JCAT Terra Operations Manual - Apollo Seiko

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Keywords

solder, iron, soldering, Solder, temperature, wire, with, condition, 4.7k, time, setting, Speed, 0-99.9mm, SP0.1-99.9, this, Amount, button, feed, down, Iron, machine, when, power, pressed., screen, sure, select, Start, reverse, Time

Transcript

J-CAT300TERRA
Operation Manual
Thank you for purchasing the J-CAT300TERRA.
Read these instructions thoroughly for proper use of this machine.
Make sure to read "Safety Notes" before you use machine. This information protects you
from possible dangers during use.
Apollo Seiko Ltd.
Rev. 1.01E
!"#$%&%'(%&)%
Safety Notes
*% This manual includes the important information to use machine safely. This
also includes useful information to prevents avoiding injury or damaging
property. Please read this manual carefully prior to connecting or operating the
J-CAT300TERRA.
*! Keep this manual nearby the machine all the time.
Supply only specified voltage
*% Do not connect to a power supply greater than the specified voltage. If not,
electrical shock and /or damage to the unit may occur.
*% Make sure that the electrical outlet is properly grounded. If the outlet is not
properly grounded, electrical shock and/or damage to the unit may occur.
Working ambient temperature and relative humidity
*% This machine have been designed to use between 0+,40+-10.,90..
Do not use this machine under the condition exceeding here-in.
Handle with care
*% This machine is designed to use solder feeder and heating iron for soldering.
If you touch a heated soldering iron, it will burn yourself. So, make sure the
iron is cool down before you are touching it for replacing the iron cartridge.
*% Please handle this machine with care. If you drop or make a big impact
/ vibration, it may cause malfunction.
If you do not use the machine for a long time
*! Please turn off the power, remove the power cable and keep it in dry and cool place.
*!
If you note malfunction on machine
*% If the machine become a malfunction, turn off the power immediately and
contact a dealer you purchased machine from.
Immunity from responsibility
*% We do take NO responsibility on a damage caused by misuse, mistake,
accident, uses in abnormal condition or natural disaster such as an
earthquake, a fire etc.
*% We do take NO responsibility on contingency loss /Business loss-Business
stop0 caused by machine stop.
*% We do take NO responsibility on a loss caused by the operation not
mentioning on this manual.
*% We do take NO responsibility on a loss caused by a wrong connection with
other equipment.
*% If for any reason the internal circuitry is tampered with altered or repaired
without written consent of Apollo Seiko, the warranty is null and void. The
customer is allowed to make necessary tooling adjustment, replace solder iron
tips and make any necessary adjustments to the temperature controller.
!"#$%1%'(%&)%
% % CONTENTS
Page No.
Safety notes .......................................................................................................... 2
Contents ................................................................................................................ 3
12Dimensions ......................................................................................................4
22Summary of J-CAT300TERRA ........................................................................ 5
32Description of J-CAT300 TERRA .................................................................5 - 6
42WK parameter setting ................................................................................ 7 - 9
52How to change TERRA system parameter .............................................10311
62Operation ...................................................................................................12 - 13
72Input and output wiring diagram ...............................................................14 - 15
82Maintenance .............................................................................................16 - 17
92Handling of iron tip ........................................................................................... 18
102Trouble shooting ............................................................................................ 19
112Care of iron tip ............................................................................................... 20
12. How to change iron cartridge ..........................................................................21
** Solder wire tube selection chart .................................................................... **
** Iron unit selection chart ................................................................................. **
!"#$%4%'(%&)%
1. JR2304 Dimensions
5 part% 6 The shaft size for tool attaching.
7 part% 6% M4 nut can be inserted into groove.
!"#$%8%'(%&)%
TERRA controller
2. Summary of J-CAT300TERRA
The RSP/RSL iron unit and ZSB feeder are built-in with J-CAT300TERRA. The DCS iron
will assure very stable soldering temperature and the ZSB will guarantee zero solder ball
soldering result.
