Power Series Ball Bonder
Installation Guide
Power Series
Installation Guide
98888-0000-006-04
Revision G
Copyright © 2014 Kulicke & Soffa Industries Inc (www.kns.com) and all subsequent revision dates. All Rights Reserved. Original English language version.
The information contained in this document is the property of Kulicke & Soffa Industries Inc and is subject to change without notice.
This document may not be reproduced or transmitted in any form, nor stored in a retrieval system of any nature, without the express written authority from:
Kulicke & Soffa Pte Ltd
6 Serangoon North Avenue 5,
#03-16, Singapore 554 910
Power Series Ball Bonder
Table of Contents
Table of Contents ............................................................................................................. ii
Use of This Manual ........................................................................................................... v
Publication ........................................................................................................................ v
Terms and Conventions Used in Manuals ..................................................................... v
Record of Changes .......................................................................................................... vi
1Safety Information ..................................................................................................... S-1
S.1
S.2
S.3
S.4
S.5
S.6
S.7
S.8
S.9
S.10
S.11
S.12
S.13
S.14
S.15
S.16
General ..................................................................................................................................S-1
Definitions .............................................................................................................................S-1
S.2.1
Warning...................................................................................................................S-2
S.2.2
Caution....................................................................................................................S-2
S.2.3
Note ........................................................................................................................S-2
Equipment-Specific Warnings.............................................................................................S-2
General Precautions.............................................................................................................S-3
Trained Operators and Service Technicians......................................................................S-4
Electrical Equipment Servicing ...........................................................................................S-5
S.6.1
Types of Electrical Hazards ....................................................................................S-5
S.6.2
Power Supply Servicing ..........................................................................................S-6
S.6.3
Lockout/Tagout Procedure......................................................................................S-6
Safe Use of Heated Material and Equipment......................................................................S-7
S.7.1
User's Responsibilities for Personal Safety ............................................................S-7
Potential Ergonomic Hazard – Microscope Use ................................................................S-7
S.8.1
Heated Equipment Servicing ..................................................................................S-7
Fire Safety .............................................................................................................................S-8
S.9.1
Fire Suppression.....................................................................................................S-8
S.9.2
Flammable Maintenance Supplies..........................................................................S-8
Emergency Off Switch..........................................................................................................S-8
S.10.1
Emergency Off Switch Specifications .....................................................................S-9
S.10.2
Test Emergency Off Switch Operation....................................................................S-9
Cover Panels .........................................................................................................................S-9
Machine Emissions ..............................................................................................................S-9
S.12.1
Ionizing and Non-Ionizing Radiation .....................................................................S-10
S.12.2
Vibration................................................................................................................S-10
S.12.3
Noise.....................................................................................................................S-10
S.12.4
Gases, Vapor, Dust...............................................................................................S-10
Warning and Safety Labels................................................................................................S-11
S.13.1
Emergency Off ......................................................................................................S-15
S.13.2
Burn Hazard Warning ...........................................................................................S-15
S.13.3
Pinch Point Hazard Warning.................................................................................S-15
S.13.4
Electrical Hazard Warning ....................................................................................S-16
S.13.5
General Hazard Warning ......................................................................................S-16
S.13.6
Disconnect Power Label .......................................................................................S-16
S.13.7
Equipment Grounding IEC ....................................................................................S-17
S.13.8
Operator ESD Connection Point Label .................................................................S-17
S.13.9
Beryllium Product Warning ...................................................................................S-17
S.13.10 Hard Stop Caution ................................................................................................S-18
S.13.11 Excessive Load Warning Against Scope Mount ...................................................S-18
Identification Label Descriptions ......................................................................................S-19
S.14.1
EFO Box Ordering Notice Label ...........................................................................S-19
S.14.2
Equipment Configuration Tag ...............................................................................S-19
S.14.3
Equipment Identification/Manufacturer’s Identification Label................................S-20
S.14.4
FDA Explanatory/Certification Label .....................................................................S-20
Laser Safety ........................................................................................................................S-21
Declaration of Exemption ..................................................................................................S-23
Installation Guide
Page ii
Table of Contents
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Power Series Ball Bonder
S.17
Shutdown and Start-up Procedures .................................................................................S-23
S.17.1
Machine Shutdown Procedure..............................................................................S-23
S.17.2
Machine Start-up Procedure.................................................................................S-24
Chapter 1: Introduction ............................................................................................... 1-1
1.1
1.2
1.3
1.4
1.5
1.6
Installation Guide Contents................................................................................................. 1-2
Specification - Site Requirements ...................................................................................... 1-3
1.2.1
Electrical Requirement for Power Supply ............................................................... 1-3
1.2.2
