Manual placement system MPL3100 for BGA, CSP and Fine-Pitch components Part No: MPL3100BA1.0e Issue Date: 02/2001
You have opted for an ESSEMTEC MPL3100 pick and place system. We thank you for this decision and congratulate to it. Your device was manufactured according highest quality standards and was tested thouroughly before shipment. It is very easy in operation, neverthless we suggest to read this manual before operating the machine. If you have any additional questions to your equipment, please don't hesitate to contact: ESSEMTEC AG Mosenstrasse 20 CH - 6287 Aesch / LU Switzerland Tel. ++41/(0)41 919 60 60 Fax. ++41/(0)41 919 60 50 Email info@essemtec.com Web www.essemtec.com or your nearest authorized ESSEMTEC distributor: Page 2 of 18 Operation manual MPL3100 Version 1.0
TABLE OF CONTENT Page 1. INTRODUCTION 1.1 Delivered items 4 2. TECHNICAL DATA 2.1 Dimensions 4 2.2 Technical overview 5 2.3 Required monitor specifications 5 3. SECURITY ADVICES AND NOTES 3.1 General 6 3.2 Safety Advices 6 4. INSTALLATION 4.1 Unpacking / Installation 7 4.2 Connections (backside of unit) 7 4.3 Connections vision box (backside of unit) 8 4.4 Connection of placement arm (backside of unit) 8 4.5 Connection of vacuum 9 4.6 Connection of ESD wrist strap 9 4.7 Switch on the system 9 4.8 Inserting the PCB fixture 10 5. CALIBRATING THE SYSTEM 11 6. OPERATING THE SYSTEM 6.1 PCB fixture 12 6.2 Pick up a component 12 6.3 Operating the vision box 13 6.4 Pre align a component 14 6.5 Align a component 14 6.6 Adjust illumination 15 6.7 Adjust zoom 15 6.8 Adjust focus 15 6.9 Placing the component 15 6.10 Setting the x/y-table to zero 16 7. WORKING WITH OPTIONAL SPLIT OPTIC CASSETTE 16 8. MAINTENANCE PLAN 18 9. OVERVIEW SPARE PARTS AND OPTIONS 9.1 Available options 17 9.2 Spare parts 17 10. WARRANTY 17 Page 3 of 18 Operation manual MPL3100 Version 1.0
1. INTRODUCTION The MPL3100 systems provide you a modular placement system for todays needs in electronic rework and placement applications. The machine is available in combination with EXPERT-LINE SMD pick and place system to offer a complete solution for prototyping. 1.1 DELIVERED ITEMS Your MPL3100 delivery includes the following items: - Base system (complete with control, arm, vacuum pick and place head, housing, x/y-table, standard vision cassette) - PCB fixture (mounted on base system) - external vacuum pump (depending of order in 220-230 V or 100-110 V) - Vacuum nozzle 10 mm - Vacuum nozzle 4 mm - Keyboard - calibration plate with calibration nozzle - power supply cable - set of tools for calibrating the system Optional included is (if ordered): - Split optic cassette (separately packed) 2. TECHNICAL DATA 2.1 DIMENSIONS: Page 4 of 18 Operation manual MPL3100 Version 1.0
2.2 TECHNICAL OVERVIEW Weight: Power supply base unit: Power supply vacuum pump: Placement force: 21 kg 100 230 V 50/60 Hz 100-110 V 50 Hz or 220-230 V 60 Hz approx. 1.5 N (upon vacuum switch is released) 2.3 REQUIRED MONITOR SPECIFICATIONS To operate the system properly a monitor with the following minimum specification has to be provided (the monitor is not delivered with the system) Horizontal resolution Monitor type Signal type Connector type required minimum 470 TV lines Colour (black and white not recommended) PC (with high class frame grabber) Flat screen PAL composite (FBAS) Cinch NOTE: If a low cost monitor is used it may influence the quality of the image. This may make the alignment of Fine-Pitch components more difficult. Page 5 of 18 Operation manual MPL3100 Version 1.0
3. SECURITY ADVICES AND NOTES 3.1 GENERAL In this manual security advices are indicated as follows: ATTENTION: Please make sure that these information are followed strictly Notes and general advices are marked as follows: NOTE: Hints and practical tips are marked as follows: TIP: 3.2 SAFETY ADVICES ATTENTION: Never open the device without having completely taken out the power plug from your power supply. ATTENTION: The placement head is equipped with a motorised z-axis. Make sure that no hands are within the movement area. When the up/down key on the keyboard is released the movement stops immediately. NOTE: The MPl3100 placer is a sophisticated mechatronic system. Therefore any changes on the mechanics or the electronics may put the system in the a mode where the machine is no longer able to full fill the specifications. Therefore, do not change anything on the system. Contact your nearest ESSEMTEC representative for any questions you might have. Page 6 of 18 Operation manual MPL3100 Version 1.0