3. Description
%
Teaching pendant
Iron unit and iron
cartridge
Solder feeder
X table
Start button
Solder tube
Air pressure adjusting screw
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A) TERRA controller front
: Temperature trend graph display
The temperature trend is displayed on the screen in
real-time.
; Temperature display!
The iron temperature is displayed. To change the
setting temperature, press the Set Temp button and
enter desired temperature using Ten key, then press
key.
Current operating WK number is displayed.
=! Heat On /Off
The iron heater is turned on/off to press this button.
> System Parameter
Press this button to change the system parameter.
?! Iron down button
While you press this button, the iron stays at
soldering position. So, when you teach soldering
position, check the position using this button.
@ Solder feed forward button
Solder wire is forwarded or reversed while this button
is pressed.
A! Power switch
Turn it on to start TERRA controller.
!
!
!
B) TERRA back
%
Power plug inlet
Air inlet "dia. 6##$
IRS232C connector
%
Iron cable connector%
Feeder cable connector%
Iron unit air outlet%
I/O connector %
Fuse
!"#$%B%'(%&)%
4. WK parameter setting%
4-1. Turn ON the robot/TERRA and do the entering of the soldering conditions (WK
parameter) and the positions.
Refer to the Operation Manual of robot and do the teaching of soldering position and
cleaning position.
Soldering condition number for point soldering 101-199
(Third soldering%-& cannot be set.)
Soldering condition number for line soldering 201-299
Soldering condition number for special point soldering 301-399
1)% Turn on the power.
2)% The screen changes to green color after while and shows the operation screen. If not
check the air supply and the iron cartridge.
Power on Orange Operation screen (Green)
% % % % % % % % % % % % % % %
%
4-2. Useful function with the teaching pendant.
Teaching screen :!
Key Action
0 The solder iron will go down while this key is pressed.
1 The solder iron will go down if this key is pressed once.
To raise, press '0( key again.
3 The solder wire feed forward while this key is pressed.
4 The machine blow an air while this key is pressed.
6 The solder wire feed reverse while this key is pressed.
Setting display screen :
Key Action
Go The machine move to the displayed position.
F4 The machine move to the displayed position and do the soldering with
the entered condition.
Soldering condition screen :
VEIW(F4)
Entering the soldering condition setting screen (WK parameter).
!"#$%C%'(%&)%
4.3! The following soldering parameter can be entered.
Point soldering (WK101-199)
WK101-199 Command Adjustable range
Point SV2 Time 0-99.9sec
1st Amount / Speed 0-99.9mm SP0.1-99.9
1st Rev. Amount / Speed 0-99.9mm SP0.1-99.9
Pre-Heat Time ! 0-99.9sec
2nd Amount / Speed 0-99.9mm SP0.1-99.9
2nd Rev Amount / Speed 0-99.9mm SP0.1-99.9
Heating Time 0-99.9sec
Line soldering (WK201-299)
WK201-299 Command Adjustable range
Line SV2 Time 0-99.9sec
1st Amount / Speed 0-99.9mm SP0.1-99.9
1st Rev. Amount / Speed 0-99.9mm SP0.1-99.9
Pre-Heat Time ! 0-99.9sec
2nd Amount / Speed 0-99.9mm SP0.1-99.9
2nd Rev Amount / Speed 0-99.9mm SP0.1-99.9
Heating Time 0-99.9sec
3rd Amount / Speed 0-99.9mm SP0.1-99.9
3rd Rev Amount / Speed 0-99.9mm SP0.1-99.9
Special soldering (WK 301-399)
The following three type can be selected. Press Enter on the top of soldering mode. Then
select from the followings.
Point! soldering With the 3rd (third) soldering
Line soldering With the pool wait
Point! soldering (No up) Iron stay down after one cycle of point soldering
WK301-399 Command Adjustable range
Point! soldering SV2 Time 0-99.9sec
Line soldering 1st Amount / Speed 0-99.9mm SP0.1-99.9
Point! soldering
(No up) 1
st Rev. Amount / Speed 0-99.9mm SP0.1-99.9
Pre-Heat Time ! 0-99.9sec
! 2nd Amount / Speed 0-99.9mm SP0.1-99.9
! 2nd Rev Amount / Speed 0-99.9mm SP0.1-99.9
! Heating Time 0-99.9sec
! 3rd Amount / Speed 0-99.9mm SP0.1-99.9
! 3rd Rev Amount / Speed 0-99.9mm SP0.1-99.9
Pool Wait Time 0-99.9sec
!