Compressed Air Requirements............................................................................... 1-3
1.2.3
Nitrogen & Forming Gas Requirement (for Cu Wire Bonding)................................ 1-3
1.2.4
Operating Environment........................................................................................... 1-3
1.2.5
Machine Dimensions (approximate) ....................................................................... 1-3
1.2.6
Machine Weight (approximate)............................................................................... 1-4
Safety Considerations.......................................................................................................... 1-5
1.3.1
General Safety Precautions.................................................................................... 1-5
Machine Installation Sequence ........................................................................................... 1-6
Storage and Transport ......................................................................................................... 1-7
1.5.1
Short Term Storage ................................................................................................ 1-7
1.5.2
Long Term Storage................................................................................................. 1-7
1.5.3
Packing and Shipping ............................................................................................. 1-7
Decommissioning and Disposal ......................................................................................... 1-8
1.6.1
Disposal .................................................................................................................. 1-8
Chapter 2: Site Preparation ......................................................................................... 2-2
2.1
2.2
2.3
2.4
Site Requirements ................................................................................................................ 2-2
Power, Earth Ground, and Compressed Air Connections................................................ 2-4
2.2.1
Power Connector Requirements............................................................................. 2-5
2.2.2
Earth Ground Cable................................................................................................ 2-5
2.2.3
Air Pressure Supply Hose....................................................................................... 2-6
2.2.4
Overcurrent Protection Device Requirements ........................................................ 2-6
Anchorage and Vibration Damping .................................................................................... 2-7
2.3.1
Anchorage .............................................................................................................. 2-7
2.3.2
Vibration Damping .................................................................................................. 2-8
Checklist: Site Preparation.................................................................................................. 2-7
Chapter 3: Unpacking/Packing - Carton (Outside USA) ........................................... 3-1
3.1
Unpacking/Packing - Carton (Outside USA) ...................................................................... 3-2
3.1.1
Unpack Machine ..................................................................................................... 3-2
3.1.1.1
Inspect Machine Shipping Carton ......................................................... 3-2
3.1.1.2
Disassemble Shipping Carton (See CAUTION above)......................... 3-4
3.1.1.3
Remove Machine from Crate Pallet ...................................................... 3-5
3.1.1.4
Assemble the modules ......................................................................... 3-8
3.1.1.5
Install Machine at Prepared Site ......................................................... 3-13
3.1.2
Checklist: Unpack Machine .................................................................................. 3-14
3.1.3
Pack Machine for Reshipment.............................................................................. 3-15
3.1.3.1
Prepare Machine for Packing.............................................................. 3-16
3.1.4
Checklist: Pack Machine for Reshipment ............................................................. 3-22
Chapter 4: Unpacking/Packing (To or From USA) .................................................... 4-1
4.1
Unpacking/Packing (To or From USA) ............................................................................... 4-2
4.1.1
Unpack Machine ..................................................................................................... 4-2
4.1.1.1
Inspect Machine Shipping Crate: .......................................................... 4-2
4.1.1.2
Disassemble Shipping Crate (See CAUTION above)........................... 4-4
4.1.1.3
Remove Machine from Crate Pallet ...................................................... 4-5
4.1.1.4
Assemble Modules ............................................................................... 4-8
4.1.1.5
Install Machine at Prepared Site ......................................................... 4-13
4.1.2
Checklist: Unpack Machine .................................................................................. 4-14
4.1.3
Pack Machine for Reshipment.............................................................................. 4-15
4.1.3.1
Prepare the machine for packing ........................................................ 4-16
4.1.4
Checklist: Pack Machine for Reshipment ............................................................. 4-22
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Table of Contents
Installation Guide
Page iii
Power Series Ball Bonder
Chapter 5: Machine Installation ................................................................................... 5-1
5.1
5.2
Machine Installation ............................................................................................................. 5-2
5.1.1
Position And Level The Machine ............................................................................ 5-2
5.1.2
Check Input Line Facilities ...................................................................................... 5-3
5.1.2.1
Check Facility AC Line Voltage............................................................. 5-3
5.1.2.2
Check Facility Air Pressure Source....................................................... 5-3
5.1.3
Facility Air/Electrical Connections........................................................................... 5-4
5.1.3.1
Install Frame Ground Cable to Facility Building Ground ....................... 5-4
5.1.3.2
Install Power Cord Plug......................................................................... 5-4
5.1.3.3
Connect Machine to Electrical Power ................................................... 5-5
5.1.3.4
Connect Machine to Air Pressure ......................................................... 5-8
Checklist: Machine Installation ........................................................................................... 5-9
Chapter 6: Machine Power Up Tests ........................................................................... 6-1
6.1
6.2
Machine Power Up Tests ..................................................................................................... 6-2
6.1.1
Power Up Machine.................................................................................................. 6-2
6.1.1.1
Apply Power to Machine ....................................................................... 6-2
6.1.1.2
Check Power Supply Outputs ............................................................... 6-3
6.1.2
Initialize Machine .................................................................................................... 6-6
6.1.3
Continue Setup ....................................................................................................... 6-7
Checklist: Machine Power Up Tests ................................................................................... 6-8
Installation Guide
Page iv
Table of Contents
98888-0000-006-04
Revision G
Power Series Ball Bonder
Use of This Manual
The purpose of this manual is to give technical data for the Kulicke & Soffa Power Series Ball
Bonder. Use the Table of Contents to find specific data.
