Onyx-29 AirVac User Manual PDF

ONYX 29
ONYX 29 User's Guide
The information contained in this User's Guide is the property of Air-Vac and shall not be repro-
duced or published to a third party in whole or in part without prior written approval of Air-Vac.
Please read this User's Guide carefully, to insure the optimal start-up and maintenance of the
equipment and to help avoid the possible creation of danger points within the system.
Every effort has been made to ensure that the information herein is complete and accurate.
However, the information in this document is subject to change without notice. Air-Vac assumes
no responsibility for any error or damages resulting from faulty operation or in observance of this
manual.
Trademark acknowledgements:
HexSight, FireBlox and FireView are trademarks of Adept Technologies, Inc.
Microsoft is a trademark of Microsoft Corporation, Inc.
Visual C++, Visual Basic and Visual Studio are trademarks of Microsoft Corporation, Inc.
Windows 2000 and Windows XP are trademarks of Microsoft Corporation, Inc.
Visual Machines is a trademark of Infotech AG.
0029.00.900
General Delivery Terms (GDT)

I. General Provisions 3. Furthermore, Air-Vac reserves the right to cede its
invoices either in whole or part.
1. The present GDT applies to all Air-Vac services as
long as no written differing agreements have been 4. If a customer’s situation deteriorates considerably
made. during the term of an order, Air-Vac has the right to
make its services dependent on a security. If this
2. Customer orders must be made in writing and, in
remains undone, Air-Vac is authorized to withdraw
order to be binding, require an order confirmation
from the contract and to claim the resulting dam-
which only applies to the contents of the agree-
ages.
ment (unless otherwise agreed).
3. Air-Vac retains all rights to proposals, drawings, V. Risk Acceptance
and other documents as long as nothing to the 1. The buyer assumes risk as follows:
contrary has been contractually agreed upon. In a.) for deliveries without setup or installation: from
particular, documents from Air-Vac may only be point of shipping or pick up. Upon request and
made available to third parties after prior approval. at the expense of the buyer, deliveries from
4. The delivered software remains the sole property Air-Vac will be insured against usual transpor-
of Air-Vac, even if license fees have been paid. tation risks.
II. Prices and Methods of Payment b.) for deliveries with setup or installation: on the
day they are taken over in the buyer’s own
1. All prices are net prices in freely available Swiss company, or if agreed upon, after an error free
Franks (CHF) - if there is no other agreement - and probation period.
are ex works excluding packaging. All incidentals,
including taxes, fees, etc. are the responsibility of 2. If the buyer ends up delaying acceptance, then he
the buyer, barring other agreements. assumes all the risk.
2. As long as nothing specific has been agreed upon, VI. Warranty/Guarantee
one third of the purchase price is payable upon or- 1. Air-Vac offers a guarantee period of 12 months
der confirmation, and the balance upon delivery. after the customer accepts responsibility.
3. All invoices must be paid within 30 days of the 2. The customer must check the delivery within 8
invoice date. Discount deductions are not allowed. workdays and register any deficiencies in writing.
For late payments, interest will be charged starting Hidden deficiencies must be registered in writing
st
on the 31 day after the invoice date, without prior within 8 workdays of their discovery. If this is not
reminder. The interest will be at least 4% above done, the goods are deemed to be approved.
the rediscount rate of the Swiss National Bank.
3. Air-Vac must be awarded sufficient time and op-
4. The buyer may only offset such claims that are portunity to correct any deficiencies. If this is de-
undisputed or legally binding. nied, then Air-Vac is released from the warranty.
III. Methods of Delivery 4. The warranty does not cover natural wear and tear
1. The time of delivery begins with the order confir- or damages that occur after responsibility accep-
mation or after clarification of all technical details tance or as a result of incorrect or negligent treat-
and any queries. ment, excessive demand, unsuitable operational
resources, and non-reproducible software errors,
2. For as long as Air-Vac is hindered in executing or among others.
delivering the order due to force majeure, the deli-
very deadline will be suspended. Force majeure 5. Under no circumstances does the buyer have a
also includes serious conditions without fault such claim to compensation for damages that are not re-
as strike, fire, enactments of import embargos, or a lated to the delivery, such as loss of production,
considerable increase of import duties as well as loss of use, loss of orders, loss of profit, as well as
considerable delays by suppliers that are essential other direct and indirect damages. This liability ex-
to executing the order. clusion does not apply to illegal intent or gross
negligence on the part of the supplier.
3. Partial deliveries are allowed, as long as their
acceptance can be expected of the buyer. VII. Court of Jurisdiction and Applicable Law
4. Installation work will be charged separately, unless 1. The court of jurisdiction is Solothurn. However,
agreed upon otherwise. Air-Vac has the right to summon the customer to
his responsible court.
IV. Retention of Ownership and Security
2. Swiss law is applicable (excluding the United Na-
1. Air-Vac retains ownership of its delivery until the tions Convention on Contracts of the International
invoice has been paid in full and is authorized un- Sale of Goods, CISG).
der its own onus to register the reservation with the
responsible registry.
2. In the case of resale, even in an integrated condi-
tion, the purchase price claim counts as being
ceded to Air-Vac. The goods subject to retention of
ownership may not be pledged nor conveyed as a
security.
Art. Nr. 800.00.007 / Version 1.4 (ONYX 29 Series 5) / 10. August 2007 4 -226
POCON T&T CE-Kennzeichnung EC-Declaration of conformity
CE-Zertifikation ONYX 29 Selective soldering system
Arbeitssicherheit
Manufacturer EC-Declaration of conformity
Manufacturer: Infotech AG, Vogelherdstrasse 4, CH-4500 Solothurn

www.infotech-automation.com
Declares, that the design and the condition of the
Type: ONYX 29 Selective soldering system

Description: Semi automated, high precision and multifunctional positioning
and selective soldering system
Serial number: 003.05.153
Certified: 4. February 2009 (according to machinery 98/37/EC)
Validated with 2006/42/EC: 5. November 2009
meets the requirements according to the following EC directives:

Machinery 2006/42/EC,
Low voltage 2006/95/EC,
Electromagnetic compatibility 2004/108/EC,
Pressure devices 97/23/EC,
Noise 2003/10/EC.
Used EN-standards: EN 12100-1, -2 EN 13849-1

EN 13850 EN 13857
EN 547-1 EN 55022/B
EN 614 EN 60204-1, -2
EN 894-2 EN 61000-4-2
EN 983 EN 61000-4-4
EN 1037 EN 14121-1-2
We would like to point out, that the installation and the initial operation of the system has to be per-
formed by our special educated personal. Only special trained personal is allowed to operate the
equipment.
When part of the system is being changed without our agreed permission, this declaration will be-
come invalid.
Solothurn, 5. November 2009 Solothurn, 5. November 2009

Infotech AG Pocon T&T
Ernest Fischer Rainer Fritzius

General Manager Director
Info@pocon.ch / info@infotech-automation.com / www.pocon.ch / www.infotech-automation.com 1 -1

0029.00.900
ONYX29 User’s Guide Chapter 1: Introduction
1: Introduction
1 Introduction ..............................................................................................................................................3
1.1 W ELCOME ...............................................................................................................................................3
1.2 ONYX 29 SYSTEM OVERVIEW .................................................................................................................3
TM
1.3 VISUAL MACHINES ................................................................................................................................6
0029.00.900 1-1
0029.00.900 1-2
1 Introduction
1.1 Welcome
Please read this User's Guide carefully before the initial set-up of the system to insure the optimal
start-up and maintenance of the equipment.
This User's Guide has been compiled in accordance with ISO 9000 and the EC machine guideline
regulations. It contains all information and instructions that are necessary for safe and trouble-free
operation of the ONYX 29 machines.
Considerable time has been spent in an attempt to provide in-depth instructions in regards to the
unpacking, installation, verification, operation and maintenance of this system.
WARNING
HOWEVER, DUE TO THE TECHNICAL COMPLEXITY OF THIS SYSTEM, CERTIFIED PERSON-
NEL MUST BE INVOLVED WITH THE INSTALLATION AND TRAINING OF YOUR NEW SYSTEM.
DO NOT ATTEMPT TO POWER UP THIS SYSTEM WITHOUT AIR-VAC PERSONNEL PRESENT.

This User's Guide must always be kept next to the machine. It is an essential part of the machine.
The safety aspects have been tested in conformance to UL and CE standards.
1.2 ONYX 29 System Overview
Intended use of the ONYX 29 SEMI-AUTOMATED SOLDERING SYSTEM

THE ONYX 29 MACHINE PROVIDES SEMI-AUTOMATED REMOVAL, SITE CLEANING AND
SOLDERING OF ADVANCED TECHNOLOGY COMPONENTS INCLUDING BGA'S, CSP'S, FLIP
CHIP, MICRO-DISCRETES, SURFACE MOUNT CONNECTORS AND FINE PITCH QFP'S AS
WELL AS TRADITIONAL LEADED DEVICES SUCH AS PLCC'S, SOIC'S AND SOCKETS.
THE ONYX 29 MACHINE IS CONFIGURED TO SUPPORT ALL LEAD FREE REWORK

PROCESSES. ALL PERIPHERALS ARE MATCHED TO FULLFILL THE HIGHER TEMPERATURE
AND TIGHTER TOLERANCE REQUIREMENTS.
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Machine overview of the standard Hot Gas System
E
D
A
G
H
F
Item A, B and C: identifies the board carrier and support features

The board carrier has two fixed (A) support arms and two adjustable rails (B) to hold the board.
Both movable arms are spring loaded to allow for board growth during heating cycles.
Front and rear knobs lock the movable arms in place.
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Each movable arm has three (3) sectional supports (C) to hold the edge of the board. These sup-
ports should be positioned to provide maximum support under the targeted component. Move the
sectional supports to the correct position(s) if edge components/clearance is an issue.
Each sectional support has a swinging board lock to secure the board to the carrier.
Bottom supports provide necessary rigidity to prevent board downward warping during the heating
and component placement steps.
The board carrier pivots upward to allow access to the underside of board. This feature simplifies
board support positioning. It is important to position board supports clear of any bottom side com-
ponents. Supports should be directly in contact with the board.
Item D: identifies a handle used to manually position the robot head.

This handle is normally used during robot training. The assembly head can be moved manually.
Note
W HEN MOVING THE ROBOT HEAD MANUALLY, MAKE SURE THE NOZZLE IS AT A SAFE
HEIGHT, OTHERWISE THE NOZZLE AND MACHINE PERIPHERALS MAY BE DAMAGED.
Item E: identifies the hot gas heater.

The hot gas heater generates hot gas (air or nitrogen). The hot gas then is guided into the hot gas
nozzles.
Note
THIS COVER SHIELDS THE HOT GAS HEATING ELEMENT FROM THE OPERATOR. THE HOT
GAS TOOL CAN GET VERY HOT.
Item F: identifies the emergency stop button.

Engage this button if any unplanned motion occurs.
Do not use it to pause a running program. It should be used only in emergency situations.
Item G: identifies the board pre-heater panels.

There are 4 independently programmable heater zones.
Item H: identifies the machine operator panel.

The buttons located on this panel provide optional operator interaction during normal program
execution.
0029.00.900 1-5
1.3 Visual MachinesTM

The VISUAL MACHINESTM Software is used to support the ONYX 29 processes including removal,
site cleaning and soldering. The base software VISUAL MACHINESTM is designed to put the focus on
the application, not the programming. It is an object oriented, modular software environment that
enables rapid implementation of complex motion, vision and process control modules. The soft-
ware uses drag and drop VISUAL WIRES to allow easy application-specific changes.
TM
VISUAL MACHINES provides VIEWS, which represent possible actions the user may select for vari-
ous operations.
The principal views are:
Operating the machine, start and stop of production programs

(Access level OPERATOR and higher)
Creating new or modifying existing production programs

(Access level PROCESS and higher)
Defining the part type specific parameter and processes

Machine and peripheral calibrations

(Access level MAINTENANCE and higher)
Displaying actual states of the machine and the peripherals

(Access level MAINTENANCE and higher)
Machine and peripheral configuration

(Access level ADMINISTRATOR and higher)
Analysis and printing of Thermal Profile Chart/Data

0029.00.900 1-6
Online help, the description of each page can be viewed directly within the page by clicking the
question mark icon (Robo Help).
0029.00.900 1-7
0029.00.900 1-8
ONYX29 User’s Guide Chapter 2: Safety
2: Safety
2 Safety ........................................................................................................................................................3
2.1 GENERAL SAFETY INSTRUCTIONS .............................................................................................................3
2.1.1 NOTES AND W ARNINGS ............................................................................................................................3
2.1.2 BASIC SAFETY INSTRUCTIONS ..................................................................................................................3
2.1.3 APPLICATION SPECIFIC SAFETY ASPECTS ..................................................................................................4
2.1.4 MACHINE WARNING LABELS ......................................................................................................................5
0029.00.900 2-1
0029.00.900 2-2
2 Safety
2.1 General Safety Instructions
2.1.1 Notes and Warnings

This manual contains safety instructions wherever required. These instructions are divided into two
categories as follows:
WARNING
A WARNING INDICATES THAT INOBSERVANCE OF THE INSTRUCTIONS CAN RESULT IN PER-
SONAL INJURY.
Note
A NOTE DESCRIBES SPECIAL ACTIONS, PROCEDURES, INSTRUCTIONS, AND INFORMATION
THAT ARE RELEVANT TO THE SUBSEQUENT SECTION OR STEP. INOBSERVANCE OF THE
INSTRUCTIONS CAN RESULT IN DAMAGE TO THE MACHINE OR TO THE PROCESS MATERIAL.
2.1.2 Basic Safety Instructions

In addition to the safety instructions in this document, the following guidelines must be observed to
prevent personal injuries in general:
WARNING
BECAUSE STRONG MAGNETIC FIELDS ARE ASSOCIATED WITH THE SYSTEM MOTOR COILS
AND MAGNET ASSEMBLY, PERSONS HAVING ACTIVE IMPLANTS (PACEMAKERS, ETC) OR
HAVING ANY OTHER FERROMAGNETIC PRODUCTS SHOULD NOT OPERATE THE EQUIP-
MENT OR ENTER WITHIN A 2 FOOT PERIMETER AROUND THE SYSTEM.
WARNING
THE HOT GAS TOOL AND THE PRE-HEATER REACH TEMPERATURES WELL ABOVE 60 DE-
GREE C. HOT SURFACE WARNING LABELS ARE FOUND ON THE COVERS OF EACH
HEATED SURFACE. DO NOT TOUCH THESE SURFACES AS SKIN CONTACT WITH THESE
SURFACES WOULD RESULT IN A SHOCK REACTION AND THEREFORE PRESENTS AN IN-
HERENT POTENTIAL THERMAL DANGER TO THE OPERATOR. IN ADDITION, OPERATOR
SHOULD KEEP HAIR AND CLOTHING CLEAR OF THE PREHEATER AREA WHEN HOT.
0029.00.900 2-3
WARNING
IF FLUX IS USED DURING THE SOLDERING PROCESSES, THE OPTIONAL FUME EXTRACTION
MANIFOLD SHOULD BE PURCHASED AND CONNECTED TO A FILTERING SYSTEM.
WARNING
ONLY QUALIFIED PERSONNEL ARE ALLOWED TO WORK ON THE PERIPHERALS WITH HIGH
VOLTAGES.
Note
READ THIS MANUAL CAREFULLY BEFORE YOU OPERATE, SERVICE OR REPAIR THE MA-
CHINE. THE MACHINE MAY ONLY BE OPERATED BY QUALIFIED PERSONNEL WHO HAVE RE-
CEIVED APPROPRIATE TRAINING.
W HEN CLEANING PARTS AND PERIPHERALS OF THE MACHINE, USE ONLY THE SUB-
STANCES RECOMMENDED. W HEN MAINTAINING AND SERVICING THE MACHINE, USE ONLY
THE TOOLS SPECIFIED.
BEFORE YOU RE-START THE SYSTEM AFTER MAINTENANCE OR REPAIR, MAKE SURE THAT
OTHER PERSONNEL, TOOLS AND FOREIGN MATERIALS ARE CLEAR OF THE MOTION AREA
OF THE SUBSYSTEMS OF THE MACHINE.
W HEN REMOVING THE BOARD CARRIER, PRE-HEATER AND THE APPLICATION BASE PLATE,
THE MAIN SWITCH IN THE BACK OF THE MACHINE MUST BE SWITCHED OFF AND LOCKED.
Note
W HEN PROCESSING ELECTRONIC BOARDS WITH ACTIVE DEVICES, THE OPERATOR MUST
BE GROUNDED WITH THE MACHINE, TO AVOID DAMAGING THE ACTIVE COMPONENTS ON
THE BOARD.
2.1.3 Application specific safety aspects
WARNING
ANY ADDITIONAL PERIPHERAL WHICH IS INTEGRATED INTO THE ONYX29 AND THE AP-
PLICATION WHICH IS BEING APPLIED ONTO THE ONYX29 MUST BE DECLARED ACCORD-
ING TO THE SAME SAFETY STANDARDS (EC DIRECTIVE MACHINERY (98/37/EC). WHEN
USING DANGEROUS SUBSTANCES, WHICH ARE OF POTENTIAL RISK FOR THE OPERATOR,
THEN ADDITIONAL SAFETY AND OPERATOR PROTECTION GUARDS OR OPERATING PRO-
CEDURES MUST BE ADDED BY THE APPLICATION RESPONSIBLE COMPANY.
0029.00.900 2-4
2.1.4 Machine warning labels