!
!
!"#$%D%'(%&)%
4-4 TERRA soldering WK commands :!
) SV2 time (sec)
Rising time to the second setting temperature
Using for setting high temperature for the high heat-sink pattern.
* 1st Amount, The first soldering feed amount (Pre-soldering) (mm)
Pre-soldering for tip or pattern.
Transfer the heat of the tip to the pattern.
+ 1st Speed, The first solder feed speed (mm/sec)
Set the feed speed of the first soldering.
, 1st Rev. Amount, The first soldering return amount (mm)
Set the soldering return amount.
When the supply of solder wire is finished the solder wire returns because of
prevention of soldering wire' waste.
-1st Rev. Amount, The first reverse speed (mm/sec)
Set the first reverse soldering speed.
. Pre-heat time
Pre-heat time is the time from the iron tip contact with the work to the start for the
supply of the second soldering.
/ 2nd Amount, Second solder feed amount (mm)
Set the solder feed amount for the pattern.
0 2nd Speed, Second solder feed speed (mm/sec)
Set the second solder speed.
1 2nd Rev. Amount, Second reverse amount (mm)
Set the solder reverse amount for prevention of solder wire's waste.
2 2nd Rev. Speed, Second reverse speed (mm/sec)
Set the second reverse speed.
3 Heating time (sec)
Heating time is the time from the supply of the second soldering is finished to the
iron tip
leaves works.
% 3rd Amount, Third solder feed amount (mm)
The third soldering is added if the additional solder need or prevent icicle4
5 3rd Speed, Third solder feed speed (mm/sec)
Set the third solder feed speed.
6 Rev. Amount, Third reverse amount (mm)
Set the third solder reverse amount.
7 Rev. Speed, Third reverse speed (mm/sec)
Set the third reverse speed.
&! Pool wait time
Solder pool time for slide soldering. The slide soldering starts delay time for
solder pooling.
!"#$%)E%'(%&)%
5. ! How to change TERRA system parameter
1) Press the Parameter key on the operation screen. The System Parameter selecting
screen appears.
2) Press System Parameter key to change. Eg. Alarm Hi
3) The setting value appears in the next parameter setting screen.
4) To change the values, press the setting value box. Then, ten key appears.
5$ Enter desired value and press key;
6$ Press ESC key.
7) Press WRITE key. The message 'Writing(! appears and the entering value is
memorized.
Note 8 If the TYPE is changed, turn off the TERRA power and turn on again.
% %
% % %%%%%%%%%%%%%%%%%% % %Parameter selecting screen
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !
Parameter setting screen Parameter setting screen
!"#$%))%'(%&)%
Initial setting (Factory setting) system parameter
9 Command Initial setting! ! ! Adjustable range! ! ! ! ! Detail
Alarm Hi 50 ! 0 - 200 ! Temp. alarm range High
Alarm Lo 50 ! 0 - 200 ! Temp. alarm range Low
TEMP 300 ! 1- 500 ! Setting temperature
SV2 Temp OFF 1 - 500 ON/OFF SV2 temperature setting
Wait Temp 250 ! 1 - 300 ! Stand by temperature setting
Feed % ! ON ! ON/OFF Solder feed :! Enable/Void
Heat% ! ON ! ON/OFF Heater! : ! ! ! ! Enable/Void
Iron U/D ! ON ! ON/OFF Iron up/down sensor: Enable/Void
U/D Time 3 ON 0 - 99 ON/OFF Iron up/down sensor error limit
Heat Auto ! ON ! ON/OFF Heater auto start when power on.