Publication
The Power Series Ball Bonder publication includes:
•
Operator’s Guide
Operator level data from bonder operation, calibration, and routine maintenance
•
Programmer’s Guide
Step-by-step instruction to teach and edit a process program for automatic bond operation
•
Reference Guide
Menu screen data from options, parameters and the related definitions
•
Maintenance Manual
Maintenance data for all primary modules
•
Material Handling System (MHS) Manual
Setup, operation, and maintenance of the MHS
•
Spare Parts Book
Selective spare parts lists with illustration for parts ordering
•
Installation Guide
Data for site requirement, packing/unpacking, installation, power-up tests and reshipment.
Terms and Conventions Used in Manuals
The format used in this publication is:
•
System modes, Graphical User Interface (GUI) buttons, MMI buttons are capitalized and
in bold. Example: PROGRAM MODE, TEACH NEW REF SYS, ENTER
•
Numeric “Hot Keys” are also in bold, followed by the function name.
Example: 1 AUTO (Mode); 3 DELETE (Menu Option)
•
Monitor messages are in initial caps. Example: Enable Eyepoint Reteach
The terminology below is used in this manual:
Term
Explanation
Chess
To move the XY table/bond head with the use of the mouse or arrow keys.
Select
1.
2.
3.
Drag
To reposition or resize an item on the display with the use of the mouse and the B1
left mouse button in a held state. To stop the drag function, release the B1 left mouse
button.
Index
To move a substrate to the next bonding sequence.
Scroll
To move a text field up or down (left to right) in the toolbar. Arrow keys or sliders are
used to do this function.
Target
Chess the XY Table to put the monitor crosshair or scan box at a specific location in
one of the display windows.
98888-0000-006-04
Revision G
Put pointer on a button or menu item and push the B1 left mouse button.
If item is highlighted (box around item), push ENTER.
Push menu item’s ‘Hot Key’.
Use of This Manual
Installation Guide
Page v
Power Series Ball Bonder
Record of Changes
Version/
Revision
Page
Issue Date
Refer to the previous version 02 for data
-
December 2010
03/B
1. All Power Series Ball Bonders added
2. New format issued
-
April 2011
03/C
ConnX Plus LCD Monitor added
3-8
3-16
4-8
December 2011
03/D
Procedures for the leveling feet in sections 3.1.1.3, 3.1.3.1,
4.1.1.3 and 4.1.3.1 updated
3-5
3-16
4-5
4-16
March 2012
04/E
1. Machine depth dimension corrected in sections 1.2.5 and 2.1
1-3
2-2
S-1
March 2014
S-18
December 2013
3-7
4-7
2-5
March 2014
00-02/A
Record of Changes
2. Safety Information updated with laser safety data and warning
04/F
Excessive load warning against scope mount assembly added
04/G
1. Foam plug release instruction added
2. The frame ground cable is supplied
Installation Guide
Page vi
Record of Changes
98888-0000-006-04
Revision G
Power Series Ball Bonder
Safety Information
The safety topics are as follows:
S.1 General
S.2 Definitions
S.3 Equipment-Specific Warnings
S.4 General Precautions
S.5 Trained Operators and Service Technicians
S.6 Electrical Equipment Servicing
S.7 Safe Use of Heated Material and Equipment
S.8 Potential Ergonomic Hazard – Microscope Use
S.9 Fire Safety
S.10 Emergency Off Switch
S.11 Cover Panels
S.12 Machine Emissions
S.13 Warning and Safety Labels
S.14 Identification Label Descriptions
S.15 Laser Safety
S.16 Declaration of Exemption
S.17 Shutdown and Start-up Procedures
S.1
General
Kulicke & Soffa refer to the latest international health and safety standards, specifications and
procedures during design and assembly of this machine. The machine is safe to operate, but
incorrect maintenance or operation could cause injury to personnel or damage to the equipment.