Label Indication
This label indicates the presence of strong magnetic
fields and is found on the X- and Y-axes motors.
Because these magnetic fields are associated with the
system motor coils and magnet track assembly, per-
sons having active implants (pacemakers, etc) or having
any other ferromagnetic products are not qualified and
are not allowed either to operate the equipment or enter
within a 0,5m perimeter around the system.
0
This label indicates hot surfaces well above 60 C.
The hot gas tool and the pre-heater are required to
0
reach temperatures well above 60 C. Hot surface warn-
ing labels are found on the covers of each such heated
surface.
Skin contact with these surfaces would result in a shock
reaction and therefore presents an inherent potential
thermal danger to the operators.
This label indicates the presence of electrical equipment
with voltages above 60 Volt.
Labels are found beside all removable covers where
electrical equipment is mounted and it is used to indi-
cate a possible shock hazard.
This label indicates the presence of a Laser diode mod-

ule with Laser class 2.
Do not stare into the beam. Direct viewing into the beam
or reflected beam can cause permanent eye damage.
(Po = 1 mW, λ = 650 nm)
This label indicates the presence of an area that pre-

sents a pinch point hazard when motion occurs. Keep
hands and all objects clear of this area.
0029.00.900 2-5
Fume
Extraction
Component Shuttle
4 labels on the X/Y axes

linear motor magnet tracks.
1 label on the base plate

below the pre-heater.
1 label on the cover of the
assembly head.
1 label is attached to the front of the vision unit
1 label on the hot gas cover

2 labels on the carrier rails. 1 label (pinch point) on the component shuttle
0029.00.900 2-6
ONYX29 User’s Guide Chapter 3: Installation
3: Installation
3 Installation ................................................................................................................................................3
3.1 TRANSPORT ............................................................................................................................................3
3.2 UNPACKING .............................................................................................................................................3
3.3 REPACKING .............................................................................................................................................4
3.4 FACILITY REQUIREMENTS .........................................................................................................................5
3.5 W ORKSTATION (OPTIONAL) ASSEMBLY .....................................................................................................7
3.5.1 MOVING THE SYSTEM ONTO THE FINAL TABLE LOCATION ..........................................................................10
3.5.2 REMOVE THE TRANSPORT SAFETY LOCKS ...............................................................................................11
3.5.3 IR OPTION AND SHIPPING BRACKET .......................................................................................................13
3.5.4 INSTALL THE PRE-HEATER .....................................................................................................................15
3.6 ELECTRICAL INSTALLATION .....................................................................................................................15
3.6.1 MAIN POWER .........................................................................................................................................16
3.6.2 ONYX29 DISPENSER OPTION (0029.08.010) INSTALLATION...................................................................19
3.7 PNEUMATIC INSTALLATION......................................................................................................................21
3.7.1 MAIN AIR SUPPLY ..................................................................................................................................21
0029.00.900 3-1
0029.00.900 3-2
3 Installation
3.1 Transport
The machines must be transported and stored in a temperature and humidity controlled environ-
ment. The temperature range shall be within –20 oC to 50 oC, the humidity shall be within 5 – 90%,
non-condensing.
The machines must be transported and stored in the supplied packaging that is designed to pre-
vent damage from normal shock and vibration. The packages must be handled carefully.
3.2 Unpacking
Before unpacking carefully inspect all shipping crates for evidence of damage during transport. If
any damage is indicated, make sure the transport agent is present during opening the crates.
Carefully unpack the crate and compare the delivery papers with the contents in the crate, but also
with your order papers.
Check the Machine ID-Label that is located on the right

ONYX 29 CE backside of the machine (when standing in front of the ma-
Serial Number: 003.02.003 chine). The serial number has to match the delivery papers
Manufactured: 2004 (only the serial number of the machine is listed on the deliv-
U 3x400/230V I 16A f 50Hz
ery papers).
S 6400VA P 6bar
Systems which are equipped for countries with 208/120VAC the label must identify the proper volt-
age configuration:
U 3x208/120V I 16A f 60Hz S 5800VA P 6bar
Store the package material carefully for further transports of the system.
The space for the system has to be ready before the system can be moved. Make sure the table
or lab bench where the system will be installed provides a stable flat surface.
0029.00.900 3-3
See the sections below for the installation guide.
WARNING
FOUR (4) PEOPLE ARE NEEDED TO MANUALLY MOVE THE MACHINE FROM THE CRATE TO
ITS FINAL LOCATION. THE MACHINE WEIGHT IS 264 LBS.
THE WEIGHT IS UNBALANCED, THE LEFT SIDE (WHEN STANDING IN FRONT) OF THE MA-
CHINE IS MUCH HEAVIER.
USE THE CORNER SPOTS ON THE BASE FOR LIFTING THE MACHINE, AS MARKED A, B, C
AND D ON THE FOLLOWING DRAWING.
A B
C D
3.3 Repacking
If the system needs to be transported to a new location, use the original packing material that has
been supplied with the machine.
If this packing material is not available any more, please contact your supplier for replacement
packaging material.
Improper packaging and handling during the transport of the system will reduce or void the war-
ranty.
Please follow the picture guides in Appendix C of this manual.
0029.00.900 3-4
3.4 Facility Requirements

Electrical:
• Machine Power: 208 VAC, 50/60 Hz, 3-phase, 25 A (max).
6’ of 12/4 power cord supplied. No plug supplied with system.
• Monitor Power: (208V) - Provided by convenience plug on machine.
• Computer Power: (208V) - Provided by convenience plug on machine.
Optional equipment:
• Time/Pressure dispense: 110/208 VAC, 50/60 Hz, 1A/.5 A, single phase.
Air/Nitrogen (Base Machine):
• Main Air Supply: 90-130 psi, 5 scfm, clean, dry air (non-condensing) source.
(Includes Board Cooling) 1/8”-18NPT with two 1/4” lines (supplied). Direct plumb.
Electrical: IMPORTANT
• This system is designed to operate on 208VAC, 3 phase.
• Under full load conditions, power must not drop below 205VAC. Verify all 3 phases.
• If the PC and monitor are connected to a separate power source, or connected through a volt-
age regulator, the machine minimum voltage is 195V.
• Under no load conditions, power must not exceed 215VAC.
Air/Nitrogen:
• With top heater and board cooling system operating, system consumes up to 25 scfm @80 psi.
With all systems activated, 70 psi. must be maintained. Requires both gas lines be direct
plumbed (no quick disconnect).
General: These requirements must be addressed prior to the installation and training
visit. This will assure you receive a productive training program within the scheduled installation
time.
Physical:
• ONYX29 Dimensions:
Base:
32W” x 32D” x 36H”
Operating with workstation:
78W” x 50”D x 55”H
• ONYX29 Weight:
ONYX29 (265 lbs.)

with workstation (365 lbs.)
0029.00.900 3-5
823
951
772.5
101.16 720
821.16
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3.5 Workstation (optional) Assembly
36” x 60” ESD Bench
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Monitor Stand
Nozzle Holder
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Triple Locking Drawer
CPU Holder
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3.5.1 Moving the system onto the final table location

Before the machine can be moved, the machine table or a strong lab bench with a flat and hori-
zontal surface must be installed. This table must be very stable to support the system. Move the
machine on top of the machine support.
WARNING
A MINIMUM OF 4 PERSONS IS NEEDED TO MANUALLY MOVE OR CARRY THE MACHINE
FROM THE CRATE TO ITS FINAL LOCATION. THE MACHINE WEIGHT IS 120 KG (264 LBS.)
THE WEIGHT IS UNBALANCED, THE LEFT SIDE (WHEN STANDING IN FRONT) OF THE MA-
CHINE IS MUCH HEAVIER.
USE THE CORNER SPOTS ON THE BASE FOR LIFTING THE MACHINE, AS MARKED A, B, C
AND D ON THE FOLLOWING DRAWING.
After the system has been moved to the proper location, the transport safety locks can be re-
moved, the cables can be connected and the system can be made ready for operation.
0029.00.900 3-10
3.5.2 Remove the transport safety locks
After the system has been moved to the proper

location, remove the X- and Y-axes transport
safety locks:
Remove the two screws.
After the two screws have been removed, the X-
axis can be moved carefully to the side. Do not
slide back, when the Y-axis is not at the correct
location, the Y-axis linear encoder scale may be
damaged.
Remove the bracket mounting screw and remove

the transport safety lock bracket.
Remove the X-carriage buffer from the bracket
and attach it in the thread where the screw was
removed. This buffer can be tightening by hand,
without the need of any tools.
Mount the screw into the location in the bracket
where the buffer was removed.
Re-attach the front Y-axis bracket with the screws

from the transport safety bracket.
Put the two original screws back into the threads
from the bracket. This way these are not getting
lost.
These screws have different lengths. During the
transport of the system, longer screws are used.
0029.00.900 3-11
WARNING
NEVER USE THE SHORT SCEWS TO ATTACH THE SAFETY BRACKET. THESE WOULD GET
LOOSE ON THE TRANSPORT.
Note
PUT THE SAFETY BRACKET WITH THE LONGER SCREWS AND THE BUFFER REPLACEMENT
SCREW INTO A SAFE LOCATION. IT WILL BE USED EACH TIME THE SYSTEM IS BEING
MOVED.
MOVE THE X-AXIS AND THE Y-AXIS FROM ONE END TO THE OTHER END, THEN MOVE BOTH
AXIS TO ABOUT THE CENTER LOCATION. THESE TWO MAIN AXIS CAN BE MOVED EASY,
WHEN THERE IS NO POWER TO THE SYSTEM, AS LINEAR MOTORS AND LINEAR ENCODERS
ARE USED.
Remove the Vision X-axis transport safety lock by removing two screws. Re-attach them in the
same location but facing up. This way the locks are always present when needed.
Note
THE VISION X- AND Y-AXIS CANNOT BE MOVED EASY. CAREFULLY MOVE THE VISION Y-
AXIS SLIGHTLY TO THE FRONT.
0029.00.900 3-12
3.5.3 IR Option and Shipping Bracket
1. Locate shipping bracket on vision assembly.
IR Probe Assembly
Shipping Bracket
Vision Assembly
Shipping Bracket
2. IR Probe will need to be removed in order to remove shipping bracket.

3. Remove the mounting screws (5) for the IR probe.
IR mounting screws (5)
0029.00.900 3-13
4. Move IR to the side in order to remove the shipping bracket.
IR Probe
5. Re-mount shipping bracket as shown for future use.

6. Re-mount IR probe.
IR Probe
0029.00.900 3-14
3.5.4 Install the Pre-Heater

The pre-heater is transported inside its separate packaging. Unpack the pre-heater and remove
the isolation material. Make sure that there is no isolation material left on the pre-heater or the
application base plate. The pre-heater feet have to be located in the appropriate holes of the base
plate. The connections are shown from the back side:
4 3 2 1
The cables of the pre-heaters can be installed in the back of the system. Install cables into the
diffuser port as required (1-4).
3.6 Electrical Installation
Note
ONLY QUALIFIED PERSONNEL ARE ALLOWED TO WORK ON THE PERIPHERALS WITH HIGH
VOLTAGES. THE GOVERNING LAWS AND REGULATIONS MUST BE OBSERVED.
W HEN WORKING WITH HIGH VOLTAGES, ALWAYS ENSURE THAT ANOTHER PERSON IS
NEAR YOU WHO IS FAMILIAR WITH ALL EMERGENCY POWER OFF CONTROLS.
MAKE SURE TO CHECK THE ELECTRICAL SCHEMATICS SUPPLIED WITH THE MACHINE.
THE MACHINE EXISTS IN 2 DIFFERENT, COUNTRY VOLTAGE SPECIFIC VERSIONS (3PE

208V AND VERSION 3PNE 400V).
0029.00.900 3-15
3.6.1 Main Power
IMPORTANT:
MAKE SURE THE MAIN SWITCH IS SWITCHED TO OFF (0).
The main 3-phase power cable is already con-

nected inside the base chassis. Use this cord to
connect to a facility power outlet.
WARNING
THE POWER SUPPLIED ON THESE PC- AND MONITOR POWER PORTS PROVIDE A VOLTAGE
OF 208 – 240 VAC, MAKE SURE THE PC AND THE MONITOR ARE CONFIGURED FOR THIS
VOLTAGE SUPPLY. OTHERWISE THE PC AND MONITOR CAN BE DAMAGED.
Main power Input of the machine support 3x 208VAC 3PE

Phase 1 & phase 2 = 208-240VAC
Each phase & earth ground = 110-126VAC
Phase 1 L1
208VAC
208VAC
Phase 2 L2
208VAC
110VAC
110VAC
Phase 3 L3
110VAC
Earth Ground PE
0029.00.900 3-16
2 1
Accura Camera Camera

Dispenser Light Ring Power
Power Power (option)
(option) (option)
1. Connect the 6-pin FireWire IEEE-1394 connector cable to the FireWire port on the back of the
machine and connect the other side to one free FireWire IEEE-1394 port of the PC.
2. Connect Ethernet cable here, then to PC.
Attach the S-video cable to the camera and connect the other
side of the S-video cable into the PC.
Attach the camera power plug provided here, then to the cam-
era power outlet as shown above.
Direct View Camera

(option)
0029.00.900 3-17
PC Power to
back of ONYX
Ethernet to
back of ONYX
FireWire to
back of ONYX
S-Video cable
from Direct View
camera (option)
0029.00.900 3-18
3.6.2 ONYX29 Dispenser Option (0029.08.010) Installation
Setup:
Dispenser – front and rear connections
Pressure – Set to 100 Kpa unless otherwise determined/directed
Time Set – 000
Mode Button – In (steady state)
Shot Button – Out (Off)
Dispenser Front
Dispense Head
0029.00.900 3-19
Dispenser Rear:
To 110V To right rear To air filter

of machine
ONYX29 Rear Pneumatic Connection: ONYX29 Rear:
Connection from control cable

(rear of Accura dispenser)
to rear of ONYX29.
0029.00.900 3-20
3.7 Pneumatic Installation

The upper unit can either be connected to a nitrogen source or tied into the lower, main air source.
3.7.1 Main Air Supply

The machine has to be supplied with clean, dry and non-condensing air.
Connect the air hose to the Pneumatic maintenance unit located at the
back left side of the machine. The lower unit is the main air source.
Make sure to use a straight connection to the main pneumatic mainte-
nance unit and not a 90 degree connection. Use at minimum a hose with
a diameter of 8mm (1/3 Inch tube).
Adjust the air pressure with the air pressure regulator until the gauge
shows 0.55 mpa (80PSI).
If a second maintenance unit is installed, this unit must be connected as
well. Normally this unit is supplied with nitrogen, however if nitrogen is
not available, then it must be connected to the compressed air source.
Otherwise it will not be possible to use the hot gas tool. Adjust the gas
pressure at the second gas pressure regulator until the gauge shows
0.55 mpa (80PSI).
0029.00.900 3-21
0029.00.900 3-22
ONYX29 User’s Guide Chapter 4: System Power Up/Down
4: System Power Up/Down

4 System Power Up / Down ........................................................................................................................3
4.1 SYSTEM POWER UP ..................................................................................................................................3
4.1.1 SWITCH ON THE MAIN 3-PHASE POWER .....................................................................................................3
4.1.2 RELEASE THE E-STOP BUTTON .................................................................................................................3
4.1.3 SWITCH ON THE SYSTEM POWER I/O AT THE ONYX 29 .............................................................................4
4.1.4 SWITCH ON MONITOR, THE PC AND LOAD THE OPERATING SYSTEM ............................................................4
TM
4.1.5 START THE VISUAL MACHINES SOFTWARE.............................................................................................4
4.1.6 LOG ON WITH THE USER NAME AND PASSWORD .........................................................................................5
4.2 STATUS BAR AND SAFETY PROTECTION W ARNINGS ..................................................................................5
4.2.1 EXECUTE THE CALIBRATION PROGRAM ......................................................................................................6
4.3 SYSTEM POWER DOWN ...........................................................................................................................6
0029.00.900 4-1
0029.00.900 4-2
4 System Power Up / Down

4.1 System power up
The steps for starting up the system are summarized below and discussed in detail on the pages
that follow:
• Switch on the main 3-phase power (normally not necessary)

• Release the E-stop button and enable power to the axes
• Switch on the system power I/O at the ONYX 29
• Switch on the monitor, the PC and load the operating system (Windows 2000 or XP)
TM
• Start the Visual Machines Software
• Log on with the user name and password
• Execute the calibration program
• Operate the system
4.1.1 Switch on the main 3-phase power

Turn on the main 3-phase power switch which is
located behind the system (90° clockwise to on).
Normally this switch is not switched off. It is
switched off only if maintenance personnel need
to have access to the power control modules in
the base of the system.
Note
PLEASE BE AWARE THAT SWITCHING OFF THIS MAIN 3-PHASE POWER SWITCH WILL
SWITCH OFF THE PC AND MONITOR AS WELL. SHUT DOWN THE PC FIRST BEFORE MA-
NIPULATING THIS SWITCH TO OFF (0).
4.1.2 Release the E-stop button

The button has to be rotated clock-wise for about
20O then it releases itself. When the E-stop button
is released, the axes have no power yet. The
power will be enabled automatically during the
axes calibration sequence.
0029.00.900 4-3
4.1.3 Switch on the system power I/O at the ONYX 29

Turn on the system power switch I/O of the ONYX 29, which is located at
the front to the left side.
4.1.4 Switch on monitor, the PC and load the operating system

Switch on the monitor, the PC and load the operating system Windows 2000 or Windows XP.
TM
4.1.5 Start the Visual Machines Software
Note
W AIT UNTIL THE PC HAS LOADED THE WINDOWS OPERATING SYSTEM. THIS MAY TAKE UP
TO 5 MINUTES.
As soon as the Windows

operating system has been
VisualMachines.lnk
loaded, double click the Icon
VISUAL MACHINESTM and the
software will be started. The system can be
configured, that VISUAL MACHINESTM starts
automatically. Refer to the Windows operator
system manual.
NOTE:
IF THE MACHINE WAS NOT POWERED ON PRIOR TO STARTING THE VISUALMACHINESTM
SOFTWARE, THE FOLLOWING MESSAGE WILL APPEAR.
SWITCH ON THE SYSTEM POWER I/O SWITCH. CLICK ON THE “CONTINUE ONLINE” BOX.
0029.00.900 4-4
4.1.6 Log on with the user name and password

Enter the User Name and Password.
4.2 Status Bar and Safety Protection Warnings

The status line at the bottom of the monitor is always displayed:
Operator name Access Shows Robot Shows which Tool holds which Nozzle on which
level status Head
Calibrated
Not calibrated
Runtime Online Pre-heater Hot Gas Tool

