeat for other brush 8 Reassemble lid Brush Replacement complete ...

Page 359: ...en must be purchased from a reputable supplier FUME EXTRACTION For the safety of the operators and working environment Metcal offers a full line of solder fume extractors From volume to bench top fume extraction Metcal has systems to purify the air by filtering harmful smoke and particulates from the working area However the RSS 1000 CVSI can be used with any fume extraction device that attaches t...

Page 360: ...sed as a means increase soldering performance when compared to conventional soldering N2 reduces oxidation during the soldering process thus increasing tip life and protecting components being soldered In addition it can reduce the amount of dross that can occur during soldering An added benefit is that nitrogen is environmentally neutral or in other words will not react with other elements Theref...

Page 361: ...t consumes a significant amount of N2 but also decrease fatigue life of tubing Once the input air has been connected to the system N2 can be toggled ON OFF via the Smart Software Once logged into the software navigate to the Toolbar at the right hand side of the work area Tap the N2 icon once to activate the flow The icon will illuminate to the gold color shown below Tap the N2 icon once more to d...

Page 362: ...x to the left of the keypad until the parameter that is behaving slowly is highlighted by the yellow ribbon Increase the speed by entering the desired value in the blue green box to the right of the yellow Speed box Tap the checkmark to proceed with the changes Don t forget to save the profile if satisfied with the changes Parameter acceleration programmed too low Within the edit program window se...

Page 363: ... cycling power does not clear error code contact Metcal Customer Support 5 Open Appears On CV Display No Cartridge Detected Loosen set screw in end effector or cartridge lock to readjust soldering cartridge so that the connector engages when inserted within end effector CV H8 AV Cable Worn Replace CV H8 AV Cable Instructions can be found here 6 Temp Appears On CV Display Power Supply is Overheatin...

Page 364: ...er feeder is designed to only work with the designated solder diameter Use of any other solder diameter will result in jamming No solder is in the feeder The Solder Feeder is equipped with a switch to detect the presence of solder In the event no solder is detected an indicator will appear in the CV menu 2 No Solder Feeder Motor Movement Solder Feeder has become unplugged at head Plug in connector...

Page 365: ... entire workpiece Choose an installation location in which lighting is controlled Dirt Debris Markings on workpiece The software will identify features with dirt debris or markings as completely separate features than those that are perfectly clean Therefore keep all workpieces visually clean by cleaning with isopropyl alcohol or appropriate cleaning solution Do NOT mark workpieces with tape or pe...

Page 366: ...a China Metcal a division of OK International 4th floor East The Electronic Building Yanxiang Industrial Zone High Tech Road Guangming New District Shenzhen P R C Tel 86 755 2726 6366 Fax 86 755 2329 5492 Email china okinternational com Sales Support Japan Sales 81 198 22 7928 Service 81 03 4520 9629 Fax 81 03 6745 1439 Email India Division of Dover India Pvt Ltd India Tel 91 9762452474 Email dran...

Page 367: ...ble Chain X X X Tip Cleaner Tray X X X X Tip Cleaner Brushes X X X X X Top Plate X X X Lubrication Linear Guides X X X Y X X Z X X Inspection of Cables Unit Power X X X X X CV Power X X X X X All Connections Pages 15 17 X X X X X As Needed Dependent on Usage WARNING Lubrication of Z θ Axes require disassembly of Computer Vision System Disassembly of Computer Vision System may require recalibration...

Page 368: ...ea X X X X X Fans X X X X Functionality of Key Components Contact Technical Support for Malfunctions Emergency Stop X X X X X Lighting Controls X X X X X Fans X X X X X Soldering Iron X X X X X Touch Screen X X X X X CCD Camera X X X X X Computer Vision Camera X X X X X ...

Page 369: ...pically damage due to wear over time will likely occur at the strain relief as indicated by the arrow In the rare event a failure occurs within the CV H8 AV itself the software will display both the Error and Open error codes within the CV Display as shown below These error codes in addition to the NCC may flash on off indicating an intermittent signal A lack of performance with a brand new CV sol...