4. INSTALLATION 4.1 UNPACKING / INSTALLATION Please check before unpacking the system if any transportation damage is visible on the outside of the packing. Please inform your freight forwarder immediately about any visible damage. Your system is delivered according the ordered specifications. Place the base system onto a stable table with enough room in the back for a free vision box movement. 4.2 CONNECTIONS (BACKSIDE OF UNIT) Connect the machine as follows: Connection for the monitor Connection for camera of the vision box Connection for an external second camera 24 V DC for placement head power supply Connection for control cable of placement head 12 V DC for vision box power supply On/Off switch Power plug (please check the voltage before plug in!) Plug for connection of vacuum pump ATTENTION: Please make sure the input voltage is the same as the vacuum pump voltage before plugging in both cables. View of connected backside Page 7 of 18 Operation manual MPL3100 Version 1.0
4.3 CONNECTIONS VISION BOX (BACKSIDE OF UNIT) Power supply for placement head. The only connector on this part is an RS232 which is used for programming the camera with an external software. This connector is only used for factory adjustments. Camera connection going to Video 1 In Connection going to 12 V DC plug 4.4 CONNECTION OF PLACEMENT ARM (BACKSIDE OF UNIT) Cable and vacuum tube from the pick and place head Power supply placement head Connection for keyboard Connection for camera control (coming from vision box) 4.5 CONNECTION OF VACUUM The vacuum is generated by an external vacuum pump. To avoid vibrations we recommend to place the pump below the table or away from the placement system. By plugging the vacuum pump directly to the MPL3100 placer it is switched on and off directly with the complete system. Switch on the vacuum pump Put the vacuum level to the maximum Attach the vacuum tube which is coming from the placement head to the vacuum out plug (simply slide the tube onto it) NOTE: In the delivery is a filter included. Use this filter if the machine is installed in an area where there is dust in the air. Simply put it between two pieces of the black tube. Page 8 of 18 Operation manual MPL3100 Version 1.0
4.6 CONNECTION OF ESD WRIST STRAP For ESD safety a earthing wrist strap can be attached to the system. 4.8 SWITCH ON THE SYSTEM On the backside of the unit (right side) the power switch is located. Switch on the system and move the head in the most upper position by pressing on the keyboard the button HEAD UP 4.9 INSERTING THE PCB FIXTURE The PCB fixture is packed separately below the base unit. Take it carefully out and unscrew on one side of the rail the stopper. Turn it around to have the movable PCB fixture bars on top. Slide the rail into the ball bearing guidance. There is a small resistance to overcome as the ball bearing unit has been pre tensioned in the factory. A fixing screw is located at the front side. It is recommend always to lock the PCB fixture rail when placing components. Page 9 of 18 Operation manual MPL3100 Version 1.0
When starting working with the machine we recommend to move the two PCB fixture bars approximately in the centre. For sliding the two PCB fixture bars, open the black thumb screws NOTE: Please make sure that the machine is on ambient temperature before using it for calibration or production. Page 10 of 18 Operation manual MPL3100 Version 1.0