Idle Online HOT Warning HOT Warning
o o
Paused Offline When above 60 C, When above 60 C,
Running blinking warning text blinking warning text
E-Stop
The status bar is machine configuration specific and may appear different on your system.
WARNING
FOR THE PRE-HEATERS AND FOR THE HOT GAS SYSTEMS, HOT TEMPERATURE WARNING
LABELS ARE DISPLAYED WITHIN THE STATUS LINE AS SOON AS THE TEMPERATURE OF
0
ONE OF THESE DEVICES EXCEEDS 60 C.
THE ACTUAL TEMPERATURE IS DISPLAYED IN A RED, BLINKING BOX.
0029.00.900 4-5
4.2.1 Execute the calibration program

The VISUAL MACHINESTM Software will prompt the operator to execute the calibration program.
• Select Yes.
Note
THE SYSTEM WILL MOVE ALL THE AXES DURING CALIBRATION. MAKE SURE THERE ARE NO
TOOLS OR ANY OTHER PARTS IN THE WORKING AREA.
The system is now ready for operation.
4.3 System Power Down

To power-down the system follow the power-up sequence in the reversed order:
• Complete the operation with the machine
TM
• Exit the VISUAL MACHINES Software, the databases are saved automatically
• Switch off the system power I/O at the ONYX 29
• Shut down the operating system Windows 2000 or XP at the PC
• Switch off the PC and monitor
Note
W HEN EXITING THE VISUALMACHINESTM SOFTWARE, AN AUTOMATIC BACKUP OF ALL
PROGRAMS AND PART TYPES IS MADE.
IN ADDITION, IF THE TOP AND BOTTOM HEATERS ARE ABOVE 600C. THE MACHINE WILL
CONTINUE TO COOL DOWN THE HEATERS UNLESS YOU INSTRUCT IT OTHERWISE.
0029.00.900 4-6
ONYX29 User’s Guide Chapter 5: Verification/Calibration
5: Verification/Calibration
5 Verification/Calibration................................................................................................................. 3
5.0 VERIFICATION/CALIBRATION MATRIX ................................................................................................. 3
5.1 ROBOT CALIBRATION ...................................................................................................................... 4
5.2 FLOW RATE VERIFICATION .............................................................................................................. 5
5.3 HOT GAS TOOL TEMPERATURE VERIFICATION..................................................................................... 6
5.4 HOT GAS TOOL CALIBRATION ........................................................................................................... 7
5.5 BOTTOM HEATER VERIFICATION....................................................................................................... 8
5.6 PLACEMENT VERIFICATION.............................................................................................................. 8
5.7 VISION SYSTEM CALIBRATION .......................................................................................................... 9
5.8 IR SENSOR VERIFICATION ............................................................................................................ 10
5.9 IR SENSOR CALIBRATION.............................................................................................................. 10
5.10 THERMOCOUPLE CHANNELS .......................................................................................................... 11
5.11 FORCE TABLE VERIFICATION.......................................................................................................... 11
5.12 FORCE TABLE CALIBRATION ........................................................................................................... 12
0029.00.900 5-1
0029.00.900 5-2
5 Verification/Calibration
The ONYX29 is factory calibrated. This section provides information regarding calibration and verifi-
cation processes.
• Verification is the process whereby calibration is verified.

• Verification procedures can be done by anyone.
• Calibration is the process whereby machine settings are actually changed.
• Calibration procedures are user/password restricted.
5.0 Verification/Calibration Matrix
Category Verification Calibration
Robot Not required. Done automatically each time

VisualMachinesTM software is started
Hot Gas Tool Every 3 months Only if verification check indicates that
calibration is required
Bottom Heater Not required Not required
Placement Accuracy Every 3 months Only if verification check indicates that

IR Sensor Every 3 months Only if verification check indicates that

TC Channels Not required Not required
Force Table Every 3 months Only if verification check indicates that

0029.00.900 5-3
5.1 Robot Calibration

Upon entry into VisualMachinesTM software, the operator will be prompted to calibrate the robot.
All motorized axes will “home” and the robot will move. When complete, the toolbar at the bottom of
the screen will show “Robot Calibrated”.
NOTE:
PROGRAMS CANNOT BE EXECUTED IF THE ROBOT IS NOT AUTO-CALIBRATED.
IF YOU EXIT AND RE-ENTER VISUALMACHINESTM SOFTWARE, BUT LEAVE THE ROBOT ON,
THE CALIBRATION MESSAGE WILL STILL APPEAR, BUT THE ROBOT WILL NOT MOVE AS RE-
CALIBRATION IS NOT REQUIRED, UNLESS THE ROBOT IS DE-POWERED THEN RE-POWERED.
THE KEY IS TO CONFIRM THAT THE ”ROBOT CALIBRATED” MESSAGE SHOWS IN THE
TOOLBAR.
IF THE ROBOT FAILS TO CALIBRATE, CONTACT AIR-VAC FOR TECHNICAL ASSISTANCE.
YOU WILL SEE A CALIBRATION RETRY MESSAGE. RETRY THE CALIBRATION. IF THE RETRY
FAILS, CONTACT AIR-VAC.
0029.00.900 5-4
5.2 Flow Rate Verification
NOTE:
THE ONYX29 INCORPORATES A PRECISION MASS FLOW CONTROLLER TO REGULATE THE
HOT AIR FLOW. THE FLOW OF THIS DEVICE IS VERIFIED PRIOR TO SHIPMENT ON ONYX
UNITS BY THE MANUFACTURER AND DOES NOT NEED ADJUSTMENT.
HOWEVER, IF VERIFICATION/CALIBRATION OF THE MASS FLOW VALVE IS A REQUIREMENT

BEFORE RELEASING THE MACHINE TO PRODUCTION, (1) THE VALVE CAN BE REMOVED
FROM THE MACHINE AND SENT BACK TO THE MANUFACTURER FOR CERTIFICATION, (2)
CUSTOMERS CAN PURCHASE A CALIBRATION KIT #1016.02.010 FROM A IR-VAC TO
PERFORM THE CALIBRATION. ONCE PURCHASED, CUSTOMER WOULD THEN MAINTAIN THE
CALIBRATION OF THIS KIT FOR FUTURE USE.
1. Go into the Maintenance view

(operator/password restricted)
and double click “Hot Gas Tool”.
2. Increase the flow rate and check the actual flow output (A)
versus the set point (B) at 10 SLM intervals between 20
and 80 SLM.
• The actual rate should be +/- 3 SLM. If the flow rate ex-
ceeds this tolerance, contact Air-Vac.
0029.00.900 5-5
5.3 Hot Gas Tool Temperature Verification
Tools required: NCAL1 Temperature nozzle
1. Open the temperature verification profile in the Air-Vac directory.

Go to Execution; Open Program folder; Open AV folder;
Select “Temperature Calibration Check – NCAL1 <date code>.itp”
2. Select basic view

3. Load NCAL1 nozzle into the Solder Head and plug the T/C of the nozzle into T/C #1.
4. Execute this program following the step-by-step prompts.
5. The actual temperature output through T/C #1 (NCAL1 nozzle) at 300 seconds should be manu-
ally recorded. (Select basic view to read board thermocouple temperature). Note that there
is a CSV file created as a part of this program so the temperature at 300 seconds can be deter-
mined from that after the run is complete.
6. If the actual temperature is within 300c +/-3 degrees (ie. 297c to 303c), re-calibration of the top
heater is not required.
7. If recalibration is required, using the value just recorded proceed to Hot Gas Tool Calibration step
#5.
0029.00.900 5-6
5.4 Hot Gas Tool Calibration

Tools required: NCAL1 Temperature nozzle
1. Open the temperature verification profile in the Air-Vac directory.

Go to Execution; Open Program folder; Open AV folder;
Select “Temperature Calibration Check – NCAL1 <date code>.itp”
2. Load NCAL1 nozzle into the Solder Head and plug the T/C of the nozzle into T/C #1.
3. Execute the program following the step-by-step prompts. Record the Ncal1 temperature at 300
seconds. A CSV file is created and can be reviewed to get the temperature after the program has
been run.
4. Verify that the target temperature is 300c +/- 3c. If the temperature is not within the tolerance
continue.
Go to Calibration View; Hot Gas Tool

Calibration; Calibration Calculator
5. At step 3, of the calibration calculator (5 min-
300@60slm temp) enter the value from the
previous run. Example: If recorded temp is 315 then
enter 315. Then Click on Compute Calibration, Apply,
Okay.
6. Repeat steps 3 – 5 as required to obtain 300c +/-
3c.
0029.00.900 5-7
5.5 Bottom Heater Verification
NOTE:
NOT REQUIRED. ACHIEVEMENT OF THE SAME BOARD PREHEAT TARGET TEMPERATURE IS
DONE DURING EVERY PROCESS TO INSURE REPEATABLE RESULTS.
5.6 Placement Verification
NOTE:
PLACEMENT VERIFICATION SHOULD BE DONE EVERY THREE MONTHS.
1. Open and execute the Placement Test Program in the Air-Vac directory.
2. Align and place a QFP160 onto a bare site using double-sided tape, device, board, and nozzle
that are supplied with the machine.
IMPORTANT:
THE LEADS ON THE QFP160 MUST NOT BE BENT OR DAMAGED. DO NOT TOUCH THE
LEADS DURING THIS PROCESS.
3. Remove the board. Inspect the placement accuracy on all four sides using a microscope. Re-
cord any “X”, “Y” errors.
4. Carefully remove the QFP without touching the leads (use the nozzle vacuum).
5. Repeat the Placement Profile a second time to verify that the results match the initial findings. If
repeated placements show the same “X” or “Y” errors, follow the instructions for calibrating the
Vision System.
0029.00.900 5-8
5.7 Vision System Calibration
NOTE:
CALIBRATION OF THE ONYX29 V ISION SYSTEM DOES NOT REQUIRE ANY MECHANICAL
ADJUSTMENT. CALIBRATION MUST BE DONE BY AUTHORIZED PERSONNEL.
1. Go to the Calibration View (operator/password restricted).

2. Double click on Vision Unit to access the vision system “X” and “Y” offsets.
• The 0,0 position on the ONYX29 is front left.
3. If the QFP leads need to move toward 0,0 in the X or Y direction, a small adjustment should be
made to the existing offset values.
4. If the QFP leads need to move away from 0,0 in the X or Y direction, a small adjustment should
be made to the existing offset values.
IMPORTANT:
THE AMOUNT OF THE OFFSET ADJUSTMENT SHOULD BE VERY SMALL, TYPICALLY .25 MM.
5. Repeat the Placement Verification Process after the offset adjustments are made. Reiterate until
the desired placement results are achieved.
0029.00.900 5-9
5.8 IR Sensor Verification
NOTE:
THE IR SENSOR IS FACTORY CALIBRATED. VERIFICATION OF THE IR SENSOR IS
RECOMMENDED EVERY 3 MONTHS.
1. Attach a K-type thermocouple to a test board with Kapton tape.

2. Teach the IR Sensor position (integrated head version) or move the IR Sensor arm to the same
position.
3. Run the IR Sensor Verification program in the Air-Vac directory. Write down the IR Sensor and
K-type thermocouple readings at 80, 100, 120 and 150 degrees.
4. If the IR Sensor is more than +/- 7.5 degrees different from the IR Sensor, proceed to the IR
Sensor Calibration section.
5.9 IR Sensor Calibration
NOTE:
CALIBRATION SHOULD BE PERFORMED BY AUTHORIZED PERSONNEL.
1. Select the Calibration View (operator/password restricted) and double-click on Vision System.
2. Adjust the IR offset value up or down, based on the average temperature differential identified
in the IR Sensor Verification section.
0029.00.900 5-10
5.10 Thermocouple Channels
NOTE:
THE THERMOCOUPLE CHANNELS ARE FACTORY CALIBRATED AND REQUIRE NO ADDITIONAL
VERIFICATION OR CALIBRATION.
5.11 Force Table Verification
NOTE:
A FORCE CALIBRATION WEIGHT (METAL “HOCKEY PUCK”) IS PROVIDED WITH EACH
ONYX29 SYSTEM.
1. Select the Maintenance view and double-click on Force Table.
2. Zero the force table, then place the calibration weight in various positions above the metal plate.
The reading should be 5.1 +/- 0.5.
0029.00.900 5-11
5.12 Force Table Calibration
Contact Air-Vac.
0029.00.900 5-12
ONYX29 User’s Guide Chapter 6: Maintenance
6: Maintenance
6 Maintenance .............................................................................................................................................3
6.0 PREVENTIVE MAINTENANCE SCHEDULE ....................................................................................................3
6.1 MAINTENANCE VIEW ................................................................................................................................5
6.1.1 MACHINE MAINTENANCE ..........................................................................................................................5
6.1.2 HEAD MAINTENANCE ................................................................................................................................6
6.1.3 FORCE SENSOR MAINTENANCE ................................................................................................................6
6.1.4 MACHINE OPERATOR PANEL MAINTENANCE VIEW .....................................................................................7
6.1.5 VISION UNIT ............................................................................................................................................7
6.1.6 HOT GAS TOOL .......................................................................................................................................9
6.2 SOFTWARE BACKUP...............................................................................................................................10
6.3 CREATE SOFTWARE ARCHIVE ................................................................................................................12
6.3.1 BLOW -OFF AIR ADJUSTMENT ...................................................................................................................13
6.3.2 VACUUM FILTER .....................................................................................................................................13
6.3.3 UPPER HEATING ELEMENT REPLACEMENT ..............................................................................................14
6.4 SPARE PART LIST ..................................................................................................................................22
6.4.1 ONYX 29 SELECTIVE SOLDERING SYSTEM .............................................................................................22
6.4.2 ONYX 29 BASE IP-500 PLATFORM 300.01.010 .....................................................................................23
6.4.3 X-Z AXIS 150MM ONYX 29 300.01.024 (OBC 30MM) ...........................................................................30
6.4.4 X-Z-AXIS 230MM ONYX 29 300.01.026 (OBC 70MM) ...........................................................................32
6.4.5 MANUALMOTION 300.00.394 .................................................................................................................34
6.4.6 THERMO COUPLE MODULE WITH 4 PORTS 300.01.040.............................................................................35
6.4.7 THERMO COUPLE MODULE WITH 8 PORTS 300.01.058.............................................................................35
6.4.8 FIELD ILLUMINATION 300.00.397 ............................................................................................................36
6.4.9 FIELD ILLUMINATION LAMP 300.00.438 ...................................................................................................36
6.4.10 ADVANCED SOLDER HEAD ONYX 29 300.01.007 ...............................................................................37
6.4.11 VISION SYSTEM WITH MFOV 300.01.050...........................................................................................45
6.4.12 BOARD HOLDER 500 MM 300.00.483 .................................................................................................51
6.4.13 PREHEATER – 5600 WATT, 19” SQUARE – 0029.06.041 .....................................................................52
6.4.14 BOARD COOLING 490 MM 300.00.409 ................................................................................................55
6.4.15 DIRECT VIEW CAMERA 300.01.045.....................................................................................................56
0029.00.900 6-1
0029.00.900 6-2
6 Maintenance
6.0 Preventive Maintenance Schedule
Machine Maintenance Activity Notes Frequency

Component
Daily Weekly Monthly
Data Backup Profiles and part types must be writ- Off-machine data X
ten to an off-machine storage media back-up is the most
(network server, memory stick, cd, critical maintenance
etc.) task. Air-Vac is not
responsible for lost
data.
Nozzles Clean nozzles of flux and inspect o- X
rings and vacuum cups
Site Clean Tool Install the SC nozzle and activate Vacuum cup should X X
(option) the SC vacuum to verify that a be replaced after 8
strong vacuum exists. Inspect tip hrs. of use
collector and blue vacuum cup for
wear.
Machine Frame Clean the machine frame and the Dry lint-free cloth, in X
machine covers case of flux, use flux
Make sure there are no flux- or dis- remover
pense media spoiled on the ma-
chine
Vision Unit Clean the protective cover glass on Kimwipes® Denatured X
the lower and on the upper side of Alcohol
the vision unit
Pneumatic Unit Drain the air regulator filters of any X
water or oil (verify the air pressure is
0.55 mba)
Vacuum Filter Replace vacuum filter if vacuum is See instructions in X
insufficient to hold component. Maintenance Section
X-Y Axes Encoder Clean the linear glass or steel scale See instructions in X
encoder carefully Maintenance Section
X-Y-Z Axis Bearings Clean all the linear bearing rails Benzine, dry lint-free X
carefully. cloth
Lubricate the bearing rails after- 3 in 1 oil
wards slightly with oil
Z-axis Lead Screw Clean the lead screw Benzine, soft brush X
Lubricate the lead screw afterwards 3 in 1 oil
slightly with oil
Computer/Machine Hard Boot 8-10 hrs per shift

Nozzle Temperature Calibration See instructions in X
Maintenance Section
Site Clean Jar Filter Change Changing filter is As required
dependent on usage
0029.00.900 6-3
6.0.1 X-Y Axes Encoder Scale Cleaning Instructions

Supplies required: Denatured Alcohol and Kimwipes® cleaning wipes.
• When cleaning the encoder scale, wet the surface with the Denatured Alcohol and allow
the alcohol to loosen the dirt (or evaporated flux solutions) before wiping.
• Using the Kimwipes®, wipe carefully side to side, not end to end. Never try to remove the
dust or dirt by rubbing very hard or using any abrasive material, this will damage the en-
coder scale!
WARNING
USE DENATURED ALCOHOL AND KIMWIPES® TO CAREFULLY CLEAN THE ENCODER SCALE.
USE OF ANY OTHER TYPE OF CLOTH OR CLEANING SOLUTION WILL DAMAGE SCALE.
Cleaning direction
side to side
Cleaning direction
Encoder Scale Y-Axis side to side
Encoder Scale X-Axis
0029.00.900 6-4
6.1 Maintenance View
Note
FOR ACCURATE SOFTWARE DESCRIPTIONS AND SOFTWARE HELP USE THE ON LINE
TM
ROBOHELP WITHIN THE SOFTWARE VISUAL MACHINES .
This section can be skipped by all Operators. It is necessary to have the access
level of Maintenance or higher to have access to the Maintenance View and its
functions. The Maintenance View is opened by clicking the Maintenance button
on the Views tab.
The Maintenance View displays a partial machine configuration in a hierarchical
tree structure. Bold marked items have an active maintain function that can be
opened or executed. Omitted items do not have any maintenance functionality.
Maintenance allows viewing and modifying the current state of the correspond-
ing item. Each peripheral may provide maintenance functions
6.1.1 Machine Maintenance