Tem Lim 500 ! 100 - 500 ! Maximum temperature
Ms-Speed 250 ! 1 - 250 ! Manual solder feeding speed
Feed Cal 100 ! 1 - 200 ! Auto solder feeding quantity adjust
TIP 1 ! 1/2 ! Tip select 1 or 2
TCL1 0 ! ±100 ! Tip type 1 ! temperature calibration
TCL2 0 ! ±100 ! Tip type 2 ! temperature calibration
T1PG 70 ! 1- 200 ! Tip type 1! Proportion Gain
T1IG 0 ! 0 - 99 ! Tip type 2! Proportion Gain
T2PG 80 ! 1 - 200 ! Tip type 1 Integral Gain
T2IG 20 ! 0 - 99 ! Tip type 2! Integral Gain
Wait time 1 ON 1- 60 ON/OFF Wait time "min.$ Enable/Void
Type
! *Note ! STA STA/ROB !
Required emergency signal
STA8! Break contact
! ! ! ! ROB8 Normal contact
!
* ! If the Wait time is ON, enter adequate Wait temp to operate in order.
!
!
!
!
!"#$%)&%'(%&)%
6. Operation
6.1! Preparation
Make sure the following matters before the operation.
1. Check the power supply, the connections of the power supply,air pressure, the
voltage! and air pressure (The suitable pressure is from 4 to 7 kg/cm2).
2. The diameter of the solder wire is correct and the wire is sufficient.
6-2 Order of operation
1. Turn ON the TERRA power supply. (Make sure the lamp for Power ON is on.)
2. Attach the solder wire with the following order.
6.3 Set of solder wire
1) Remove the tube and pull solder wire
through first. Then attach the solder tube.
2) Set the solder wire as per the diaggram. And
make sure to set solder wire on the shortage
sensor.
3)! If the release lever is upper position, the
cutting blade/pinch roller does not feed a
solder wire. So, when you would like to
feed the wire, put down the leaver before.
!
!
!
!
!
!
!
6.4 Turn on the robot power
1. Turn ON the Robot power supply and press Start button.
2. The screen changes to green color after while and shows the operation
screen. If not check the air supply and the iron cartridge.
3. Press the start button and one cycle operation will start.
(1)
(2)
(3)
!"#$%)1%'(%&)%
6.5! How to adjust RSP iron unit ! !
4)! Solder wire feeding position can be adjusted.
Upper adjusting screw : Up down direction
Lower adjusting screw! : Side way direction
5) ! Iron up down speed can be adjusted by
turning screws after undoing nut.
Upper black screw : Raising speed
Lower white screw : Go down speed
6)! Second solder feeding position can be altered
by moving this screw. Adjusting the screw
position, First solder wire can be put between
the iron tip and a solder pattern.
Move it to lower : The same feeding positions.
Move it to upper : The second feeding
position become higher and the first solder
would be melt! down between the iron tip and
a solder pattern.
F8G%
SEL1
TLP 281
A2
4.7k
SEL2
TLP 281
A3
4.7k
SEL4
TLP 281
A4
4.7k
TLP 281
A5
4.7k
TLP 281
A6
4.7k
TLP 281
A7
4.7k
TLP 281
A8
4.7k
TLP 281
4.7k
TLP 281
4.7k
INPUT
TLP 281
4.7k
TLP 281
4.7k
TLP 281
4.7k
IRON U/D
TLP 281
4.7k
B1
TLP 281
4.7k
TLP 281
4.7k
TLP 281
4.7k
TLP 281
4.7k
A11
A12
A13
A14
SEL8
SEL16
SEL32
SEL64
A10 START
STOP
RESET
S+(FW)
S‐(REV)
A15
A16 AIR BLOW
A17
A18
SEL200
SEL100
LINE MOVE END
A19
B2
PinNo.
OUTPUT
B3
B4
B5
B6
B7
TLP 523
TLP 523
TLP 523
TLP 523
TLP 523
TLP 523
TLP 523 B11
READY
RUNNING
END
AUX OUT
SOLDER ERROR
ACK
HEATER ERROR
GND
0V
0V
B19
B20
TERRA TERRA
INSIDE 24V
INSIDE 24V
EXT 24V
24V
DS1
EXTIN
EMR
A1
EMR connection is the break contact.