Keep the machine in the condition specified in this manual. During operation and maintenance,
apply all safety precautions to prevent injury to personnel and damage to the machine. Standard
safety procedure and local safety regulations apply.
The machine is used in the production of semiconductors. Do not use the machine for other
functions. Mechanical or electrical changes made without approval can have an unwanted effect
on the safe and satisfactory operation of the machine.
Kulicke & Soffa accept no responsibility for injury or damage (direct or indirect) caused if one of
these conditions are found:
(1) The machine is used for other tasks
(2) Made changes to the machine that are not approved
(3) Use tools, materials, equipment or procedures that are not approved.
You must read this safety chapter before you operate the bonder.
S.2
Definitions
This manual uses the terms Warning, Caution and Note for important data. Select links below for
more data.
S.2.1 Warning
S.2.2 Caution
S.2.3 Note
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Safety Information
General
Installation Guide
Page S-1
Power Series Ball Bonder
S.2.1
Warning
WARNING:
The symbol and the term WARNING go before text that is safety related and show a potentially
hazardous situation. If you ignore the warning, it could cause death or serious injury. Warnings
appear before the related task. Read the warnings before you do the task.
All WARNINGs are printed in Bold italic letters.
S.2.2
Caution
CAUTION:
The symbol and the term CAUTION go before text that is safety related and show a potentially
hazardous situation. If you ignore the caution, it could cause minor or moderate injury. It can also
be used to alert against unsafe practices. Cautions appear before the related task. Read the
cautions before you do the task.
All CAUTIONs are printed in Bold italic letters.
S.2.3
Note
Note:
The term Note goes after the text and gives more data that can help you during a task, or gives
you data about the machine. Notes are printed in Bold italic letters.
S.3
Equipment-Specific Warnings
WARNING:
Type 4 Electrical Hazard! The power supply module supplies a hazardous voltage of
420 VDC. This power is used on the X and Y motors and XY amplifier. Before you get access
to the power supply, the XY amplifier, the X and Y motors or their related cables, make sure
that the machine power is off. Disconnect the power supply module from the AC mains. Make
sure that the red safety LED adjacent to the 420 VDC connector on the power supply is off
(approximately after five minutes) before you get access to the power supply module, XY
amplifier, and the X and Y motors.
WARNING:
Type 4 Electrical Hazard! Do not touch the electronic flame-off (EFO) wand or the gold wire
during operation or manual EFO firing. The system makes a spark between the EFO wand
and wire which can cause an electrical shock if you touch it during EFO firing. The potential
shock hazard is not usually life threatening (as given in IEC Publication No. 479). But, K&S
recommends that personnel with unusual heart conditions or artificial heart stimulation
devices (such as pacemakers) must not be permitted to operate or do maintenance on the
equipment.
WARNING:
Type 4 Electrical Hazard! The EFO can transmit a maximum of 5 KV on different internal
parts of the EFO control box and on the high voltage cable. Do not open the EFO box. If it
becomes necessary to hold the high voltage cable or remove the box, disconnect the EFO box
power cable and wait for five minutes. Be careful at all times and apply safety precautions
when you touch or do servicing on the EFO control box and high voltage cable.
Installation Guide
Page S-2
Safety Information
Warning
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Revision G
Power Series Ball Bonder
WARNING:
Electro-magnetic Fields! Servo motors that move the bond head and optics have strong
magnetic fields. The artificial heart stimulation devices (such as pacemakers) may operate
incorrectly during bond head movement. Thus, personnel with such devices must not be near
the equipment while it is in operation.
WARNING:
Type 4 Electrical Hazard! Do not touch the clamp assembly when machine power is on. The
clamp is operated by an electrical potential of maximum 500 VDC. When used with heavy wire
or copper kit, the clamp assembly can cause an electrical shock if you touch it. But the
potential shock hazard is not life threatening.