Select a bold marked item of the hierarchical Machine Mainte-
nance tree: Clicking on this button will open the selected
maintenance function. Clicking on this button will refresh the
tree view.
The OK button closes the main calibration page.
Note
THE MAINTENANCE TREE CAN APPEAR DIFFERENTLY
DEPENDING ON THE SYSTEM CONFIGURATION.
THE FOLLOWING SECTIONS SHOW THE MOST

IMPORTANT MAINTENANCE PERIPHERALS AND
FUNCTIONS.
0029.00.900 6-5
6.1.2 Head Maintenance

The head maintenance page displays information of the
current attached tool.
Selecting another tool entry in the Current mounted
Tool list and clicking OK changes the tool in Visual-
Machines.
WARNING
CHANGING THE CURRENT MOUNTED TOOL
DOES NOT CHANGE IT PHYSICALLY. PLEASE
MAKE SURE THAT THE LINKED TOOL CORRE-
SPONDS TO THE MOUNTED ONE.
The status bar shows the current mounted tool/nozzle

combination on the head.
Signals:
The actual state of the head signals are displayed in a
graphical format. The digital signal to switch the Vacuum
and Blow off air is available. Clicking on the button be-
low the digital signal display toggles the current state.
Also the Vacuum sensor can be monitored.
6.1.3 Force Sensor Maintenance

The force sensor maintenance page displays the
current load on the force sensor table.
Zero Force Sensor button resets the force sensor to
0 N.
The Force Threshold field can be used to check the
functionality of the system. Values set in this page
have no effect during program execution. As soon as
the force table has reached the set Threshold force,
then the Trigger signal is activated.
0029.00.900 6-6
6.1.4 Machine Operator Panel Maintenance View

Through the Maintenance View, the Operator Panel buttons can be diagnosed:
Panel Buttons:
Start indicates the state of the Start-Button
Stop indicates the state of the Stop-Button
Enable indicates the state of the Enable-Button
Manual indicates the state of the Release-Button
Option1 indicates the state of the Option-Button
Option2 indicates the state of the Light-Button
Additional Panel Signals:

Option1 Allows enabling/disabling the option
Option2 Allows enabling/disabling the field illumination
6.1.5 Vision Unit

The Maintenance view of the Vision unit peripheral can
display live streaming video. It allows changing light unit
parameters and also camera features. All signals and
motion axis can be operated in this menu page. Values
set in this page have no effect during program execution
Show Live Video activates the live video page.
Laser Pointer sets the Laser Pointer output. If activated
it displays a small red dot on a mounted board. It is lo-
cated in the front section of the vision cube.
Move Park Position button moves the vision cube to its
defined park position. If the Multiple Filed of View option
is installed it may move the Vision-X and the Vision-Y
axes.
Move Laser Position button moves the vision cube to
its position, where the laser pointer is exactly in the cen-
ter location of the nozzle. This position is used for teach
processes with laser pointer guidance.
Move CFoV Position button moves the vision cube to
its position, where the vision center image is exactly in
the center location of the nozzle. At the same time the
Z-axis moves the nozzle into the correct focus level. This
level can temporary be influenced by entering an Object
Thickness value.
The Zoom slider moves the motorized Vision-Zoom axis
of the vision unit.
The Vision-X Axis slider moves the motorized Vision-X axis of the vision unit.
The Theta Axis slider moves the Theta axis.
The Center Theta Axis moves the Theta-axis to its center position.
0029.00.900 6-7
Live Video
Live video is being displayed.
Clicking the Grid button shows a grid in front of the
live video. The number of grid lines in x- and y-
direction can be changed by editing the correspond-
ing text fields.
Clicking on the Parameters button opens the cam-
era parameter adjustment page. It allows modifying
camera features, such as contrast and brightness.
The Light Intensities of the linked Light Unit peripheral can

be adjusted. The brightness and the contrast of the image
can be directly changed. The new values are immediately
transmitted to the camera so that the effect can be checked
on the screen.
The Show all features button is only available for users with
Administrator access level or higher.
Clicking on the Show all features button expands the page
and shows additional parameters that can be adjusted. The
parameters are depending on the camera type and driver;
only the supported features are shown.
Selecting a feature allows changing its value by dragging the
slider below the list. Enabling the check box of a one-push
feature allows changing its state. The white balance one-
push feature for example, does allow executing directly a
white balance operation of the camera. The white balancing
effect can be seen on the live video.
The Apply Camera Default button sets all features back to
the last saved state.
Clicking on the Save Camera Default button does save the
current feature setting as the default setting. These values
will be used to initialize the camera at each start of Visual-
Machines.
The Video Parameters button opens the driver dialog to
modify directly video parameters. This page is depending on
the installed camera driver and is not part of this documenta-
tion.
Note
SHOW ALL FEATURES SHOW CAMERA SUPPORTED FEATURES. THE AVAILABLE VALUES
AND ONE-PUSH FEATURES ARE DEPENDING ON THE INSTALLED CAMERA TYPE AND
DRIVER.
0029.00.900 6-8
6.1.6 Hot Gas Tool

The Maintenance of the Hot Gas Tool displays the
actual state of the current mounted nozzle.
• Choose a nozzle from the drop-down list that is
mounted on the tool.
• Click the OK button to save the current setting.
Note
BY CHANGING THE NOZZLE YOU HAVE TO
MAKE SURE THAT THE RIGHT NOZZLE IS
PHYSICALLY CORRECTLY MOUNTED
The status bar is showing the current mounted tool /

nozzle combination on the heads.
Heating Control:
Current Temperature shows the actual temperature
of the Hot Gas Tool. If this is bigger than the max
temperature in the configuration page, the hot gas
tool is not connected.
Monitor Opens a new window where the heating
curve is being displayed.
Enable button enables/disables the heater.
Temperature Set Point Sets the target temperature for the heater.
Temperature Speed: Sets the speed for the heater to reach the defined set point.
Hot Air Flow Control:
Current Flow shows the current hot air flow
Hot Flow Set Point for the tool
Heater by-pass (fast cool down) Switches the valve that the heater element is by passed for rapid
cool down processes.
Heating Graph:
The Clear button clears the graph
Click on Add TC button to select a thermocouple channel that
gets displayed in the heating graph
0029.00.900 6-9
6.2 Software Backup

It is important to make safety copies of all the software parameters of the system and of all the
programs. VISUALMACHINESTM provides a backup utility, which allows backing up configuration- and
program files automatically at the launch or exit of VISUALMACHINESTM. These files are stored
within a ZIP-File.
If the PC is connected to a network, then it is essential that the back-up directory is re-defined to a
network location which is part of a regular system back-up.
WARNING
IT IS IMPORTANT TO ALWAYS HAVE UP TO DATE SOFTWARE BACKUPS. THE CONFIGURA-
TION DATABASE, THE LIBRARY- AND USER DATABASE AND THE PROGRAMS MUST BE
SAVED TO BACKUP DEVICES ON A REGULAR BASIS. USE OTHER BACKUP LOCATIONS
THAN THE MACHINES PC HARD DISK.
AIR-VAC IS NOT RESPONSIBLE FOR ANY LOST DATA.
The Backup utility is setup per default, that at every launch and exit of VISUALMACHINESTM all rele-
vant database files are saved into a ZIP file into the default backup directory:
C:\Program\VisualMachines\Backup
This backup has been made on November 17, 2006.
Note
IF A SYSTEM MUST BE RE-INSTALLED, IT IS POSSIBLE TO REUSE AN AUTOMATIC CREATED
BACK-UP DURING THE INSTALLATION OF VISUALMACHINES. CONSULT AIR-VAC ON HOW
TO RE-INSTALL THE SOFTWARE AND THE BACKUP.
The Backup utility can be found on the Utilities bar with the appropriate access level.
0029.00.900 6-10
Use Backup Now to start immediately a backup process.

Click on Show Backup Folder to open an explorer win-
dow showing the content of the actual backup folder.
Click OK to close the window.
Files to backup:
Configuration Database - The Configuration Database
of the machine is backed up.
Global Library Database - The library containing the
patterns from the line and dot dispenser is backed up.
User database - The database containing user accounts
for VisualMachines is backed up.
Program Files - All VisualMachines programs are
backed up. It is also possible to Include all subdirecto-
ries of the program directory.
Backup Schedule:
At Launch of VisualMachines a backup is created at every startup of VISUALMACHINES.
Backup Directory:
This field shows the actual path, where the ZIP-
compressed files are stored.
Click on … to browse the folder using the
Please select folder dialog
Create new folder prompts to type in a name
for the new folder that will be created in the ac-
tual folder
0029.00.900 6-11
6.3 Create Software Archive
Note
EACH TIME A QUESTION REGARDING THE SOFTWARE, OR REPORTING A SOFTWARE- OR
PROCESS PROBLEM, PLEASE HAVE THE APPROPRIATE SOFTWARE ARCHIVE READY. THE
SOFTWARE ARCHIVE CAN BE CREATED VERY EASILY, IT MERGES MULTIPLE BACK-UP
FILES INTO A ZIP FILE.
The Administrator application can be opened by double clicking onto the icon on the desk top or by
CTL-ALT-A.
The Create Archive function is useful to create a special compressed archive file.
Note
THE COMPRESSED FILES ARE ZIP COMPATIBLE AND CAN BE RE-USED AS THE RESTORE
OPTION DURING VISUALMACHINES INSTALLATION (SEE INSTALLATION). FOR FURTHER IN-
FORMATION PLEASE SEE THE ONLINE HELP WITHIN THE ADMINISTRATOR APPLICATION.
0029.00.900 6-12
6.3.1 BLOW-OFF AIR ADJUSTMENT

The ONYX 29 assembly head supports vacuum and blow-off air to pick-up and place objects. The
blow-off air is used to insure disengagement of the part from the nozzle. This is especially impor-
tant for small, lightweight parts.
The Blow off adjustment throttle valve is located below the Solder head cover.
To get access to the throttle valve, remove the two screws of the head cover.
Switch off the assembly head vacuum using the Head

peripheral in the Maintenance view. Switch on the blow-
off air. Adjust the manual blow-off air adjustment valve,
until the blow-off air can be felt at the nozzle.
After the proper adjustments, lock the throttle valve, switch off the blow off air and install the head
cover again.
6.3.2 VACUUM FILTER

The ONYX 29 assembly head vacuum uses an inline filter. The filter is located under the back
cover of the head. If the process includes heavy evaporating flux, then the filter must be replaced
on a regular base.
0029.00.900 6-13
6.3.3 Upper Heating Element Replacement
1.Take of the white Cover
White Cover Screw
2.Take of the Top Cover by
Top Cover
3.Loosening the two set Screws and take off the Plate
Plate Set Screw
0029.00.900 6-14
4.Loosen the three Screws and slide the top Cover

through the Tube
Screw Top Cover
5.Take of the three Screws and lift up

the Cover
Cover Screw
0029.00.900 6-15
6.Take of the three Screws and slide the

Pipe through the Tube Screw
Pipe
7.Loosen the two screws, take off the Connector

and slide the Connector Bracket to the rear side
Connector Screw Connector

Bracket
0029.00.900 6-16
8.Take off the black Wiring (two), remove the Tube,

unscrew the GND Screw , disconnect the
Connector.
Tube Black Wiring GND Screw Connector
9.Loosen the Screw, one from the Top Side, and

one by using the Allen Key.
Screw Screw Top

Allen Key Side
0029.00.900 6-17
10. Remove the old Heating Element, mount the new Heating
Element back until you get to the mechanical end Limit.
Heating Element
Note: To remount all removed parts follow the same procedure backwards.
0029.00.900 6-18
Temperature Calibration:
11.Mount the Cal Nozzle ,connect the Hand Hold Meter

Note the Temperature
Temperature Cal Nozzle
Hand Hold Meter
12.Go to Calibration , double click Hot Gas Tool enter the

readout Value in 1.Ambient Temperature Temp.
then select Get Value the Software will calculate the Value
in mV, verify that the Value in 2.SpecifyTargetTemperature
Temp. is 300
Double Click Enter and Select
0029.00.900 6-19
13.Go to Maintenance, Double click

Hot Gas Tool enter Temperature set
Point 300 Temperature speed 65
Hot Flow Set Point 60 SLM click on
Enable
Select
14.Activate Temperature Adv. The Moitor

start after 300 sec. Check the read out
on the Hand Hold Meter note the Value
sample 280 °C
0029.00.900 6-20
15.Go back to Calibration double click Hot Gas Tool

enter the difference Value you get from the Hand Hold Meter
Sample 280°C enter the Value in calibration Calculator
3. 5Min.300°C@60SLM Temp. Then select Computer Calibration
Double Click Enter and Select
Note: The Calibration is done exit the screen and start the Visual Machine Software
0029.00.900 6-21
6.4 Spare Part List

Complete spare part lists are attached in the APPENDIX A.
Note
ALL PARTS DECLARED IN SPARE PART CLASS 1, THE WEAR AND TEAR COMPONENTS, ARE
NOT COVERED BY THE WARRANTY, SEE THE GENERAL DELIVERY TERMS.
Spare Part Classes

1 SPARE PARTS WHICH NEED TO BE REPLACED ON A REGULAR BASE AND WHICH
NEED TO BE STORED AT THE CUSTOMER, W EAR AND TEAR PARTS
2 SPARE PARTS WHICH NEED TO BE REPLACED SELDOM
3 SPARE PARTS WHICH SHOULD NOT NEED TO BE REPLACED
6.4.1 ONYX 29 Selective soldering system

Amount Unit Spare part Article Article description
class number
1 Stk. - 300.01.010 IP-500 Platform
1 Stk. - 200.01.292 Application base plate
1 Stk. - 300.01.024 X-Z-Axis 150mm ONYX 29 (OBC 30mm)
300.01.026 X-Z-Axis 230mm ONYX 29 (OBC 70mm)
1 Stk. 2 109.02.013 ONYX 29 Air-Vac operator panel cover
1 Stk. - 300.01.057 Supply 3Ph 3x208VAC
1 Stk. - 300.00.394 Manual Motion
1 Stk. - 300.01.040 Thermocouple module with 4 ports
300.01.058 Thermocouple module with 8 ports
1 Stk. - 300.00.397 Field illumination
1 Stk. - 300.01.007 Advanced solder head
1 Stk. - 300.01.050 Vision system with MFOV
1 Stk. - 300.00.483 Board holder 508 mm
1 Stk. - 700.00.007 HexSight Acquisition Software license
1 Stk. - 700.01.000 VisualMachines Software license
1 Stk. 800.01.057 ONYX 29 (3x208VAC) – Electrical documentation
0029.00.900 6-22
6.4.2 ONYX 29 Base IP-500 Platform 300.01.010
Pos. Article number Article description

602 300.01.011 X-Y system
603 300.01.015 Base
Pos. Amount Unit Spare part Article Article description

class number
305 1 Stk. 3 109.16.091 Network cable RJ45 Cat. 5e, Length 0.5m
308 1 Stk. 3 109.16.034 Cable FireWire 6pin/6pin, Length 2m
309 1 Stk. 3 109.16.101 Network cable RJ 45 Cat. 5e, Length 2m
310 2 Stk. 3 109.16.109 System cable 3x0.75mm2, Length 2m
601 1 Stk. 3 300.00.989 IT-MAS2 with Force- and Temp. sensor
0029.00.900 6-23
300.01.011 X-Y System

602 300.01.012 Side part left
603 300.01.013 Side part right
604 300.01.014 Y-Beam

class number
601 1 Stk. 3 300.00.431 Transport safety lock
0029.00.900 6-24
300.01.012 Side part left

class number
307 6 Stk. 3 109.11.008 Disk magnet d10x5 NdFeB
308 1 Stk. 3 109.32.022 Linear encoder scale
309 2 Stk. 2 109.51.056 Warning label strong magnetic field
0029.00.900 6-25
300.01.013 Side part right

class number
0029.00.900 6-26
300.01.014 Y-Beam

class number
316 2 Stk. 3 101.04.002 Puffer d 11mm, SJ-5303
320 7 Stk. 3 102.00.012 Linear bearing MNN 9-G1
326 1 Stk. 3 109.32.022 Linear encoder scale
327 2 Stk. 2 109.51.056 Warning label strong magnetic field
602 1 Stk. 3 300.01.059 Linear motor coil
603 1 Stk. 3 300.01.063 Analog linear encoder MS20.04
0029.00.900 6-27
300.01.015 Base A ( 1: 2 )

class number
319 4 Stk. 3 100.00.223 Fitting screw d6 / M5x8 BN13
326 1 Stk. 2 109.02.009 Emergency switch
327 1 Stk. 3 109.02.010 Contact element with 2 opener
328 1 Stk. 3 109.02.014 Motor safety switch, lockable, 16A
329 1 Stk. 3 109.02.015 One phase switch on/off black
330 4 Stk. 2 109.04.025 Force sensor 130x30x22mm
331 1 Stk. 2 109.09.007 Power Supply SP100-24 (Ua=24VDC/4.2A)
332 1 Stk. 2 109.09.010 Open Frame Netzteil NFM-20-12
333 1 Stk. 2 109.09.016 Power Supply SP320-48 (Ua=48VDC/6.7A)
336 4 Stk. 3 109.14.002 Solid - State - Relays 75 -264VAC/ 10A
343 1 Stk. 3 109.24.009 LED green, flat, chrom, 24VDC
345 2 Stk. 3 109.55.007 Miniature switch 3+1 close pos. (24VDC)
601 1 Stk. 3 300.00.011 Distribution board Operator Panel
602 1 Stk. 3 300.00.026 Operator panel complete
611 1 Stk. 3 300.00.959 MAX2-48V Controller cpl.
614 1 Stk. 3 300.01.064 Encoder cable X-axis IP-500
615 1 Stk. 3 300.01.066 Motor cable X-axis IP-500
616 1 Stk. 3 300.01.071 Fibre optic cable single length =1.05m
617 1 Stk. 3 300.01.076 Cable harness Y-axis
Pos. Sub module Article description