Max DC24V 100mA for each pin.
※External/internal power selection
can be changed by DS1 switch on CPU board.
B15
B16
B17
!"#$%)8%'(%&)%
Input
Pin No. Signal Description
A1 EMERGENCY No voltage break contact
STA mode : Emergency stop If A1 and B1 opens.
ROB mode : Emergency stop If A1 and B1 contacts.
A2% Prog SEL 1% Solder condition select 1. Read when Start button is pressed.
A3% Prog SEL 2% Solder condition select 2. Read when Start button is pressed. %
A4% Prog SEL 4% Solder condition select 4. Read when Start button is pressed. %
A5% Prog SEL 8% Solder condition select 8. Read when Start button is pressed. %
A6% Prog SEL 16% Solder condition select 16. Read when Start button is pressed. %
A7% Prog SEL 32% Solder condition select 32. Read when Start button is pressed. %
A8% Prog SEL 64% Solder condition select 64. Read when Start button is pressed. %
A9% %
A10% START% Automatic start
A11% STOP% Partial stop %
A12% RESET Error reset%
A13% S+% Manual solder feeding forward %
A14% S-% Manual solder feeding reverse%
A15 Iron U/D% Manual Iron up and down%
A16 Air blow% Manual air blow%
A17 Prog SEL 100% Solder condition select 100. Read when Start button is pressed.
A18 Prog SEL 200% Solder condition select 100. Read when Start button is pressed.
A19 Slide ACK% Slide soldering end.
A20 %
OUTPUT
B1 EMERGENCY Emergency stop if
STA mode :A1B1 opens ROB mode : :A1B1 contact
B2% READY% Ready for automatic operation
B3% RUNNING% Terra is running
B4% CYCLE END% One cycle end
B5% ACK% Slider start signal
B6% Solder Error% Solder shortage or clogging error
B7% Temp Error% Iron temperature error
B8% %
B9% %
B10% %
B11% AUX OUT1% Out signal for iron up/down. Use for soldering count
B12%
B13% %
B14% %
B15 OUT P24V% DC24V(500mA) supply
B16 OUT P24V% DC24V(500mA) supply
B17 EXT.P24V% DC24V(500mA) can be entered
B18 %
B19 0V%
B20 0V
!"#$%)9%'(%&)%
8. Maintenance
8-1 Daily inspection requirement items are as follows:
Note: when the inspection, turn off the power and cool down the iron tip.
1) Existence of solder wire:
If the solder wire is not sufficient, please change to new one.
2) Wear of iron tip
If soldering result become unstable, please change it to new one. The life time
of the iron tip is depend on the heating time, the solder feeding point and speed.
3) Breaking of heater
The causes of a breaking of heater when the lamp for indication of temperature
error is on and the temperature controller (TM-104) is normal are as follows:
(1) The breaking of heater. Change the iron cartridge
(2) The breaking of the relay cord (CC-2F) Change the iron cord.
(3) The iron tip is worn. Change the iron cartridge
4) Air pressure
Make sure the air pressure if it is adequate. (4-5kg/cm2)
5) Clog of the tube set
If the top (exit side) of the tube set clog by a flux or solder wire, please get rid of it
and clean it with alcohol.
6) Up/down movement
Make sure if the up/down movement of iron unit of iron unit is smooth. Also, make
sure if there is no flux sticking in moving parts.
7) Cutting blade and pinch roller for solder wire feeding
Make sure flux or solder does not stick to the above parts. If so, clean it with a
soft
(brass) wire brush and alcohol.
8-2 After every 5,000 points soldering
Check the solder tip temperature with a thermometer. Refer to the page 7 for
thermo-controller temperature display calibration.
8-3 Every month
Make sure a solder wire run through the solder wire tube. If not, clean the inside
tube or replace.
8-4 Every year
Send the thermometer to an authorized agent for the calibration.%
%
%
%
%
!"#$%)B%'(%&)%
8.5 ZSB feeder adjustment and alignment
If the ZSB (Zero solder ball) feeder is used, the cutting depth and the alignment
have to be adjusted properly as follows :
%
%
1) Remove the cover after
loosing three setting screws.