5. CALIBRATING THE SYSTEM Due to vibrations during the transport it might be necessary to calibrate the system after installation. The same procedure can be used to check the system if the calibration is okay. Target of the calibration is to align the mechanic axis precisely to the optical axis. To do: A. CHECKING THE CALIBRATION 1. insert the calibration plate into the PCB fixture 2. replace the vacuum nozzle with the calibration nozzle 3. lower the placement head by using the motorized lowering 4. lower the calibration nozzle manually until the nozzle fits exactly into the precise hole within the calibration plate Use the x/y-table for finding the hole. Do not apply any pressure to the calibration plate or nozzle. Move the nozzle up and down to verify that the nozzle fits the calibration hole. 5. Move the head completely up with the motorised function 6. Check the image on the monitor If the image is not exactly fitting (nozzle/hole) the system has to be realigned as follows: BAD GOOD B. ADJUSTING THE ALIGNMENT 1. open the screw of the vision box fixation on both sides 2. on top of both screws are small hex screws located adjust those until the image on the monitor is as shown as GOOD. 3. Tighten the vision box fixation screws properly 4. do the check again as described under point A if necessary. NOTE: It might be necessary to toggle between the two adjustments screws to get the image correct. Page 11 of 18 Operation manual MPL3100 Version 1.0
6. OPERATING THE SYSTEM 6.1 PCB FIXTURE The MPL3100 system is equipped with a moveable PCB fixture. This allows to position the board prealigned below the placement head. A blocking function allows to lock the movable holder in place for avoiding unwanted movements. Both side rails of the PCB fixture can be adjusted. One of the two sides is equipped with a spring loaded PCB clamping system. open here to adjust position of the rails. Hold with thumb and forefinger the slider and bring it to the desired position. Slide the PCB in and out from the front. NOTE: Do not attach the right slider to narrow to the board, so the spring loaded clamp can work properly. 6.2 PICK UP A COMPONENT Place the component with a vacuum pen into the centreing station on the left side of the PCB fixture. Page 12 of 18 Operation manual MPL3100 Version 1.0
Lower the placement head by using the motorised function. NOTE: For safety reasons the button for moving the head up and down has to be pressed continously. Lower the head always completely up and completely down Bring the nozzle manually down by using fine-adjustment z-height knob on the right side of the placement head. When the Vacuum LED on the placement Head is switched on, the z-axis can be Manually highered. Move then the placement head up by using the HEAD UP button on the keyboard NOTE: Depending the height of the Component it might be necessary to adjust the fixing height of the vacuum nozzle. Use the hex screw driver which is included in the tool set. 6.3 OPERATING THE VISION BOX Move out the vision box completely by holding it here. When completely pulled out the camera image is displayed on the monitor. The knob with the red illumination indication is used for adjusting the light intensity for the component bottom side. The knob with the green illumination Indication is used for adjusting the light intensity for the PCB surface side. Page 13 of 18 Operation manual MPL3100 Version 1.0
6.4 PREALIGN A COMPONENT After picking up the component, you can see the bottom side of the component superimposed over the grid of the centering station. Pre-Adjust the rotation of the component on the rotation knob on the placement head of the component by using the grid within the centering station. 6.5 ALIGN A COMPONENT Move the PCB under the vision system. Position the placement position roughly in the centre of the camera image. You see now the board surface as well as the bottom of the component. Lock the movable PCB fixture in this position. As there are differences in component heights the component bottom side has to be adjusted to the same optical axis as the PCB surface. For doing this use the manual fine-adjustment z-height. TIP: Adjust the PCB so that you may see on one side of the component the leads/balls of the component directly beside the related pads of the PCB. Lower or higher now the component until component and pads are displayed in the same grid size. Fine-tune now the x/y-axis by using the integrated micrometer table, till you get a perfect fit. TIP: When working with BGA s you may use after fine alignment the CAM PRESET 2 function to zoom closer for verification if the alignment is perfect. Page 14 of 18 Operation manual MPL3100 Version 1.0