0029.00.900 6-28
Pos. Sub module Article description

613 300.01.039 Connector module
300.01.039 Connector module

class number
305 3 Stk. 1 109.05.025 Fine fuse 6.3A fast blow, type SP 5 x 20
306 1 Stk. 1 109.05.026 Fine Fuse 4A fast blow, type SP 5x20
307 10 Stk. 1 109.05.036 Fine fuse 8A slow blow, SPT 5x20mm
313 1 Stk. 2 109.51.005 Warning label 25 x 25mm lightning
602 1 Stk. 3 300.00.514 Cable foot switch
0029.00.900 6-29
6.4.3 X-Z Axis 150mm ONYX 29 300.01.024 (OBC 30mm)

601 300.01.023 X-Z-Axis 150mm base module (OBC 30mm)

class number
305 2 Stk. 3 101.04.003 Parabolic buffer type KP d=20mm
0029.00.900 6-30
300.01.023 X-Z Axis 150mm base module (OBC 30mm)

class number
318 1 Stk. 3 101.18.002 Z-axis break 86621-03H00-24V
319 1 Stk. 3 101.22.007 Ball bearing 4/10/4
320 1 Stk. 3 101.22.033 Axial bearing ZKLR 0624.2Z
321 1 Stk. 2 101.28.006 Power grip belt GT 2MR-112, 6m
601 1 Stk. 2 300.00.038 Z-Encoder complete
602 1 Stk. 3 300.00.907 Z-Motor complete
0029.00.900 6-31
6.4.4 X-Z-Axis 230mm ONYX 29 300.01.026 (OBC 70mm)

601 300.01.025 X-Z-Axis 230mm base module (OBC 70mm)

class number
305 2 Stk. 3 101.04.003 Parabolic buffer type KP d=20mm
0029.00.900 6-32
300.01.025 X-Z-Axis 230mm base module (OBC 70mm)

class number
318 1 Stk. 3 101.18.002 Z-axis break 86621-03H00-24V
319 1 Stk. 3 101.22.007 Ball bearing 4/10/4
320 1 Stk. 3 101.22.033 Axial bearing ZKLR 0624.2Z
321 1 Stk. 2 101.28.006 Power grip belt GT 2MR-112, 6m
601 1 Stk. 2 300.00.038 Z-Encoder complete
602 1 Stk. 3 300.00.907 Z-Motor complete
0029.00.900 6-33
6.4.5 ManualMotion 300.00.394
601
601
302 301 303 2 1 303 3
601
Schrauben von Encoder verwenden

class number
301 2 Stk. 3 101.22.016 Ball bearing 6/13/5 686 2Z
601 1 Stk. 2 300.00.321 Encoder manual motion
0029.00.900 6-34
6.4.6 Thermo couple module with 4 ports 300.01.040
601
301
302
6.4.7 Thermo couple module with 8 ports 300.01.058
301
601/ 602
302
1
0029.00.900 6-35
6.4.8 Field illumination 300.00.397
601 601

class number
601 2 Stk. 3 300.00.438 Field illumination lamp
6.4.9 Field illumination lamp 300.00.438
303
304
301
302
601
303

class number
601 1 Stk. 3 300.00.433 Illumination board field illumination
0029.00.900 6-36
6.4.10 Advanced solder head ONYX 29 300.01.007

602 300.01.004 Pneumatic unit
603 300.01.018 Advanced solder head

class number
302 1.1 m 3 106.17.001 Polyurethane - Tube d = 8mm, black
303 6 m 3 106.17.002 Polyurethane - Tube d = 6mm, black
304 1 Stk. 3 109.27.006 Amplifier 1-Q-EC DEC 24/1
0029.00.900 6-37
300.01.004 Pneumatic unit

602 300.00.969 Pneumatic chassis
603 300.01.019 Pneumatikchassis Seitenteil
606 300.01.022 Site Clean System
607 300.01.029 Site clean system hose

class number
303 1 Stk. 1 106.02.005 Air-filter nylon white
304 2 Stk. 3 106.06.001 3/2 Solenoid valve SYJ 314M-5LOU-Q
309 0.1 m 3 106.17.006 Silicon-Tube di=6mm, da=9, transparent
604 1 Stk. 3 300.01.020 Maintenance unit air
605 1 Stk. 3 300.01.021 Maintenance unit nitrogen
608 1 Stk. 3 300.01.055 Site clean interface
610 1 Stk. 3 300.01.070 Fibre optic cable dual length= 2.85m
0029.00.900 6-38
300.00.969 Pneumatic chassis

class number
308 1 Stk. 3 106.06.005 3/2 Solenoid valve VK 332 5 D0-M5
310 1 Stk. 3 106.12.002 Vacuum ejector 24l/min
311 1 Stk. 3 106.15.002 Pneumatic safety valve, AS1001F-04
315 1 Stk. 3 109.14.002 Solid - State - Relays 75 -264VAC/ 10A
319 2 Stk. 3 109.27.006 Amplifier 1-Q-EC DEC 24/1
602 1 Stk. 3 300.00.959 MAX2-48V Controller cpl.
0029.00.900 6-39
300.01.019 Pneumatic chassis side part

class number
306 1 Stk. 3 106.01.003 Flow Through Muffler
307 3 Stk. 3 106.06.005 3/2 Solenoid valve VK 332 5 D0-M5
309 1 Stk. 3 106.12.006 Vacuum Pump (Venturi)
320 1 Stk. 3 106.20.009 Mass Flow Controller Vögtlin
0029.00.900 6-40
300.01.022 Site clean system

class number
302 1 Stk. 2 106.02.003 Canister site clean system
305 1 Stk. 1 106.02.004 Filter element site clean canister
300.01.029 Site clean system hose

class number
305 1 Stk. 1 106.17.010 High temperature tube 0.5OD x 0.25ID
0029.00.900 6-41
300.01.018 Advanced solder head ONYX 29

602 300.00.464 Theta-axis drive ONYX 29
603 300.00.465 Theta-axis poti ONYX 29
604 300.01.006 Advanced solder head base

class number
304 2 Stk. 2 101.28.007 Power grip belt GT 2MR-74 6M
307 1 Stk. 2 109.51.006 Warning label 25 x 25mm hot surface
602 1 Stk. 3 300.00.464 Theta-axis drive ONYX 29
603 1 Stk. 3 300.00.465 Theta-axis poti ONYX 29
0029.00.900 6-42
300.00.464 Theta-axis drive ONYX 29

class number
601 1 Stk. 3 300.00.614 Gear motor Theta-axis
300.00.465 Theta-axis poti ONYX 29

301
304

class number
1 1 Stk. 3 200.01.225 Pulley Z13
301 1 Stk. 3 109.12.026 Potentiometer (10-turns) PD2310 1kOhm/2W
0029.00.900 6-43
300.01.006 Advanced solder head base

class number
310 1 Stk. 3 101.22.026 Rotational spacer 6x8x12x7
311 1 Stk. 3 101.22.027 Rotational spacer 8x10x15x7.5
312 1 Stk. 3 101.22.028 HEPCO bearing (excenter)
313 2 Stk. 3 101.22.029 HEPCO bearing
314 0.12 m 3 106.17.006 Silicon-Tube di=6mm, da=9, transparent
315 1.25 m 3 106.17.008 Silicon-Tube di=4, da=7, black
601 1 Stk. 1 300.00.140 Hot air heater complete 2000W
602 3 Stk. 3 300.00.473 Stick complete
606 1 Stk. 2 300.00.888 AC Power Supply 230/12VAC 0.5VA
0029.00.900 6-44
6.4.11 Vision system with MFOV 300.01.050

601 300.00.454 Mechanical Stop X complete
603 300.00.564 Distance block vision system
605 300.01.047 Vision unit base module
606 300.01.048 Prism attachment fix
607 300.01.049 Y-carriage vision
608 300.01.072 Vision Y-guiding plate
0029.00.900 6-45

class number
5 1 Stk. 3 200.02.490 Transport safety lock Vision Y
308 1 Stk. 3 109.04.028 Inductive sensor IWFM 18U7504/S35A
604 1 Stk. 3 300.00.819 Gear motor Vision X
300.00.454 Mechanical stop complete
301 (Kleber)
300.00.564 Distance block vision system
0029.00.900 6-46
300.01.047 Vision unit base module

class number
3 2 Stk. 3 200.01.131 Protection glass
317 0.03 m 3 106.17.002 Polyurethane - Tube d = 6mm, black
318 1 Stk. 3 108.00.013 FireWire camera DFK 21F04
319 1 Stk. 3 108.01.004 Macro zoom objective Computar MLH-10X
320 1 Stk. 3 108.06.010 Tele converter 2x with C-mount
321 2 Stk. 3 109.08.003 Fan 40x40x10 mm, 24 VDC
322 1 Stk. 3 109.16.095 Firewire cable 6pin/6pin, Length 3m
323 1 Stk. 3 109.24.019 Laser Pointer FP-65
324 1 Stk. 2 109.51.058 Warning label 15 x 15mm laser beam
602 1 Stk. 3 300.00.457 Upper illumination board
603 1 Stk. 3 300.00.458 Lower illumination board
604 1 Stk. 3 300.00.459 Potentiometer Vision Zoom-axis
605 1 Stk. 3 300.00.460 Gear motor vision
0029.00.900 6-47
300.01.048 Prism attachment fix
302
1
301

class number
1 1 Stk. 3 200.01.123 Beam splitter prism 30mm
0029.00.900 6-48
300.01.049 Y-carriage vision

class number
0029.00.900 6-49
300.01.072 Vision Y-Guiding plate

class number
601 1 Stk. 3 300.00.568 Motor vision Y-axis
602 1 Stk. 3 300.00.636 Motor/Encoder Interface Card
0029.00.900 6-50
6.4.12 Board holder 500 mm 300.00.483
309 601 307
307
4
10 5 306
1
2
7 304
301 304 305
3 303
8
302
309
6 305
9

601 300.00.373 Board holding clamp

class number
15 4 Stk. 3 200.00.206 Bearing
302 4 Stk. 3 100.12.007 High hand screw M3x10
303 4 Stk. 3 101.27.003 Spring Nr. 9005.02.001
304 8 Stk. 3 102.02.001 Bearing Sferax 1017 B-BL GO
601 6 Stk. 3 300.00.373 Board holding clamp
300.00.373 Board holding clamp

2
class number
301 1 Stk. 3 101.27.002 Spring VD-063N 303
301
304
305
302 306
1
0029.00.900 6-51
6.4.13 Preheater – 5600 watt, 19” square – 0029.06.041
0029.00.900 6-52
0029.00.900 6-53
0029.00.900 6-54
6.4.14 Board cooling 490 mm 300.00.409

(Board cooling to 300.00.761)

class number
0029.00.900 6-55
6.4.15 Direct view camera 300.01.045

class number
302 1 Stk. 3 108.00.013 FireWire camera DFK 21F04
303 1 Stk. 3 108.01.004 Macro Zoom Objective Computar MLH-10X
304 1 Stk. 3 109.16.095 Firewire cable 6pin/6pin, Length 3m
* 1 Stk. 3 108.06.010 Tele converter 2x with C-mount
601 1 Stk. 3 300.01.384 Ring light direct view camera
602 1 Stk. 3 300.01.387 Cable illumination direct view camera
* Optional
0029.00.900 6-56
ONYX29 User’s Guide Chapter 7: General Specifications & Options
7: General Specifications & Options

7 ONYX 29 Specifications, Overview and Options ..................................................................................3
7.1 GENERAL SPECIFICATIONS .......................................................................................................................3
7.2 OPTIONS .................................................................................................................................................4
7.2.1 70MM (2.75”) TOP SIDE CLEARANCE ........................................................................................................4
7.2.2 SITE CLEANING SYSTEM ..........................................................................................................................4
7.2.3 IR SENSOR..............................................................................................................................................5
7.2.4 BOARD COOLING SYSTEM ........................................................................................................................5
7.2.5 UNIVERSAL INSERTION TOOL ....................................................................................................................5
7.2.6 AUTOMATIC COMPONENT SHUTTLE...........................................................................................................6
7.2.7 PASTE-ON-DEVICE MICRO STENCIL ADAPTER ..........................................................................................6
7.2.8 FLUX DIP PEDESTALS ..............................................................................................................................7
7.2.9 DIRECT VIEW CAMERA & MOUNT ASSEMBLY ............................................................................................7
7.2.10 DISPENSING SYSTEM ...........................................................................................................................8
7.2.11 FOUR (4) ADDITIONAL THERMOCOUPLE PORTS.....................................................................................8
7.2.12 FUME EXTRACTION MANIFOLD..............................................................................................................9
7.2.13 ERGONOMIC W ORKSTATION.................................................................................................................9
0029.00.900 7-1
0029.00.900 7-2
7 ONYX 29 Specifications, Overview and Options

7.1 General Specifications
Dimensions and Weight Width 32” (823 mm)
Depth 32” (821 mm)
Height 38” (951 mm)
Weight 120 kg (264lbs)
Electrical 3-phase power U (Voltage) (3 x 240 VAC)
I (Current) (16 A)
S (Power) (5800 VA)
F (Frequency) (60 Hz)
Air source Air pressure 4 - 6 bar 100 l/min
-2
Axes acceleration X 1,5 ms Limited to guarantee
-2
Y 1,5 ms operator safety
-2
Z 1,5 ms
-1
Axes speed X 0,15 ms Limited to guarantee
-1
Y 0,15 ms operator safety
-1
Z 0,15 ms
Working area X 15.7” (400 mm)
Y 15.7” (400 mm)
Z 150 mm (30 OBC mm) Optional 70 OBC mm
Theta +/- 12 degree
Vision-X 60 mm
Vision-Y 220 mm
Vision-Zoom 3 – 30 mm FOV (Field Of View)
Axes resolution X 0,001 mm
Y 0,001 mm
Z 0,001 mm
* Process Accuracy X +/– 0,009 mm
+/– 3 Sigma Y +/– 0,009 mm
Z +/– 0,020 mm
o
Theta +/– 0,02
Board dimensions Maximum size 20” x 20” (508 x 508 mm)
Maximum thickness 6 mm
Clearness above 30 mm optional 75 mm
Clearness below 20 mm optional 30 mm
Pre-heater area 19” x 19” (490 x 490 mm)
Vision system Object size 0,2 x 0,2 to 70 x 70 mm
Illumination Component illumination with adjustable light intensity
Board illumination with adjustable light intensity
Vision X/Y/Zoom Closed loop motorized Focus manual adjustable
Values based on glass flip chip placements on glass substrate, further variation of accuracies available upon machine configuration.
0029.00.900 7-3
7.2 Options
7.2.1 70mm (2.75”) Top Side Clearance

Objective
• Provide increased top side clearance for assem-
blies with vertical daughter cards or tall devices
that exceed the standard 30mm (1.2”) top side
clearance.
Includes:
• Machine frame modifications for additional
clearance.
• Longer z-axis stroke to access the board.
Photo
• 1.9” tall through hole device fits easily under the
Vision System.
• Extended z-axis stroke enables nozzle to reach
the board to rework the BGA.
7.2.2 Site Cleaning System

Objective
• Fully automated removal of residual site solder
without damaging the pads or solder mask.
Eliminates the need for traditional solder
iron/solder wick process and associated issues
(ie. manual intervention, mechanical contact of
pads).
How It Works:
• The site cleaning tool pattern is automatically
generated based on the part dimension.
• Hot gas reflows the residual solder on the pads. Heat
• A vacuum sensor continuously adjusts the height
of the composite vacuum tip to provide non- Vacuum
contact site cleaning.
Notes Of Interest:
• Non-contact site cleaning will become critical for lead-free rework due to the significantly
higher temperature required to reflow the residual site solder.
• Small, medium and large composite vacuum tips provided.
• Micro tips and collectors also available.
Photos:
• Various size composite tips.
• (Inset) Site cleaning system in process.
0029.00.900 7-4
7.2.3 IR Sensor
Objective
• Provides process repeatability by insuring that
the board is at the exact same target tempera-
tures each time before localized reflow begins.
How It Works:
• Operator is instructed to position the sensor
head at the beginning of the process.
• The non-contact temperature sensor monitors
topside board temperature and automatically
triggers the localized reflow process once the
target temperature is reached.
Photo
• Non-contact IR Sensor with pivoting head and laser pointer.
7.2.4 Board Cooling System

Objective
• Provides controlled cool down of both the device
and assembly to effectively manage time-over-
reflow and to facilitate handling of the assembly
after rework.
How It Works:
• High laminar flow of cool air is directed between
the bottom heater and the assembly, providing Cool Air Flow
rapid cooling.
• Programmable control allows the cooling air to
be turned on/off whenever desired.
Notes Of Interest:
• The cooling rate of the solder joint after reflow is critical. The faster the cooling rate, the
smaller the solder grain size and the higher the fatigue resistance.
Photos:
• Illustration of laminar flow of cool air passing between the bottom of the board and top of
preheater.
• Software controlled cool down.
7.2.5 Universal Insertion Tool

Mechanically self-centers any square device for accurate
pick up. Used in conjunction with component shuttle.
Photo:
• Mechanically centered 35mm SBGA.
• (Inset) 6mm Flip Chip.
0029.00.900 7-5
7.2.6 Automatic Component Shuttle

Objectives:
• Provides a safe, repeatable location for compo-
nent pick up, flux dipping and drop off away from
the heated work area.
• Eliminates manual component loading and re-
moval in the heated work area.
How It Works:
• Software-controlled pneumatic shuttle enters the
work area for pick up, flux dipping or drop off
then exits the work area.
• Shuttle-based component pick up and flux dip-
ping is force controlled.
Notes Of Interest:
• Multi-location pick and flux dipping capability for
multi-processing of small devices (custom tool-
ing required).
Photos:
• Home position away from work area.
• Work position for force-controlled component
pick-up.
7.2.7 Paste-On-Device Micro Stencil Adapter