WARNING:
Class 1 Laser Hazard! The bond head Z-axis encoder has a Class 1 laser (and in certain
models, the x-axis and y-axis encoder). While the encoder sensor head is installed on the bond
head (or XY table), the laser is not dangerous to you. Unless specified in the maintenance
procedure, make sure that the machine power is off before you do servicing or remove the
encoder from the bond head (or XY table).
WARNING:
Burn Hazard! Hot surfaces can cause burns. The workholder is hot during and after
operation. Use heat-resistant protective gloves or let surface temperatures decrease to less than
60°c before you touch the workholder.
WARNING:
Hazardous Material! The bond head link is made from a Beryllium alloy that can be a
potential carcinogen. Hazardous dust is made when this material is cut, removed, or ground.
Do not machine or try to rework the bond head. Do not cause scratches on the link with small,
sharp tools when you do work around the bond head area. This may cause particles that can
enter your skin. A material safety data sheet for Beryllium and its safety application is
available from K&S. Refer to your local K&S support for more data.
WARNING:
Injury Hazard! During operation, some modules of the machine move without a warning.
Keep hands, tools, and loose items away from the MHS, XY table, and bond head areas.
S.4
General Precautions
Apply these general safety precautions before you operate, adjust, or do servicing on this
equipment:
•
Components of the workholder are very hot. Do not let your fingers, or materials with a
low melting point to touch the hot areas
•
Obey all WARNINGS and CAUTIONS written in the texts of the machine manuals
•
Always disable all motors before you put your hands near the bond head, XY table, MHS
and other energized systems
•
Keep your hands away from the bond area during machine operation
•
Operate the bonder with covers installed at all times
•
Disconnect the electrical service to the bonder before you remove the rear covers or open
the card rack door (unless machine power is necessary for a specific maintenance task)
•
Standard precautions related to live electrical circuits must be taken at all times
•
Do not put tools or materials on the MHS or bonder when you do maintenance
98888-0000-006-04
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Safety Information
General Precautions
Installation Guide
Page S-3
Power Series Ball Bonder
•
•
S.5
Apply the manufacturer's recommended safety precautions when you use chemical
material
Solvents and aerosols, if used, must be compatible with the bonder serviceable location
and the process
Trained Operators and Service Technicians
The users for operation and maintenance must receive training in machine operation and
maintenance given by Kulicke & Soffa. The Performance Based Equipment Training (P.B.E.T.)
given by Kulicke & Soffa makes sure that the personnel can operate and do maintenance on the
machine. There are two levels of training:
•
Level One
Level One training includes basic machine operation and maintenance. Machine Operators
must complete this training before they are permitted to operate the machine.
•
Level Two
Level Two training includes advanced machine operation and maintenance. Service
technicians must complete the two levels of training (Level One and Level Two).
Data on the training and locations can be found on “www.kns.com”.
Installation Guide
Page S-4
Safety Information
Trained Operators and Service Technicians
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Revision G
Power Series Ball Bonder
S.6
Electrical Equipment Servicing
CAUTION:
Before you apply AC power to the machine, read through the safety items below.
S.6.1 Types of Electrical Hazards
S.6.2 Power Supply Servicing
S.6.3 Lockout/Tagout Procedure
S.6.1
Types of Electrical Hazards
At times, it is necessary to get access to some areas of the machine to do setup procedures,
calibrations or regular maintenance procedures. If work in these areas are related to components
near opened energized circuits, the steps to do the work specifies the type of electrical hazard.
The types of electrical hazards are:
•
Type 1: Equipment is fully de-energized (electrically cold)
•
Type 2: Equipment is energized
Live circuits have insulations.
•
Type 3: Equipment is energized
Live circuits are open and accidental contact is possible. Potential exposures are less than
30 VRMS (42.2 volts peak).
•
Type 4: Equipment is energized
Live circuits are open and accidental contact is possible. Potential exposures are more than
30 VRMS (42.2 volts peak) or there are radio frequencies.
•
Type 5: Equipment is energized
Measurements and/or adjustments include entry into the equipment or equipment
configuration does not let you use clamp-on probes.
Note: Electrical hazard of types 3 through 5 are clearly shown in the Power Series machine
manuals.
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Revision G
Safety Information
Electrical Equipment Servicing
Installation Guide
Page S-5
Power Series Ball Bonder
S.6.2
Power Supply Servicing
CAUTION:
You can cause damage to the machine if you apply power that is below the specified voltage
range. Do not connect the machine to source power unless the source power is in the range of
200 VAC to 240 VAC. If the source power is below this range, a step-up transformer is
necessary (see NOTE below).