Page 370: ... of 396 1 Remove CV Cartridge if any from the assembly by rotating the cartridge lock 90 counterclockwise 1 1 Pull out from the assembly once in the correct orientation 2 Use an M2 hex key to loosen the set screw of the Spring Retainer on the CV H8 AV ...

Page 371: ...ut of the Solder Wire Feeder to remove the Solder Wire Feeder tubing 4 Carefully cut all cable ties along the path of the CV H8 AV cable 4 1 Take careful note where cable ties are placed as the locations have been chosen for optimal flexibility while minimizing the risk of binding and decreasing fatigue life of strain relief ...

Page 372: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 372 of 396 5 Remove the cable from the assembly and place CV H8 AV on gantry until it is fully disassembled from unit ...

Page 373: ... the four M3 pan head machine screws and remove the washers of the CV Power Supply enclosure at the rear of the unit 7 Lift off the lid of the enclosure to gain access to the connectors of the CV H8 AV 8 Disconnect the CV H8 AV from the two ports of the CV Power Supply ...

Page 374: ...d by grasping each side and lifting in the direction coaxially to the connector 8 2 The RF Connector bottom port can be disconnected by unthreading the connector and lifting in the direction coaxially to the connector 9 Discard the old CV H8 AV responsibly 9 1 Do NOT trash send out for proper electronics recycling ...

Page 375: ...RSS 1000 CVSI 7000 5970 Rev A page 375 of 396 10 Feed the new CV H8 AV cables through their respective cutouts on the cover 11 Connect the 6 Pin Mini DIN Plug to the top port and the RF connector to the bottom port ...

Page 376: ...000 5970 Rev A page 376 of 396 12 Seat the CV Power Supply enclosure lid and fasten the four M3 pan head machine screws and washers 13 Route the CV H8 AV cable along the path shown in Step 6 replacing all cable ties along the way ...

Page 377: ...der Rotate clockwise to secure in place 15 Tap the Home Button to ensure the End Effector is positioned at 0 0 0 0 X Y Z Θ 16 Slowly and carefully jog the End Effector down in the Z Direction towards the calibration fixture stopping at roughly 5mm above the fixture 17 Tap the Motion Control button to toggle to the fine adjustment menu ...

Page 378: ...rtridge gently contacts the fixture 18 1 Please note that the orientation of the cartridge will likely no longer be aligned at this point and or out of position in the X Axis DO NOT loosen set screw of the Cartridge Lock to account for orientation or position issues see next step 19 Slide the Spring Retainer of the CV H8 AV down until a sufficient amount of pressure has been applied to the End Eff...

Page 379: ...1 Use an M2 hex key to torque the set screw of the Spring Retainer once in place 19 1 1 Torque to 1 4 N m 19 0 in lbs 20 Remove cartridge lock and reinsert 20 1 If the required force is too great for comfort unfasten set screw and repeat Step 27 otherwise proceed ...

Page 380: ...r signal is received loosen the set screw and repeat steps 27 28 with greater spring force than previously applied 21 1 1 Restart the system via the power switch on the front of the unit 21 2 If no errors appear proceed to next step 22 Reconnect the Solder Wire Feeder tubing and hold in place with locking nut CV H8 AV Replacement Complete ...

Page 381: ...ts Part Number Description AC RSS 05 SWFKIT Solder Wire Feeder Kit Ø 0 5 MM AC RSS 06 SWFKIT Solder Wire Feeder Kit Ø 0 6 MM AC RSS 08 SWFKIT Solder Wire Feeder Kit Ø 0 8 MM AC RSS 10 SWFKIT Solder Wire Feeder Kit Ø 1 0 MM AC RSS 12 SWFKIT Solder Wire Feeder Kit Ø 1 2 MM All kits can be adapted to any unit with a few simple steps Use the following procedure to change out the Solder Wire Feeder to ...