Component-specific micro stencil applies solder paste di-
rectly to the component spheres.
Pasted device in stencil is placed in micro stencil adapter,
which is used in conjunction with the component shuttle to
pick the pasted device.
Notes Of Interest:
• Air-Vac does not supply the component-specific
micro stencils. Recommended supplier is Mini
Micro Stencil (760-591-3804).
Photos:
• MLF68 with center ground pad in micro stencil (solder paste applied to device).
• Micro stencil installed into adapter for direct pick from shuttle.
0029.00.900 7-6
7.2.8 Flux Dip Pedestals

Stainless steel fluxing pedestals with precision-machined
depth provides controlled application of tacky flux directly to
the solder spheres on the device.
Used in conjunction with the component shuttle.
Notes Of Interest:
• Various sizes and depths available. Recom-
mended depth is 50% of ball height.
Photo
• PBGA196 imprint on flux pedestal in component
shuttle.
7.2.9 Direct View Camera & Mount Assembly

Objective
• Provides high magnification
site viewing including the abil-
ity to verify component reflow
has occurred.
How It Works:
• Operator is instructed to posi-
tion the DV camera on the
site. Focus, zoom and lighting
adjustments are made to op-
timize clarity.
• The site image is integrated
with the software and dis-
played on the PC monitor.
Notes Of Interest:
• The DV camera is a valuable
process development aid especially for difficult to see tiny devices.
• The DV camera is also recommended for use in conjunction with the dispensing option
to provide dispense inspection capability.
Photos:
• Camera/mount assembly.
• Close-up view of BGA spheres.
0029.00.900 7-7
7.2.10 Dispensing System

• Provides on-machine dispensing of flux, solder
paste, adhesive, epoxy or underfill.
• Proprietary time/pressure dispenser features
automatic pressure compensation and pro-
grammable vacuum adjustment for accurate and
repeatable results.
• Uses precision DL Technology dispense nee-
dles.
• Automatic pattern generation software makes
creating dispensing patterns a snap.
Notes Of Interest:
• Dispensing requires ambient machine/assembly
temperature. Nozzle cool air injection and the
board cooling system can be simultaneously ac-
tivated to prepare the machine and assembly for
dispensing, however this is not practical from a
time standpoint for each individual rework proc-
ess.
• The on-machine dispense option is typically
used in either a batch mode or for low volume,
specialty applications.
7.2.11 Four (4) Additional Thermocouple Ports

Objective
• Four (4) additional TC channels (total of 8) provides ad-
ditional monitoring capability for advanced process de-
velopment applications. The ONYX29 includes four (4)
TC channels.
0029.00.900 7-8
7.2.12 Fume Extraction Manifold

Objective
• Removes flux vapors from the work environment
for operator health and safety. Exhaust
Includes: Manifold
• Fume extraction manifold and hose assembly.

Notes Of Interest:
• Requires connection to a central exhaust or self-
contained filtering system.
7.2.13 Ergonomic Workstation

Objective
• Provides a self-contained work cell environment for the machine and operator.
Features:
• 60”W x 36”D ultra-sturdy construction with anti-static laminate surface and CPU holder.
• Available accessories include lockable storage drawer, nozzle rack, monitor stand and
keyboard tray. All are designed for ergonomic operation.
0029.00.900 7-9
0029.00.900 7-10
ONYX29 User’s Guide Chapter 8: Program Execution
8: Program Execution
8 Program Execution ..................................................................................................................................3
8.0 EXECUTION VIEW , MAIN EXECUTION .........................................................................................................3
8.0.1 PROGRAM HEADER ..................................................................................................................................3
8.0.2 PROGRAM ERROR CONTROL: ...................................................................................................................5
8.1 EXECUTION MONITOR ..............................................................................................................................5
8.2 PROGRAM STATUS ...................................................................................................................................6
8.3 DIRECT SIGNAL MANIPULATION .................................................................................................................6
8.4 MACHINE OPERATOR PANEL ....................................................................................................................6
0029.00.900 8-1
0029.00.900 8-2
8 Program Execution
Note
FOR ACCURATE SOFTWARE DESCRIPTIONS AND SOFTWARE HELP USE THE ON LINE
TM
ROBOHELP WITHIN THE SOFTWARE VISUAL MACHINES .
8.0 Execution View, Main Execution

After starting VISUAL MACHINESTM, the
Execution View is opened automatically.
Otherwise the Execution View is opened
by clicking the Execution button on the
Views tab.
The Execution View allows opening and
executing existing programs.
All access levels allow the access to the Execution View
and its functions.
A program must be loaded and selected for execution.
There can only 1 program be selected for execution. The
exception is when executing calibration sequences, then
the selected program is temporarily removed. At the end of
the calibration it is automatically selected again.
The Main Execution provides the functionalities to load, to
start and to stop programs. When there are program er-
rors during the program execution an error message is
displayed in the Program Error Control section, so that the
user can interact with the program execution.
8.0.1 Program Header

The header shows the name and the description of the
selected program. If no program is selected, it will display
"No Program…"
Clicking on this Quick Select button will open a sub-

menu with all loaded programs. Selecting a program from
the pull-down list will directly assign it to the execution so
that it can be started.
Clicking on this Select or open program button will

open the "Select and Open Program" window. It is possible
to browse for finding the correct programs in various direc-
tories and then to select programs.
0029.00.900 8-3
Clicking on this Close the current program for Execution button will unload the current se-
lected program.
Clicking on this Copy the current selected program button will copy the selected program. It
will let the user give a new internal name and description. The program does get directly selected
in the execution.
The Options button opens a pull-down menu where you can enable/disable some display options
like the Monitor or the Program Status window (see below).
Cycle field defines the number of repetitions of the program before the program execution is fin-
ished. The left field shows the current execution status.
Dry Run Enable/Disable mode allows operating the system without using any heat.
Training Enable/Disable mode allows training pre-defined process parameters.
Note
TRAINING MODE ALLOWS SETTING PROCESS PARAMETERS IN REAL ENVIRONMENT DUR-
ING THE PROGRAM EXECUTION, FOR EXAMPLE TEACHING POSITIONS, SETTING DIMEN-
SIONS OR SETTING LIGHT PARAMETERS. TRAINING MODE FUNCTIONALITY DEPENDS ON
EACH PROCESS AND MAY APPEAR DIFFERENT DEPENDING ON THE SYSTEM CONFIGURA-
TION.
ONLY QUALIFIED PERSONNEL WITH THE LABEL “TECHNICAL OPERATOR” OR HIGHER HAS
ACCESS TO THE TRAINING MODE THROUGH THE “DIRECT ACCESS FEATURE”.
Inspection Enable/Disable mode allows executing View processes in the program. If this option is
disabled, the View processes are not executed. When using interactive soldering processes, the
executed profile will be shown at the end of the process sequence when enabled.
Speed sets the velocity in percent for the robot axes.
Click the Start button to run the currently selected program
Click the Pause button to pause the currently running program
0029.00.900 8-4
8.0.2 Program Error Control:

The Program Error Control gets always enabled when there
is an error occurring during the program execution. The user
can make decisions how to continue by clicking the following
buttons:
Resume button will go on with the next process in the
loaded program
Retry button will retry a procedure within the process
Skip button will skip a procedure within the process or even
the whole process by continuing with the next one
Stop button immediately aborts the current running program
Process Properties button is active when process proper-
ties are available
Note
THE MEANING OF THE ERROR CONTROL BUT-
TONS IS DIFFERENT FROM ERROR TO ERROR. THE TEXT BESIDES EACH BUTTON WILL DE-
SCRIBE ITS EFFECT ON THE PROGRAM/PROCESS EXECUTION
8.1 Execution Monitor

The Monitor window can be enabled under the pull down Options, see section above. Tempera-
ture curves of peripherals are being displayed during program execution:
Using the Menu button opens a new submenu:

Clear Monitor will clear all curves on the monitor.
Hide Monitor will hide the monitor. Click on the Monitor button in Program
Control strip to show it again.
Display Legend will show a legend below the graph.
Display Last Values will show the last values of the monitor lines below the
graph.
Zoom all option allows zooming the whole history of the captured values.
Export… will open an export dialog that allows saving the graph to a file or
to clipboard in different image formats.
Export to File… will open a dialog to save the graph by values to a *.csv file
that can be imported in Microsoft Excel.
Below the standard entries you can see a list of all peripherals that are supporting the monitoring
function. By clicking on a peripheral name, you can select an entry to add its curve to the graph.
0029.00.900 8-5
8.2 Program Status

The Program Status window is open automatically as soon
as the execution of a program is started. It shows the position
of the execution in the currently running program.
Icons in the tree have the following meaning:
Process has still to be done

Currently running process
Process has done successfully
Process was having an error
8.3 Direct signal manipulation

Below the program error control menu, depending
on the system configuration, digital output signals
are listed which may be selectable during a
paused execution.
8.4 Machine Operator Panel
START Starting a program for execution. This button has the same function as the START
BUTTON in the EXECUTION VIEW and of the foot switch (optional). A program can be
executed only when it is loaded and selected. The program name must appear in
the header of the EXECUTION VIEW , when it is properly selected. For program exe-
cution the Emergency-stop button must be released and the power to the axes
must be enabled.
If a program is paused it is possible to re-start the program by selecting the START

BUTTON.
STOP Stops, pauses the program at the next program step. This button has the same
function as the PAUSE BUTTON in the EXECUTION VIEW .
If the program is already paused, activating the STOP BUTTON again, stops the pro-
gram from execution, the program can not be continued it needs to be restarted.
0029.00.900 8-6
ENABLE The ENABLE BUTTON is used to enable the axes power after the E-stop has been
released. When the axes power is enabled, the axes can not be moved manually.
Once the power is enabled, the power can be disabled using this button again.
MANUAL Once the power is enabled, the MANUAL BUTTON switches the control of an axis to
the Manual Motion Mode (ManualMotion)…. Turning the ManualMotion wheels on
the operator panel moves the selected axis. This can be used especially to teach
points on an axis. The selected axis can be moved manually this way.
ManualMotion start level Æ All axes are enabled

ManualMotion first level Æ Left wheel = X-axis (coarse or fine)
Æ Right wheel = Y-axis (coarse or fine)
ManualMotion second level Æ Left wheel = Z-axis (coarse or fine)
Æ Right wheel = No axis assigned
ManualMotion third level Æ Left wheel = X-axis (fine or coarse)
Æ Right wheel = Y-axis (fine or coarse)
ManualMotion fourth level Æ Left wheel = Z-axis (fine or coarse)
Æ Right wheel = No axis assigned
ManualMotion fifth level Æ Starts again at first level…
To disable the ManualMotion mode, select the Enable button which enables all
axes and deactivates the manual motion mode.
During the vision alignment process, these wheels are used to match the compo-
nent to the board.
OPTION The option button has no factory defined function. It can be used for any function
within the process sequences.
LIGHT The light button is used to switch on and off the Field Illumination.
THETA Using these buttons allows rotating the Theta axis for alignment of
the part on the nozzle.
0029.00.900 8-7
0029.00.900 8-8
ONYX29 User’s Guide Chapter 9: Electrical Modules and Schematics
9: Electrical Modules/Schematics
9 Electrical Modules & Schematics...........................................................................................................3
9.0 ELECTRICAL MODULES AND LOCATIONS .....................................................................................................3
9.0.1 IT-MAS MODULE OF THE ONYX 29 LEFT COLUMN .....................................................................................4
9.0.2 ELECTRICAL MODULES OF THE ONYX 29 ADVANCED SOLDER HEAD ...........................................................5
9.1 DISTRIBUTED CONTROL SYSTEM ...............................................................................................................5
9.1.1 MAX2 CONTROLLER ................................................................................................................................6
9.1.2 IT-MAS2 MASTER CONTROLLER ..............................................................................................................7
9.2 CONTROL SYSTEM INTERFACE TABLE (I/O LIST).........................................................................................7
9.2.1 I/O TABLE ONYX 29 BASE MODULE .........................................................................................................8
9.2.2 I/O TABLE ONYX 29 HEAD MODULE .........................................................................................................9
9.2.3 GENERAL PURPOSE CONTROLLERS .........................................................................................................10
9.3 FUSES OF THE ONYX 29 .......................................................................................................................11
9.3.1 FUSES ON THE BACK PANEL ....................................................................................................................11
9.4 ELECTRICAL SCHEMATICS ......................................................................................................................12
0029.00.900 9-1
0029.00.900 9-2
9 Electrical Modules & Schematics

All the machine peripherals in general are operated at low voltages (below 60VDC). All motors in
the system are powered with 48 VDC. All digital signals are operated at 24VDC, and all analog
signals are operated at 0-10 VDC. To remove the base plate, disconnect the pre-heater and the
board cooling hose, remove the cover screws in each corner and remove the screws located be-
low. Then the base plate can be removed carefully.
9.0 Electrical modules and locations

The power input, fuses and DC-power generation is located below the base plate. All fuses are
accessible from the back, without removing the base plate.
F A F
G
C B
D
E
F F
Ident Description Page Column Description

A Q41 Main Power on/off 4 1 Main 3-phase power switch
B G43 Power supply 24 VDC 4 3 Generates 24VDC power for all I/O’s
C G44 Power supply 48 VDC 4 4 Generates 48VDC power for all motors
D G45 Power supply 12 VDC 4 5 Generates 12VDC direct view camera
E N146 Motor controller for Theta 14 6 General Purpose controller Theta axis
F B84 4 force sensors 8 4-8 Force sensors of force sensor table
G X101 MAX-2 Base module 10 1 X/Y, Manual Motion and general I/O
0029.00.900 9-3
9.0.1 IT-Mas module of the ONYX 29 left column

The IT-MAS2 Master module is responsible as the computing bridge between the “Ethernet world”
PC and the distributed system controllers. On the IT-MAS2 Master module all the system synchro-
nization tasks are being performed, such as coordinated motion of two axes. The IT-MAS2 Master
can be connected over RS232, or as in this application using Ethernet. The IT-MAS2 Master then
communicates over fiber optic with the other distributed MAX2 control modules. When replacing
the IT-MAS2 Master module, make sure the corresponding IP-address is being downloaded (de-
fault IP-Address = 192.168.1.100)
B5 B1
B2
A B3 B4

A V317 Power LED 31 7 Indicates the power state of the system
B N81 IT-Mas2 8 1 Communication bridge IT-MAS2
B1 Four thermocouple inputs 8 1-4 Thermo couples from front panel
B2 Four force sensor inputs 8 4 Force sensor amplifier
B3 Ethernet connection to PC 8 2 Communication to PC
B4 RS232 connection to PC 8 3 Only for programming (not connected)
B5 Fiber optic ring input /output 8 4 Info-link bus to distributed controllers
0029.00.900 9-4
9.0.2 Electrical modules of the ONYX 29 advanced solder head

Inside the Advanced- or Economy solder head, there is another MAX2 controller module with the
corresponding distribution card located. All head motors and all head I/O signals are supported up
in the head:

N101 Head module controller 10 1 Head motion and head I/O controller
X101 Head module distribution 10 1 Head motion and head I/O distribution
9.1 Distributed control system

The ONYX 29 uses a distributed control system. A single module contains amplifiers to drive two
servo motors and includes all the needed analog and digital I/O channels. Because of the high
density of its electronics, one control module replaces a conventional VME or industrial computer
chassis. Also because of their small size and mass, they can be placed on moving axes, for ex-
ample inside the Solder head, and in small spaces near the actual sensor and motors that are
used throughout the system.
0029.00.900 9-5
MAX2 MAX2
Head Base
Camera
IT-MAS2 Vision unit
Info-Link Optional
Direct view
camera
FireWire
External
Network
Ethernet FireWire
PC
Function Location Controller Address IP-Address

Master Controller Left column IT-MAS2 0x00 192.168.1.251
Slave Controller #1 Head INFO-MAX2 0x10 -
Slave Controller #2 Base INFO-MAX2 0x20 -
PC 192.168.1.100
Subnet Mask: 255.255.255.0
9.1.1 MAX2 controller

The MAX2 controllers are used to control the
motion axes, the digital- and analog signals
used in the system.
MAX2 Module
2 DC- or 3-phase motors (200 Watt)
2 PWM signals (2.5A)
2 Encoder input signals
16 Digital output signals (24V, 2A)
16 Digital input signals (24V)
4 Analog output signals (16 Bit)
14 Analog input signals (16 Bit)
0029.00.900 9-6
When replacing a MAX2 controller module,

make sure the address switch in the front of
the new MAX2 is set identically as on the
replaced module and all jumper positions must be
set the same. Additionally the configuration soft-
ware of that particular controller must be down
loaded to the controller.
The MAX2 controller can communicate with a PC
directly over RS 232. Within the ONYX 29, the
MAX2 controllers communicate over the fiber op-
tic cable Info Link with the IT-MAS2 (Master con-
troller).
9.1.2 IT-MAS2 Master controller

The IT-MAS2 Master module is responsible as the computing bridge between the “Ethernet world”
PC and the distributed system controllers. On the IT-MAS2 Master module all the system synchro-
nisation tasks are being performed, such as coordinated motion of two axes. The IT-MAS2 Master
can be connected over RS232, or as in this application using Ethernet. The IT-MAS2 Master then
communicates over optic fibre with the other distributed MAX2 control modules. When replacing
the IT-MAS2 Master module, make sure the corresponding IP-address is being down loaded cor-
rectly (default IP-Address = 192.168.1.100)
IT-MAS2 Master controller module

Master computer for the entire system with communication bridge
PC machine (Ethernet) to distributed controllers Info-link (fibre optic
ring). Included is the force sensor amplifier which is link directly
with the motion hardware.
4 Thermocouple channels
4 Force sensor input channels
9.2 Control system interface table (I/O list)
Note
FOR A SYSTEM SPECIFIC I/O LIST, USE THE DOCUMENTS BELONGING TO THE EQUIPMENT
ALL LABELS ARE DEFINED WITH PAGE AND COLUMN NUMBER OF THE SCHEMATICS. FOR
EXAMPLE M168 REPRESENTS A MOTOR WHICH CAN BE FOUND ON PAGE 16, COLUMN 8.
0029.00.900 9-7
9.2.1 I/O table ONYX 29 Base module