Note: If the source input voltage is in the range of 100 VAC to 120VAC, a step-up transformer
is necessary. This is to increase the input voltage to the required 200 to 240 VAC range.
The step-up transformer is installed between the Power Series power supply and the
source input voltage. Speak your local Kulicke & Soffa support for more data about this
feature.
The DC power to all components on the Power Series are supplied by the power supply through
the Power Distribution Unit (PDU). But the +420VDC supply to the XY amplifier comes directly
from the power supply through an approved cable.
CAUTION:
There is a red safety LED adjacent to the 420 VDC connector on the power supply, which,
when come on shows that there is voltage of more than 60 VDC. Make sure that this safety
LED is off before you disconnect the power supply, XY amplifier, or X and Y motors. See
figure above for location.
A
A
Safety LED Location
Figure S-1: Safety LED on the Power Supply
Configuration setup is not necessary for the power supply. Make sure that the source AC line
voltage is in the range of 200 to 240 VAC. Also, frequency differences in the source input
voltage are applied automatically.
S.6.3
Lockout/Tagout Procedure
Kulicke & Soffa recommends that you use a power connector locking device. When you remove
power from the machine, put the lockout device (user supplied) on the power cable. This is to
prevent accidental power connection to the machine during maintenance. Attach the tagout
device on the lockout device is recommended. This gives a clear warning to all personnel that the
machine cannot be operated until the tagout device and the lockout device are removed. Refer to
OSHA Standard (29 CFR 1910.147) for data on the control of hazardous energy with lockout/
tagout procedures.
Installation Guide
Page S-6
Safety Information
Power Supply Servicing
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Revision G
Power Series Ball Bonder
S.7
Safe Use of Heated Material and Equipment
The workholder heaters are hot and it will burn your skin immediately if you touch the heaters or
components near the heaters without protection. Apply safety precautions when you load or
remove the hot materials or do servicing in the area around the workholder to prevent injury.
S.7.1
User's Responsibilities for Personal Safety
It is your responsibility to operate and do servicing on the machine safely. You must know all the
hazards and their related safety precautions. Examine all of the safety data given with the
equipment. Read the WARNINGs in the machine manuals, and know the areas of the machine
with hazardous labels.
S.8
Potential Ergonomic Hazard – Microscope Use
There is a potential ergonomic hazard when you use the microscope installed on the machine.
The eyepieces of the microscope are 1380 mm (54.3 inches) above the ground. For some
machine users, this eyepiece height is too low to use. For others, the eyepiece height is too high
to look through the microscope. The height of the microscope is not adjustable. To prevent
potential injury, apply these precautions when you use the microscope:
WARNING:
Do not stay on tiptoe when you look through the microscope. This is not a stable position and
this may cause you to fall down.
S.8.1
(1)
If the eyepieces are too high, put your feet on a step while you look through the
microscope. This lets you to look through the eyepieces easily, but the maximum step
height must not be more than 100 mm (4 inches).
(2)
If the eyepieces are too low, make sure that the time to look through the microscope (in a
bent position) is no more than 20 seconds at a time. During intervals, make sure that you
stay up straight for approximately 10 seconds after each view (of 20 seconds). To prevent
potential injury, the maximum number of views at the microscope in a bent position is two
for each day (with rest after each 20 second view).
Heated Equipment Servicing
Set the heaters to off and give sufficient time for the workholder heaters to cool fully before you
start the maintenance procedure.
To make sure that the workholder heaters are cool:
(1)
In the Temperature Configuration dialog, set 1 TURN ALL ZONES to OFF.
(2)
Monitor the heat zone temperatures shown on the monitor screen.
(3)
When the shown temperatures equal the ambient temperature (approximately 25 °C), start
the maintenance procedure.
98888-0000-006-04
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Safety Information
Safe Use of Heated Material and Equipment
Installation Guide
Page S-7
Power Series Ball Bonder
S.9
Fire Safety
This section shows the fire suppression equipment necessary for the machine and the storage of
flammable supplies.
Select links below for more data:
S.9.1 Fire Suppression
S.9.2 Flammable Maintenance Supplies
S.9.1
Fire Suppression
The machine is operated in a clean room that has fire detection and fire suppression equipment.