Page 382: ...the set screw and remove top alignment funnel 4 Using an M1 5 hex key turn the mounting screws of Solder Wire Detection switch counter clockwise 4 1 Do NOT remove screws completely as this will require disassembly of Solder Wire Feeder to gain access to nut plate to which the screws are fastened to ...

Page 383: ...VSI 7000 5970 Rev A page 383 of 396 5 Use an M1 5 Ball End L Key to loosen the set screw and remove bottom solder alignment funnel 6 Loosen locking nut of the solder wire feeder assembly and pull down to remove from assembly ...

Page 384: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 384 of 396 7 Loosen lucking nut of the solder wire feeder tubing adjustment assembly 8 Pull tubing from back side ...

Page 385: ...e tube from front side 10 Use a M1 5 hex key to loosen the 2x set screws of retaining ring until set screws begin to protrude from the driving gear 10 1 Pro Tip Reduce speed of solder wire feeder to 2 mm s and tap the Pulse Solder Feeder Forward button until the other set screw is accessible ...

Page 386: ...ER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 386 of 396 11 Remove retaining ring 12 Remove feed gears 12 1 Note Gears will both come out at the same time 13 Fit the new feed gears together as shown below ...

Page 387: ...all feed gears with the larger diameter wheel on the left and with the gear teeth facing down 15 Place retaining ring onto post of the left feed gear and torque set screws to 0 4 N m 3 5 in lbs 16 Insert new solder alignment funnel on the bottom and torque set screw ...

Page 388: ...e top and torque set screw 18 Adjust Solder Wire Detection switch such that the arm of the switch lies in the solder path 18 1 Test location by inserting solder through the top funnel to confirm solder activates switch 18 2 There will be an audible click when the switch has been properly engaged ...

Page 389: ...screws of Solder Wire Detection switch 20 Slide locking nut of solder wire feeder over the new tubing with the raised feature of the locking nut facing away from the tubing 21 Insert tubing until there is about 1mm of clearance between the tubing and the Solder Wire Feeder gears ...

Page 390: ... A page 390 of 396 22 Insert bottom portion of guide tubing through the locking nut of the Solder Wire Feeder Tubing Alignment assembly 23 Insert the nozzle tubing through the underside of the assembly 23 1 Tighten locking nut once in place ...

Page 391: ... made with the feed gears 25 Tap the Pulse Solder Feeder Forward button within the solder feeder options menu to feed solder through tubing until it comes out through the nozzle 25 1 The solder may need to be pushed further into feed gears by hand in order for the gears to bite into the solder to feed it forward ...

Page 392: ...cement fuses can be purchased from any electronic components distributor as long as they meet the following specifications required for the robot Fuse Specifications Attribute Value Fuse Type Fast Blow Fuse Dimensions Ø 5 mm x 20 mm LG Voltage Rating 250 VAC Current Rating 2 A Mounting Style Holder Clip Termination Style Clip 1 Toggle the main power switch to the OFF position OFF ...

Page 393: ...ER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 393 of 396 2 Unplug the main power cord 3 Using a flat head screwdriver pop open fuse box clip 4 The unit comes equipped with one spare fuse shown by the arrow ...

Page 394: ...USER MANUAL RSS 1000 CVSI 7000 5970 Rev A page 394 of 396 5 Remove blown fuse 6 Push out the spare fuse using a flat headed tool 7 Place the new fuse in the clip as shown ...

Page 395: ...1000 CVSI 7000 5970 Rev A page 395 of 396 8 Insert the fuse box clip with the fuse image facing the outside of the machine 9 Push clip all the way in until seated 10 Plug in main power cord Replacement of Fuse Complete ...

Page 396: ... immediately to ensure the highest quality soldering Use the following pictures to identify a good cartridge from one that may be in need to be replaced Thank you for reading our manual Don t forget to visit our website for the latest in soldering as well as keeping up to date on the latest software and manual for the RSS 1000 CVSI Robotic Soldering System http www okinternational com metcal Good ...

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