Signal Motor Pin Remarks SW Sig Name
Motor 1 X-Axis motor X25 X
Motor 2 Y-Axis motor X26 Y
PWM (High Current)
PWM 1 X27 Base_PWM1
PWM 2 X28 Base_PWM2
Analog Inputs
AI 01 Site clean vacuum sensor internal Base_AI_SiteCleanVacuum
AI 02 Mass flow air valve input X19/1 Base_AI_MassFlow
AI 03 Pyrometer temperature sensor (Option) X19/3 Base_AI_Pyrometer
AI 04 Theta-axis potentiometer X20/9 Base_AI_ThetaPos
AI 05 Thermoresistor Pre-heater 1 (PT100) X20/11 Base_AI_PreHeater1Temp
AI 06 Thermoresistor Pre-heater 3 (PT100) X21/19 Base_AI_Preheater3Temp
AI 07 Thermoresistor Pre-heater 4 (PT100) X21/25 Base_AI_PreHeater4Temp
AI 08 Thermoresistor Pre-heater 2 (PT100) X22/17 Base_AI_Preheater2Temp
AI 09 X11 Base_AI_9
AI 10 Thermocouple Channel 5 X12 Base_AI_THC_5
AI 14 Thermocouple offset measurement internal Head_AI_PT100_onBoard
Analog Outputs
AO 01 Mass flow air valve output X17/1 Base_AO_MassFlow
AO 02 Theta-Axis speed X17/6 Base_AO_ThetaSpeed
AO 03 X18/11 Base_AO_03
AO 04 X18/16 Base_AO_04
Encoder Inputs
X-Axis encoder X7
Y-Axis encoder X8
Handw heel lef t X5
Handw heel right X6
Digital Inputs
DI 01 Start push button & Foot sw itch X34/1 Base_DI_FootSwitch
DI 02 Stop/Abort push button X34/2 Base_DI_StopButton
DI 03 Enable/Release axes push button X34/5 Base_DI_ReleaseButton
DI 04 Manual push button X34/6 Base_DI_ManualButton
DI 05 Option push button X35/9 Base_DI_OptionButton
DI 06 Light/Field illumination push button X35/10 Base_DI_FieldIllumination
DI 07 Theta-Axis movement cw push button X35/13 Base_DI_ThetaJog CW
DI 08 Theta-Axis movement ccw push button X35/14 Base_DI_ThetaJogCCW
DI 09 Manual loader base position X36/17 Base_DI_MLBasePos
DI 10 Manual loader w ork position X36/18 Base_DI_MLWorkPos
DI 11 X36/21 Base_DI_11
DI 12 X36/22 Base_DI_12
DI 13 X37/25 Base_DI_13
DI 14 X37/26 Base_DI_14
DI 15 AC pow er synchronization (heaters) X37/29 Base_DI_PowerSync
DI 16 Internal enable signal (E-Stop) X37/30 Internal (from X1/5) Base_DI_EStop
Digital Outputs
DO 01 Site clean vacuum valve X30/1 PNP Base_DO_SiteCleanVacuumSwitch
DO 02 Nitrogen sw itch valve X30/3 PNP Base_DO_NitrogenSwitch
DO 03 Board cooling valve X30/5 PNP Base_DO_BoardCooling
DO 04 Out light, external camera X30/7 PNP Base_DO_Light
DO 05 Out dispenser, external dispenser contr. X31/9 PNP Base_DO_Dispenser
DO 06 Pre-heater 1 (SSR relay) X31/11 PNP Base_DO_PreHeater1
DO 10 Manual loader valve X32/19 PNP Base_DO_MLSwitch
DO 11 X32/21 PNP Base_DO_11
DO 12 X32/23 PNP Base_DO_12
DO 13 X23/4,5 NP N Base_DO_13
DO 14 Theta-axis disable/brake X24/4,5 NP N Base_DO_ThetaON
DO 15 X23/3 NP N Base_DO_15
DO 16 Theta-axis direction X24/3 NP N Base_DO_ThetaDir
0029.00.900 9-8
9.2.2 I/O table ONYX 29 Head module

Signal Motor Pin Remarks SW Sig Name
Motor 1 Z-Axis motor X25 Z
Motor 2 Vision Y-Axis motor X26 VY
PWM (High Current)
PWM 1 Object illumination X27 Head_PWM_ObjectIllumination
PWM 2 Board illumination X28 Head_PWM_BoardIllumination
Analog Inputs
AI 01 Nozzle vacuum sensor internal Head_AI_NozzleVacuum
AI 02 X19/1 Head_AI_02
AI 03 X19/3 Head_AI_03
AI 04 Vision Zoom-Axis potentiometer X20/9 Head_AI_VisionZoomPos
AI 05 Vision X-Axis analog sensor X20/11 Head_AI_VisionXPos
AI 06 X21/17 Head_AI_06
AI 07 X21/19 Head_AI_07
AI 08 X22/25 Head_AI_08
AI 09 Nozzle hot gas heater (type K) X11 Head_HotGasTemp
AI 10 X12 Head_AI_10
AI 14 Thermocouple offset measurement internal AI_PT100_onBoard
Analog Outputs
AO 01 Vision X-Axis speed X17/1 Head_AO_VisionXSpeed
AO 02 Vision Zoom-Axis speed X17/6 Head_AO_VisionZoomSpeed
AO 03 X18/11 Head_AO_02
AO 04 X18/16 Head_AO_03
Encoder Inputs
Z-Axis encoder X5
Vision Y-Axis encoder X10
Digital Inputs
DI 01 X34/1 Head_DI_01
DI 06 X35/10 Head_DI_06
DI 07 X35/13 Head_DI_07
DI 08 X35/14 Head_DI_08
DI 09 X36/17 Head_DI_09
DI 10 X36/18 Head_DI_10
DI 11 X36/21 Head_DI_11
DI 12 X36/22 Head_DI_12
DI 13 X37/25 Head_DI_13
DI 14 X37/26 Head_DI_14
DI 15 X37/29 Head_DI_15
DI 16 Internal enable signal (E-Stop) X37/30 Internal (from X1/5) Head_DI_EStop
Digital Outputs
DO 01 Nozzle hot gas heater (SSR relay) X30/1 PNP Head_DO_HotGasHeater
DO 02 Nozzle vacuum X30/3 PNP Head_DO_NozzleVacuum
DO 03 Nozzle blow off air X30/5 PNP Head_DO_NozzleBlowOff
DO 04 Heater element by-pass X30/7 PNP Head_DO_HeaterByPass
DO 05 Field illumination X31/9 PNP Head_DO_FieldIllumination
DO 06 Laser pointer X31/11 PNP Head_DO_LaserPointer
DO 07 Z-Brake X31/13 PNP Head_DO_ZBrake
DO 08 X31/15 PNP Head_DO_8
DO 13 Vision X-Axis disable/brake X23/4,5 NP N Head_DO_VisionXON
DO 14 Vision Zoom-Axis disable/brake X24/4,5 NP N Head_DO_VisionZoomON
DO 15 Vision X-Axis direction X23/3 NP N Head_DO_VisionXDir
DO 16 Vision Zoom-Axis direction X24/3 NP N Head_DO_VisionZoomDir
0029.00.900 9-9
9.2.3 General purpose controllers

The general purpose controllers are used for the Vision-X
axis and for the Vision-Zoom axis.
The Vision-X and Vision Zoom axes are located under the
head cover:
On both controllers, the potentiometer has to be adjusted
fully open (completely to the clockwise side).
The 3 jumpers on the controller boards have to be open,
not set.
Jumper Pins Description Selected

J1 1-2 When closed, then the shield is connected to chassis ground Yes
2-3 When closed, then the shield is connected to 24VRET No
J2 1-2 Analog Input AGND and 24VRET No
J3 Reference voltage for the connected potentiometer:
1-2 DC/DC Converter (GND) and DGND Yes
2-3 DC/DC Converter (GND) and 24VRET No
Do not move modules around system. The modules are configured for its
perpendicular use and cannot be moved from the base to the x/y or to the
head.
0029.00.900 9-10
9.3 Fuses of the ONYX 29

The 3-phase main power switch has included a 16A internal fuse per phase. If the fuse is acti-
vated, the main switch is automatically switched off. After the problem has been fixed the switch
can be switched on again. No fuses need to be replaced.
9.3.1 Fuses on the back panel

The fuses on the back panel are shown to the left, addi-
tionally every installed pre-heater channel includes a fuse
per phase.
Ident Description Fuse type Voltage Remarks

F51 Power Outlet connector, phase F 6.3A 100-240VAC (50/60Hz) PC & Monitor
F52 Power Outlet connector, neutral F 6.3 A 100-240VAC (50/60Hz) Phase in the US
F43 Power Logic voltage F 4A +24VDC I/O logic power
F45 Power Motor voltage F 6.3A +48VDC (+43VDC) Adjusted to 43 VDC
F71 Hot Gas system, phase T 8A 240 VAC
F72 Hot Gas system, neutral T 8A 240 VAC
F62 Pre-heater 1 phase T 8A 240 VAC
F62.1 Pre-heater 1 phase T 8A 240 VAC
Please note that the Fuse identification matches the location of the electrical schematics. For ex-
ample Fuse F42 is listed on page 4 in column 2 in the electrical schematics (except F1 and F2).
0029.00.900 9-11
9.4 Electrical Schematics
Note:
THE ELECTRICAL SCHEMATICS ARE SUBJECT TO CHANGE AND MAY BE DIFFERENT COM-
PARED WITH YOUR SYSTEM CONFIGURATION. THEREFORE MAKE SURE TO CHECK THE
DETAILED ELECTRICAL SCHEMATICS PROVIDED WITH THE EQUIPMENT.
800.01.067 ONYX29 (208VAC)
0029.00.900 9-12
ONYX29 User’s Guide Chapter 10: Pneumatic Schematics
10:
10: Pneumatic Schematics
0029.00.900 10-1
ONYX29 User’s Guide Chapter 10: Pneumatic Schematics
0029.00.900 10-2
ONYX29 User’s Guide Chapter 11: Troubleshooting
11:
11: Troubleshooting
11 Troubleshooting.......................................................................................................................................3
11.0 NO POWER ..............................................................................................................................................3
11.1 THE EMERGENCY STOP CAN NOT BE RELEASED ........................................................................................3
11.2 NO AIR PRESSURE...................................................................................................................................3
11.3 HOT GAS HEATER CAN NOT BE ENABLED, NO HEAT IS BEING GENERATED ...................................................3
11.4 NOT ENOUGH VACUUM AT THE NOZZLE ......................................................................................................3
11.5 HEIGHT DURING SITE CLEAN PROCESS IS NOT CONSTANT ...........................................................................3
11.6 SITE CLEANING TOOL DOES NOT REMOVE RESIDUAL SOLDER .....................................................................4
11.7 ROBOT FAILS TO CALIBRATE/SENSOR ERROR MESSAGE .............................................................................4
11.8 NOZZLE HITS VISION CUBE ........................................................................................................................4
11.9 NOZZLE DOES NOT PICK UP DEVICE IN COMPONENT SHUTTLE .....................................................................4
11.10 NOZZLE DROPS PART PRIOR TO FORCE PLACEMENT ..............................................................................5
11.11 NOZZLE DOES NOT REMOVE DEVICE AFTER REFLOW..............................................................................5
0029.00.900 11-1
0029.00.900 11-2
11 Troubleshooting
11.0 No Power
• Check if the main 3-phase power is switched on (on the back side of the system).
• Check if the system I/O switch of the ONYX 29 is switched on.
• Check all the fuses according to the Chapter 9 Fuses of the ONYX 29
• Make sure the green LED on the right side of the operator panel is turned on.
11.1 The Emergency Stop can not be released

• Check if the system has power. If there is no power on the system see the previous section.
• Make sure the emergency switch button on the front panel is released.
• Check that none of the axes are at its mechanical limit. Move all axes slightly in the direction
center of the traveling range.
11.2 No Air Pressure

• Check the facility pressure, the input pressure into the machine and into the machine sup-
port.
• Check the power of the system. The system must be powered on, the machine support main
switch and the machine main switch.
11.3 Hot Gas Heater can not be enabled, no heat is being generated
• Check that the E-stop is released and enough air pressure into the system
is provided (see previous sections). The safety system status should be at
the state Safety system: READY.
• Check the hot gas system fuse F71 of the ONYX 29 (see Chapter 9 Fuses)
• Check that a nozzle with the type HOT GAS NOZZLE is mounted. This can be seen in the
maintenance screen of the Hot gas system.
• Make sure that the temperature reading makes sense otherwise the analog sensor is not
properly connected.
11.4 Not enough vacuum at the nozzle

• Check the facility pressure and the input pressure into the machine, the input pressure must
be above 5.5 bar (80 PSI).
• Check if the nozzle flange has a perfect seal. If this cannot be tested, mount the camera
calibration nozzle and check the vacuum with the calibration nozzle mounted.
11.5 Height during site clean process is not constant

• If the site clean moves away from the board during the site clean process, check the blue
vacuum cup to be sure a proper vacuum connection has been made.
• Also, check to see if the tool is clogged with solder.
0029.00.900 11-3
11.6 Site Cleaning Tool does not remove residual solder

• Check to see if the site clean tool is clogged with solder or if a good vacuum connection has
been made. There should be strong vacuum at the composite tip. Lead-free solder requires
higher process temperature (top and bottom heater settings) to reflow it.
11.7 Robot fails to calibrate/sensor error message

• The sensor in the pneumatic shuttle (option) needs to be adjusted.
11.8 Nozzle hits vision cube

• Each nozzle has a specific overall length. Check the status bar at the bottom of the screen
to see what nozzle should be in the machine. Most likely, the wrong nozzle has been in-
stalled.
11.9 Nozzle does not pick up device in component shuttle

• Nozzle not installed in machine properly – vacuum leak.
• Insufficient vacuum – vacuum tube in nozzle damaged or blocked, new o-ring/cup required.
• Component pick is force controlled. Do not touch the machine during this step.
0029.00.900 11-4
11.10 Nozzle drops part prior to force placement

• Keep hands off machine during this event.
• If problem continues, see force verification procedure.
11.11 Nozzle does not remove device after reflow.

• Device not fully reflowed.
• No or low vacuum.
• Programming issue.
0029.00.900 11-5
0029.00.900 11-6
ONYX29 User’s Guide Appendix
Appendix
Appendix A: Complete List of Spare Parts.....................................................................................................3
RECOMMENDED SPARE PARTS PACKAGE ................................................................................................................5
Appendix B: Standard Hot Gas Flow Tables .................................................................................................7
Appendix C: Picture Guides for Re-Packaging..............................................................................................9

TRANSPORT SAFETY LOCKS FOR THE MACHINE .......................................................................................................9
Appendix D: Exporting and Importing Programs ........................................................................................13
Appendix E: ONYX29 Dispenser ...................................................................................................................17

1.1 SETUP ...................................................................................................................................................17
1.2 INITIAL DISPENSER TOOL CONFIGURATION..............................................................................................19
1.3 OTHER SETUP .......................................................................................................................................20
1.4 RUNNING DEMO: TARRAY 144 10MM DISPENSE PROCESS ....................................................................22
1.5 CREATING A NEW PROGRAM .................................................................................................................24
1.6 NEEDLE SIZE & PASTE MESH .................................................................................................................33
0029.00.900 A-1
0029.00.900 A-2
Appendix A: Complete List of Spare Parts

Unit Class Article # Description Remarks
Stk. 1 106.02.005 Air-filter nylon white
m 1 106.17.008 Silicon – Tube d = 7mm, black
Stk. 1 109.05.022 SMD - Fuse OMF 125, 4A fast blow
Stk. 1 109.05.025 Fine Fuse 6.3A fast blow, type SP 5 x 20
Stk. 1 109.05.026 Fine Fuse 4A fast blow, type SP 5x20
Stk. 1 109.05.036 Fine Fuse 8A slow blow, SPT 5x20mm
Stk. 1 300.00.140 Hot air heater complete 2000W
Stk. 2 106.02.004 Filter Element Canister
Stk. 2 109.02.009 Emergency switch
Stk. 2 109.02.013 ONYX 29 Air-Vac operator panel cover
Stk. 2 109.04.025 Force sensor 130x30x22mm
Stk. 2 109.04.026 DMS Force sensor amplifier
Stk. 2 109.09.003 DC/DC - Wandler 24V/5V 400mA
Stk. 2 109.09.004 DC/DC - Wandler 24V/5V, 400mA
Stk. 2 109.09.005 DC/DC - Wandler 24V/12V, 80mA
Stk. 2 109.09.006 Power Supply SP300-48 (Ua=48VDC/6.25A)
Stk. 2 109.09.007 Power Supply SP100-24 (Ua=24VDC/4.2A)
Stk. 2 109.32.001 Rotational encoder, ERN 1020, 500 Steps
Stk. 2 109.32.002 RSF Reader head linear encoder
Stk. 2 109.51.005 Warning label 25 x 25mm lightning
Stk. 2 109.51.056 Warning label 25 x 25 mm magnetic field
Stk. 2 300.00.038 Z-Encoder complete
Stk. 2 300.00.105 Board holding clamp
Stk. 2 300.00.321 Encoder manual motion
Stk. 3 100.00.223 Fitting screw d6 / M5x8 BN13
Stk. 3 100.12.007 High hand screw M3x10
Stk. 3 101.04.002 Puffer d 11mm, SJ-5303
Stk. 3 101.04.003 Parabolic buffer type KP d=20mm
Stk. 3 101.22.002 Axial Bearing
Stk. 3 101.22.007 Bearing 4/10/4
Stk. 3 101.22.016 Ball Bearing 6/13x5 686 2Z
Stk. 3 101.27.002 Spring VD-063N
Stk. 3 101.27.003 Spring Nr. 9005.02.001
Stk. 3 101.28.006 Power grip belt GT 2MR-112, 6m
Stk. 3 102.00.012 Linear bearing MNN 9-G1
Stk. 3 102.02.001 Bearing Sferax 1017 B-BL GO
Stk. 3 103.01.010 EC-Motor EC16 with transmission
Stk. 3 103.01.011 Motor EC22 with transmission and encoder
Stk. 3 103.01.013 DC-Motor RE 26 18 Watt
0029.00.900 A-3