The only requirement is to make sure that the fire extinguishing agent is applicable for the
removal of electrical and electronic fires. The machine contains no flammable liquids or gases
and does not use flammable liquids or gases during operation. If there is no area specified to put
the fire suppression equipment where the machine operates, the fire suppression equipment must
be available near the machine. Only personnel approved to extinguish fires can use the fire
suppression equipment. If there is a fire, fumes from the machine are the same as those found
from the combustion of electrical or electronic equipment. Apply standard discharge and
cleaning procedures at all times.
S.9.2
Flammable Maintenance Supplies
Some preventive maintenance procedures use isopropyl alcohol and grain alcohol for cleaning
and grease removal which are flammable liquids. Large quantities of alcohol (more than 1 liter)
must be put in storage with reference to local regulations. At a minimum, the alcohol must be
kept in approved containers with clear labels. You must keep the containers out of the production
area in fireproof lockers. When the use of alcohol is necessary for machine maintenance, use
only in small quantities in tightly closed container with label. Keep the alcohol away from open
flames or other sources of ignition at all times.
S.10
Emergency Off Switch
The Power Series emergency off switch is on the front right side of the upper console. It is a
latching switch with a large red knob surrounded by a yellow label. The switch is large and clear
to see, and conveniently in position. This is to make sure that the user can easily find and use it,
if an emergency power down of the system is necessary.
Push the switch knob in to start an emergency power down process. This causes the power
supply contactor to open and to remove all AC power from the equipment. To start up the bonder
after an emergency power down, release the emergency off switch. Then push the machine off
switch once, and push the machine on switch to start up the machine.
CAUTION:
When you push the emergency off switch during bonding, operation may result in the loss of
the process program and possibly cause damage to the material. Make sure that you clear all
leadframes from the workholder before you restart the bonder after an emergency off
condition.
Select links below for more data:
S.10.1 Emergency Off Switch Specifications
S.10.2 Test Emergency Off Switch Operation
Installation Guide
Page S-8
Safety Information
Fire Safety
98888-0000-006-04
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Power Series Ball Bonder
S.10.1
Emergency Off Switch Specifications
•
•
•
S.10.2
Switch Location: Front, right side corner of the upper console.
Switch Description: Latching switch with large red knob and a yellow label imprinted with
the term “EMERGENCY OFF”. When activated, the switch latches in the on position.
The switch knob must be turn clockwise to release and unlock the switch.
Functions:
•
Emergency Off- Push the emergency off switch:
When you push in the switch, it cuts off all AC power to the system by the release of
the power supply contactor.
•
When the emergency off switch is pushed:
The emergency off switch stays in the latched position to prevent unauthorized use
of the machine. If the “ON” switch button is pushed with the emergency off switch
latched down, the machine power continues to stay off. Go to the next step to restart
from emergency off.
•
Restart from emergency off:
Turn the switch knob clockwise to release the switch and reset the emergency off
switch. This will release the switch to reset to the “out” position. Push the machine
OFF switch and then push the machine ON switch button to start up the machine.
Note: The equipment will not restart unless the emergency off switch is reset to the
“out” position.
Test Emergency Off Switch Operation
A test of Emergency Off Switch operation must be done regularly as part of the scheduled
machine preventive maintenance. The test must also be done immediately after the machine is
installed at your site, during initial start up.
In this test, the user must operate the switch to make sure that power is immediately removed
from the machine. The main power switch will not return power to the machine when the
emergency off switch is activated (latched down).
S.11
Cover Panels
The machine covers include the workholder cover, input and output magazine handler covers,
upper console cover panel and lower console cover panel. They give protection to the trained
personnel from hazards related to the movement of the mechanical parts, heating elements and
electrical subsystems of the equipment. The covers must be in place and attached during all
normal operations. They must be opened or removed by trained service personnel only.
S.12
Machine Emissions
This section gives the various types of machine emissions for Power Series Ball Bonder. Select
links below for more data:
S.12.1 Ionizing and Non-Ionizing Radiation
S.12.2 Vibration
S.12.3 Noise
S.12.4 Gases, Vapor, Dust
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Safety Information
Emergency Off Switch Specifications
Installation Guide
Page S-9
Power Series Ball Bonder
S.12.1
Ionizing and Non-Ionizing Radiation
•
•
S.12.2
Ionizing Radiation:
There are no sources of ionizing radiation in the machine.
Non-ionizing Radiation:
The machine has been tested to show compliance with EN 61000-6-4, “Generic Emissions
for Industrial Environments.”