2) loosen the setting nut.
3) Adjust the screw to make the
cutting blade center of the
lower roller V grove.
4) Adjust the depth screw the
cutting blade to penetrate into
flux core. %
5) Tighten the setting nut 2).
6) Put back the cover and
tighten three screws .
3) Adjusting screw
for alignment!
2) Setting nut for
the adjusting screw
4) Adjusting screw for
the cutting depth.
:;!<=>??! @?A! @B>?C@! DE>!
FGH!D??I?>!BEJ?>!
The cutting blade to be the center of
the lower roller V grove and the
depth should the center of the
solder wire as indicated.
!"#$%)C%'(%&)%
9. HANDLING OF IRON TIP
: Attach iron tip, then the vinyl resin coating on
the iron tip is cracked and peel off during the
temperature rising. Please use it after
making pre- soldering by solder including
flux.
; Iron tip should be placed at iron stand after
pre-solder on iron tip. If tip is left at the stand
without solder after cleaning , the tip cannot
be wet with solder.
< Please remove oxidations of flux lightly by
wet sponge with water. If using the dry
sponge or wiping too much, tip will not be
wetted by solder easily.
= Do not file the iron tip because the iron
plating under the tip is the very important.%
%
%
%
%
%
%
%
If a tip is not getting wet with solder!!
: Remove pre-solder on tip completely.
; Remove oxidation by a sand paper after
cooling down the iron tip to room
temperature.
< Turn on the power and make pre-solder on
the iron tip during rising the temperature.
The tip will wet with solder by the above process.
!"#$%)D%'(%&)%
10. TROUBLE SHOOTING
This table is designed to help trouble shoot common problems that may occur with the
Echo unit. If you have tried the recommended solution and the problem persists, please
contact Apollo Seiko directly for technical support.
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11. CARE OF IRON TIP
Introduction
Soldering is a technique which connects a metal to another metal by alloy reaction.
Solder material melts, but mother material (metal pieces on the work-piece) never melt
by soldering.
There are three important factors (Three great factors of soldering) for the alloy reaction
as follows:
* Cleaning the metal surface
* Formation of alloy layer which by melting solder and connecting to metal surface
* Heat source which should be maintained in suitable temperature in order to form
alloy layer by soldering.
Solder iron tip is related to the formation of alloy layer and the heat source.
So, It is very important for a good care of solder tip to make a stable soldering.
Care of iron unit
Apollo soldering tip, HI-TIP (AS, HQ, TM and TB model) realized the high
performance and long life by using oxygen-free copper as a mother material with
special iron plating and careful after treatment.
Usually, the life of the tip is about 50,000 points. However, if it is used at more than
400+ or if solder with a bad solder feeding position, the life is shorten extremely to
approximately 5,000 points caused by "Iron plate Corrosion". Therefore, please
use it with suitable condition. If the condition is proper, the life exceeds 100,000
points.
1) Check iron tip by eyes every fixed time
2) Check for soldering defect
There are many solder defects except the above mentioned as follows:
" Solder shortage", "Icicle", "Solder excess", "Burning film" etc.
Please select suitable condition by seeing through the solder states.
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12.% How to change iron cartridge%%
%
1) Make sure to turn the power off and coll down the
iron cartridge room temperature and pull down
the iron cartridge to replace a new one. If it does
not come out, using silicone ring pull it down
strongly. In case flux is jammed, remove it
carefully with an alcohol.
2) To attach a new one, insert it gently until the
holder end.
Then turn it until you feel the position key in the
position.
When you feel a clicking, insert it firmly.
Do not turn the iron cartridge while the key is
not in the position or the key is damaged.
Apollo Seiko Ltd
8-14-11 Ikegami, Ohta-ku
Tokyo, Japan r146-0082
Tel: +81.3.3753.7911
Fax: +81.3.3753.7801
E-mail: info@apolloseiko.co.jp
URL: http://www.apolloseiko.co.jp
Pull out
to remove
Insert gently
to fit

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