Stk. 3 103.03.004 Linearmotor coil LMD 05-030
Stk. 3 106.00.001 Maintenance unit (filter/controller)
Stk. 3 106.02.003 Canister, Site Cleaning
Stk. 3 106.06.001 3/2 Way magnetic valve
Stk. 3 106.06.005 3/2 pneumatic valve
Stk. 3 106.12.002 Vacuum ejector 24l/min
Stk. 3 106.15.002 Pneumatic safety valve, AS1001F-04
m 3 106.17.001 Polyurethane - Tube d = 8mm, black
m 3 106.17.006 Silicon-Tube di=6mm, da=9, transparent
m 3 106.17.008 Silicon-Tube di=4, da=7
Stk. 3 106.20.001 Manometer, d=50mm / G 1/8 / P= 0 - 10ba
Stk. 3 106.20.009 Mass Flow Controller Vögtlin
Stk. 3 108.00.003 Camera FireView-1C IEEE-1394
Stk. 3 108.01.004 Macro Zoom Objektiv Computar MLH-10X
Stk. 3 109.02.010 Contact element with 2 opener
Stk. 3 109.02.015 One phase switch on/off black
Stk. 3 109.04.028 Inductiv sensor IWFM 18U7504/S35A
Stk. 3 109.11.004 Disk magnet d7x3 NdFeB
Stk. 3 109.14.002 Solid - State - Relays 75 -264VAC/ 10A
Stk. 3 109.14.004 PhotoMos Relais AZQ202D / 2.7A
Stk. 3 109.16.034 Cable Firewire 6pin/6pin, Length 2m
m 3 109.16.040 Encoder cable RSF
Stk. 3 109.16.064 Cable Firewire 6pin/6pin, Length 0.5m
Stk. 3 109.16.065 Cable Firewire 6pin/6pin, Length 1m
Stk. 3 109.17.003 Spring loaded contact pin (400 °C)
Stk. 3 109.20.039 Ceramic terminal block
Stk. 3 109.24.009 LED green, flat, chrom, 24VDC
Stk. 3 109.24.015 Opto coupler DEK-0E 5VDC/48VDC/100
Stk. 3 109.24.019 Laser Pointer FP-65
Stk. 3 109.24.020 Opto coupler DEK-0E 24VDC/48VDC/100
Stk. 3 109.27.006 Verstaerker 1-Q-EC DEC 24/1
Stk. 3 109.32.012 520 mm Glass scale for MS6X
Stk. 3 109.55.007 Mini switch 3+1 Closing (24VDC)
Stk. 3 109.55.008 Mini switch 3+1 Closing (230VAC)
Stk. 3 200.00.206 Bearing
Stk. 3 200.01.131 Protection glass
Stk. 3 200.01.312 Interface pipe
Stk. 3 300.00.011 Distribution board Operator Panel
Stk. 3 300.00.026 Operator panel complete
0029.00.900 A-4

Stk. 3 300.00.147 FireBlox-1 interface card
Stk. 3 300.00.149 Firewire interface card
Stk. 3 300.00.236 FireBlox-1 digital controller/amplifier
Stk. 3 300.00.291 Digital I/O-cable X/Y-module
Stk. 3 300.00.292 Analog I/O-cable X/Y-module
Stk. 3 300.00.303 Motor cable Y-axis IP-500
Stk. 3 300.00.304 Encoder cable Y-axis IP-500
Stk. 3 300.00.390 Encoder cable X-axis
Stk. 3 300.00.415 FireBlox-1 head interface card
Stk. 3 300.00.429 Vaccum Sensor Card
Stk. 3 300.00.432 Single 3 Phase Amplifier Card
Stk. 3 300.00.433 Illumination board filed illumination
Stk. 3 300.00.438 Field illumination lamp
Stk. 3 300.00.450 Z-Motor complete
Stk. 3 300.00.457 Upper illumination board
Stk. 3 300.00.458 Lower illumination board
Stk. 3 300.00.471 Fan vision complete
Stk. 3 300.00.473 Stick complete
Stk. 3 300.00.476 RS232 Interface cable
Stk. 3 300.00.487 Thermocouple Card (0-5V/0-10V)
Stk. 3 300.00.518 Site clean hose complete ONYX 29
Stk. = pieces / m = meter / Fl. = bottle
Recommended spare parts package

Amount Unit Class Article # Description Remarks
5 Stk. 1 106.02.005 Air-filter nylon white
1 m 1 106.17.008 Silicon – Tube d = 7mm, black
5 Stk. 1 109.05.022 SMD - Fuse OMF 125, 4A fast blow
5 Stk. 1 109.05.025 Fine Fuse 6.3A fast blow, type SP 5 x 20
5 Stk. 1 109.05.026 Fine Fuse 4A fast blow, type SP 5x20
5 Stk. 1 109.05.036 Fine Fuse 8A slow blow, SPT 5x20mm
1 Stk. 1 300.00.140 Hot air heater complete 2000W
0029.00.900 A-5
0029.00.900 A-6
Appendix B: Standard Hot Gas Flow Tables
Nozzle Conversion Table – Standard DRS Nozzle Flow% LPM
Flow Rate Conversion

DRS Flow % ONYX LPM
15 12
20 16
25 20
30 23
35 27
40 31
45 35
50 40
55 44
60 48
65 50
70 53
75 57
80 60
85 64
90 69
95 72
100 82
105 86
to previous Air-Vac equipment

LPM – Liter per minute
0029.00.900 A-7
0029.00.900 A-8
Appendix C: Picture Guides for Re-Packaging

The package material for the ONYX 29 machine and for the machine support has been designed es-
pecially. The machine shall not be shipped without this proper package material.
WARNING
NEVER MOVE THE MACHINE WITHOUT PROPER PACKAGING. ALSO WHEN MOVING THE SYSTEM
IN HOUSE, USE A PROPER SUPPORT WITH DAMPING. NEVER MOVE THE MACHINE DIRECTLY ON
A TROLLEY.
STRONG VIBRATION, WITHOUT THE PROPER DAMPING MATERIAL BELOW THE MACHINE WILL
DAMAGE THE LINEAR BEARINGS.
NEVER TRANSPORT THE SYSTEM WITH THE PRE-HEATER IN PLACE. THE PRE-HATER MUST BE
REMOVED, PACKED SEPERATELY AND TRANSPORTED IN VERTICAL POSITION.
Transport safety locks for the machine

1 (Lock Vision X-axis) 2 (Lock Vision Y-axis)
3 4
WARNING
NEVER USE THE SHORT SCREWS REMOVED WITH THE Y-AXIS END PIECE, USE THE EXTRA
LONG SCREWS PROVIDED WITH THE BRACKET. ATTACH THE BRACKET AS SHOWN ON THE
LEFT PICTURE FIRST, AND THEN MOVE THE AXES WITH THE BRACKET CAREFULLY INTO FINAL
PLACE, (THE Y-AXIS GLASS ENCODER CAN GET DAMAGED EASY)!
0029.00.900 A-9
5 (pre-heater packed separately) 6 (Machine on the pallet without pre-heater)
7 (Machine from the top) 8 (X/Y-axes bracket in place, use long screws!)
9 (Right side cushion) 10 (Machine on pallet with wooden crate)
0029.00.900 A-10
11 (With cushions in place) 12 (With left side compartment)
13 (Ship all extra material in left compartment) 14 (With left side compartment)
15 (Use plastic cover with wooden crates) 16 (Cardboard packaging)
WARNING
NEVER TRANSPORT THE SYSTEM WITH THE PRE-HEATER IN PLACE. THE PRE-HATER MUST BE
REMOVED, PACKED SEPERATELY AND TRANSPORTED IN VERTICAL POSITION.
0029.00.900 A-11
0029.00.900 A-12
Appendix D: Exporting and Importing Programs
Programs and part types can be transferred from one machine to another using the Export/Import func-
tion.
Go To Programming
Open a program
Highlight program to copy
Click on Open (or double click on pro-

gram.
Click on Import and Export Program

Icon.
Click on Export selected Program.
0029.00.900 A-13
Click on Yes to “Do you want to

open the export folder?”.
Highlight program(s) to copy.
Right click mouse and select copy.
Use arrow of Address bar to locate

and select drive to be used to
transfer program(s).
For thumb drive, right click and

select paste.
For CD drive, right click and select

paste. Click on “Write these files to
CD.” Follow directions for CD
writer.
Close screen.
For thumb drive, Go to “Safely

Remove Hardware” at bottom right
side of screen.
Click on Stop.
Remove thumb drive or disk when

finished.
Click on Close. Then Ok.
0029.00.900 A-14
Go to Programming View.
Click on Import and Export Pro-

gram Icon.
Select Import Program.
Highlight program to transfer.
Double click on program or click on

Save.
Select folder to copy into.
0029.00.900 A-15
Select part type to copy into.

Preferred Path.
Select if you wish to write over part

type with same name.
Select if you wish to save with a

different part type name.
Click Ok.
Program will be imported.
The program will be loaded to the

Program Editor of the Program-
ming View.
0029.00.900 A-16
Appendix E: ONYX29 Dispenser

1.1 Setup
Accura Dispenser –front and rear connections

Accura Dispenser
Pressure – Set to 100 Kpa
Time Set – 000
Mode Button – In (steady state)
Shot Button – Out (Off)
Dispenser Front
Dispense Head
IMPORTANT:
BEFORE PROCEEDING WITH THE INSTALLATION OF THE DISPENSE HEAD, BE SURE THAT THE
PREHEATER, BOARD, AND THE Z-AXIS HEAD HAVE BEEN COOLED DOWN TO NEAR AMBIENT
TEMPERATURE.
0029.00.900 A-17
Dispenser Rear:
To 110V To right rear To air filter

of machine
ONYX29 Rear Pneumatic Connection: ONYX29 Rear:
Connection from control cable (rear of

Accura dispenser) to rear of ONYX29.
0029.00.900 A-18
1.2 Initial Dispenser Tool Configuration
• This will be done at AV unless the customer orders a Dispenser at a later date (call technician
group to configure dispenser if this is the case).
• If you see the dispenser tool listed in the machine configuration page, the dispenser is config-
ured.
Dispense Tool and 25g Needle are Configured:
0029.00.900 A-19
1.3 Other Setup
Configure Force Table

1. Go to Configuration/Force Table/Table Configuration.
2. Verify that the Z motion step value has been changed from -0.001 to -0.010. This will make force
placement happen much faster.
1 2
0029.00.900 A-20
Configure Vision Image

Also confirm that the Vision Unit image has been “flipped”, otherwise you will be at the opposite corner
from where you need to be when you teach the four corner pads for dispensing.
3. Go to Configuration/Vision Unit
4. Go to Camera Driver/Show Video Parameters.
5. Confirm Image/Flip is checked.
6. Select OK.
Flip Vision Image
7. To confirm vision image configuration: Maintenance/Vision/Show Live Video/Parameters/Show All

Features/Video Parameters/Image Flip Box should be checked.
8. Save Camera Default
0029.00.900 A-21
1.4 Running Demo: TARRAY 144 10mm Dispense Process

Parameters developed for 144 I/O, .8mm pitch, .45mm pad, Heraeus F365SN63-86D4 (type 4) solder
paste.
Purging
1. Go to Maintenance/Tools/Dispense Tools.
2. If hot gas tool is not highlighted, click on Robot Head.
3. Change current mounted tool to Dispense Tool.
0029.00.900 A-22
4. Dispense Tool and Tools will now be highlighted. Click on Dispense Tool under Tools. Current
Mounted Needle must be for 25 gauge.
5. Activate the pressure switch to create a paste “rope” prior to dispensing. If you cannot get a con-
tinuous straight rope, remove the needle and clean it. The “rope” should break only under its
own weight. If it does not, there could be air in the system and you must purge material out
until this condition is satisfied.
6. Open and run program for TARRAY 144 (10mm) Dispense only.
0029.00.900 A-23
1.5 Creating A New Program
To Add Needle Sizes

1. Go to Maintenance/Robot/Head.
2. Change Current Mounted Head from Hot Gas to Dispense
Configure New Needle

1. Go to Configuration/Dispenser Tool.
2. Click on “Add New Item” to add a new needle.
3. Double click on “needle”.
4. Change the name and description to the needle size.
1
3
0029.00.900 A-24
Machine Identification of New Needle

1. Go to Maintenance/Dispenser Tool.
2. Change current mounted needle to the new needle.
3. Select OK.
Calibrate New Needle.

4. Go to Calibration.
5. Under Tools, double-click on the new needle. Change the Z offset to 5.0mm.
6. Select apply, then OK.
2
(reference)
4 (Z Offset
must be 5.0)
0029.00.900 A-25
Add Dispense Process List to Part Type
1. Select the part type that you want to dispense (or create a new part type).
2. Add a new process list.
3. Name the new process list name “Dispense”.
4. Double click on the dispense Process List to go to Process List Editor.
0029.00.900 A-26
Change to Proper Needle and Dispense Tool

1. Change tool to “Dispense” tool.
2. Change nozzle to desired needle.
1 2
Program Blocks:
3. Create the following three blocks:
• Stop Heating (Preheater) with all active sections checked.
• Dot (Dispenser Tool)
• View (Vision Unit)
Dot Dispenser Tool

Position:
Place
checked
Teach
checked
0029.00.900 A-27
Go to Pattern:
1. Uncheck “Automatically Optimize Pattern”.
Dispense Pattern
2. Click on Dot Pattern Editor.
3. Click on Add.
4. Define Name.
5. Enter number of dots for X and Y.
6. Enter pitch for X and Y.
7. Click on Generate.
8. Click on OK.
1 4
6 5
0029.00.900 A-28
Z-Height Parameters
1. Make the following changes:
• Check “Measure Z-Height”
• Select “Force Table”.
• Check “First Dot”.
• “Approach Height” should be 1.00mm.
• “Table Force” should be .25N.
0029.00.900 A-29
Dispense Dot Parameters

2. Check “Use current mounted needle”.
.20 sec
.2 mm
.3 sec
Dispense Motion Parameters
1.0 mm
40%
.2 sec
10%
.5 mm
1.5 mm
0029.00.900 A-30
Dispense Purging Parameters

No data input required.
Programming
1. Go to Programming/Assemblies.
2. Under available Process Lists check “Dispense” and “AT”.
0029.00.900 A-31
NOTE
BE SURE THE MACHINE AND THE HOT GAS HEAD ARE AT AMBIENT TEMPERATURE PRIOR TO
DISPENSING. USE THE BOARD COOLING SYSTEM AND COOL AIR BYPASS.
Maintenance
You can put the entire Dispense Head including paste and needle in the refrigerator for storage.
Attached are photos to disassemble Dispense Head for cleaning.
• Dispense Head – Disassembled for Cleaning
• Needles – Use Corresponding Gauge Cleaning Tools to Clean
0029.00.900 A-32
1.6 Needle Size & Paste Mesh
The pad diameter determines the needle size. Use the largest possible needle. Must use a proper mesh paste
based on needle size. Too large a mesh will not dispense through small needles.
0029.00.900 A-33
0029.00.900 A-34

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ONYX 29

ONYX 29 User's Guide

General Delivery Terms (GDT)

Manufacturer EC-Declaration of conformity

Manufacturer: Infotech AG, Vogelherdstrasse 4, CH-4500 Solothurn

Declares, that the design and the condition of the

Type: ONYX 29 Selective soldering system

meets the requirements according to the following EC directives:

Used EN-standards: EN 12100-1, -2 EN 13849-1

Solothurn, 5. November 2009 Solothurn, 5. November 2009

Ernest Fischer Rainer Fritzius

Info@pocon.ch / info@infotech-automation.com / www.pocon.ch / www.infotech-automation.com 1 -1

DO NOT ATTEMPT TO POWER UP THIS SYSTEM WITHOUT AIR-VAC PERSONNEL PRESENT.

1.2 ONYX 29 System Overview

Intended use of the ONYX 29 SEMI-AUTOMATED SOLDERING SYSTEM

THE ONYX 29 MACHINE IS CONFIGURED TO SUPPORT ALL LEAD FREE REWORK

Machine overview of the standard Hot Gas System

Item A, B and C: identifies the board carrier and support features

Item D: identifies a handle used to manually position the robot head.

Item E: identifies the hot gas heater.

Item F: identifies the emergency stop button.

Item G: identifies the board pre-heater panels.

Item H: identifies the machine operator panel.

1.3 Visual MachinesTM

The principal views are:

Operating the machine, start and stop of production programs

Creating new or modifying existing production programs

Defining the part type specific parameter and processes

Machine and peripheral calibrations

Displaying actual states of the machine and the peripherals

Machine and peripheral configuration

Analysis and printing of Thermal Profile Chart/Data

2.1.1 Notes and Warnings

2.1.2 Basic Safety Instructions

2.1.3 Application specific safety aspects

2.1.4 Machine warning labels

This label indicates the presence of a Laser diode mod-

This label indicates the presence of an area that pre-

4 labels on the X/Y axes

1 label on the base plate

1 label on the hot gas cover

Check the Machine ID-Label that is located on the right

See the sections below for the installation guide.

3.4 Facility Requirements

ONYX29 (265 lbs.)

3.5 Workstation (optional) Assembly

36” x 60” ESD Bench

Triple Locking Drawer

3.5.1 Moving the system onto the final table location

3.5.2 Remove the transport safety locks

After the system has been moved to the proper

Remove the bracket mounting screw and remove

Re-attach the front Y-axis bracket with the screws

3.5.3 IR Option and Shipping Bracket

1. Locate shipping bracket on vision assembly.

2. IR Probe will need to be removed in order to remove shipping bracket.

IR mounting screws (5)

4. Move IR to the side in order to remove the shipping bracket.

5. Re-mount shipping bracket as shown for future use.

3.5.4 Install the Pre-Heater

3.6 Electrical Installation

THE MACHINE EXISTS IN 2 DIFFERENT, COUNTRY VOLTAGE SPECIFIC VERSIONS (3PE

3.6.1 Main Power