6.6 ADJUST ILLUMINATION Adjust the red and green illumination to get best possible contrasts. NOTE: Do not position the placement system close to a window or within a highlighted working area as side illumination may influence the contrast of the image. 6.7 ADJUST ZOOM The system is equipped with two preset zoom areas. The first preset is covering the maximum possible component size 40 x 40 mm. The second preset is set to 15 x 15 mm which IS mainly used for CSP s or if working with the optional split optic cassette. When working with the manual zoom function (+/-), a third preset is automatically stored when switching off the system (saves the last used manual zoom stage). 6.8 ADJUST FOCUS The focus of the system may be manually adjusted to overcome differences in PCB heights and different zoom factors. 6.9 PLACING THE COMPONENT When the component is properly aligned on the vision system, push back the vision system completely. You will hear a click and the camera image is switched off. Only in this position the head can now be lowered motorized. Press for doing this the HEAD DOWN button on the keyboard. Page 15 of 18 Operation manual MPL3100 Version 1.0
Lower now the component slowly to the surface of the PCB. Watch the LED indication on the pick-and place head carefully. As soon as the LED is switched off, stop lowering the z-axis and rotate the lowering knob into the other direction. NOTE: The applied placement force is around 1.5 N, which is the same force automatic SMD pick and place systems apply. By lowering further after the vacuum is switched off you may apply more placement pressure for special components (if needed). 6.10 SETTING THE X/Y-TABLE TO ZERO POSITION It is recommended to set the x/y-table always to its centre position. On the micrometer adjustment knobs two red rings indicate approximately the centre of the table. Another possibility is to move the PCB fixture below the vision system (pulled out) so the pick-up pin is located in the centre of the image. Adjust then the x/y-table till the centre of the nozzle fits the centre of the grid. 7. WORKING WITH OPTIONAL SPLIT OPTIC CASSETTE For placing large Fine-Pitch components, an optional split optic cassette is available. It can be inserted at the place of the standard cassette which comes with all systems. First, take out the standard cassette by opening the locking. Take then the cassette carefully out by Holding it on the handle. Page 16 of 18 Operation manual MPL3100 Version 1.0
Move the vision box in a middle position where you can lift out the cassette. Insert the split vision cassette with the label front to the front and slide it into its place. Fix the cassette by locking it with the locking screw. The split optic cassette is equipped with a high precision mirror system which allows to magnify two corners of a component for a precise alignment. Due to the optical nature of such a system you may only see in a part of the monitor the magnified leads/pads. NOTE: Only square components can be viewed with this system. Page 17 of 18 Operation manual MPL3100 Version 1.0
8. MAINTENANCE PLAN The following maintance tasks have to be effected as described. If not effected the warranty on a system can be limited. Tasks Daily Weekly Monthly Clean the system from solderpaste, dust X Clean the prism system with glas cleaner X Grease the tooth rail with machine grease X Use an oil towel for cleaning the PCB fixture rail X Use an oil towel for cleaning the two head rails X 9. OVERVIEW SPARE PARTS AND OPTIONS 9.1 AVAILABLE OPTIONS Splitoptic cassette for edge view of large components 9.2 SPARE PARTS Nozzle 10 mm diameter Nozzle 4 mm diameter motordrive complete with connectors control board motordrive (mounted from the back in arm system) control board visionbox vacuum switch board placement head Keyboard with connection cable Calibration set complete (calibration plate + nozzle) Vacuumpump 220 230 V Vacuumpump 100 110 V Video cable PL500-Monitor (BNC/Cinch-Cinch) 10. WARRANTY The device was manufactured to highest quality standard. A warranty is granted on the system during 12 months after installation. The warranty is limited to parts exchange only and does not include the visit of a service technician. Also not included are wear out parts, as vacuum nozzles. Page 18 of 18 Operation manual MPL3100 Version 1.0