Vibration
If the machine is installed as specified in the Installation Guide, the machine will not let out any
appreciable vibration when in operation. Make sure that the machine on its leveling feet and with
no contact between the machines and site walls or other equipment. Elastomer vibration isolators
are used on the leveling feet to support the machine and prevent vibrations from the machine to
transmit it to the floor.
S.12.3
Noise
Continuous acoustical noise emitted by the machine will not be more than 85 dB(A). This is
measured from the user position as prescribed in ANSI S1.13 “Methods for the Measurement of
Sound Pressure Levels.”
S.12.4
Gases, Vapor, Dust
The machine produces no gases, vapors, or dust as a result of its operations.
Installation Guide
Page S-10
Safety Information
Ionizing and Non-Ionizing Radiation
98888-0000-006-04
Revision G
Power Series Ball Bonder
S.13
Warning and Safety Labels
This section gives the safety and identification labels on the Power Series Ball Bonder. The
safety labels inform trained users and trained service personnel that a hazardous condition may
exist in the general area of each of those labels. This requires caution if actions must be done in
those areas. The identification labels are informative and intended to help trained users and
trained service personnel to do their duties safely.
F
A
B
C
D
B
B
E
A
S.13.2 Burn Hazard Warning
D
S.13.5 General Hazard Warning
B
S.13.3 Pinch Point Hazard Warning
E
S.13.8 Operator ESD Connection Point Label
C
S.13.4 Electrical Hazard Warning
F
S.13.1 Emergency Off
Figure S-2: Machine Front and MHS Safety Label Tags
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Safety Information
Warning and Safety Labels
Installation Guide
Page S-11
Power Series Ball Bonder
A
D
C
A
B
A
S.13.4 Electrical Hazard Warning
C
S.13.5 General Hazard Warning
B
S.13.7 Equipment Grounding IEC
D
S.14.2 Equipment Configuration Tag
Figure S-3: Machine Safety Label Tags (rear view)
Installation Guide
Page S-12
Safety Information
Warning and Safety Labels
98888-0000-006-04
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Power Series Ball Bonder
D
C
B
A
A
S.13.4 Electrical Hazard Warning
C
S.14.3 Equipment Identification/Manufacturer’s Identification Label
B
S.13.6 Disconnect Power Label
D
S.14.4 FDA Explanatory/Certification Label
Figure S-4: Lower Console Front Safety Label Tags
A
B
A
S.13.4 Electrical Hazard Warning
B
Clamp Driver Board
Figure S-5: Card Cage Safety Label Tags
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Safety Information
Warning and Safety Labels
Installation Guide
Page S-13
Power Series Ball Bonder
A
B
C
A
S.14.1 EFO Box Ordering Notice Label
B
S.13.4 Electrical Hazard Warning
C
S.13.3 Pinch Point Hazard Warning
Figure S-6: EFO and MHS Safety Labels
A
A
S.13.9 Beryllium Product Warning
Figure S-7: Bond Head Safety Label
Installation Guide
Page S-14
Safety Information
Warning and Safety Labels
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Power Series Ball Bonder
S.13.1
Emergency Off
Figure S-8: Emergency Off Label
•
•
•
S.13.2
Label: Emergency Off Label
Description:
This label identifies and increases the visibility of the emergency off switch. This label
makes sure that all users are fully aware of its location and function.
Color: Black on yellow background
Burn Hazard Warning
Figure S-9: Burn Hazard Warning Label
WARNING:
Hot temperatures can go as high as 200°C.
•
•
•
S.13.3
Label: Burn Hazard Warning
Description:
Trained users and service personnel are warned of hot surfaces in the workholder area and
on the bond head and optics assembly.
Color: Black on yellow background
Pinch Point Hazard Warning
Figure S-10: Pinch Point Warning Label
•
•
•
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Label: Pinch Point Hazard Label
Description:
Trained users and Service Personnel are warned to keep hands and fingers clear of the
area. This applies to the front and rear areas of the input and output magazine handlers and
on the front of the workholder area.
Color: Black on yellow background
Safety Information
Emergency Off
Installation Guide
Page S-15
Power Series Ball Bonder
S.13.4
Electrical Hazard Warning
Figure S-11: Electrical Hazard Warning Label
•
•
•
S.13.5
Label: Electrical Hazard Warning Label
Description:
This label alerts trained service personnel to the presence of high voltage in the area.
Color: Black on yellow background
General Hazard Warning
Figure S-12: General Hazard Warning Label
•
•
•
S.13.6
Label: Warning, General Hazard Label
Description:
This label alerts trained service personnel (TSP) to the presence of danger at the
workholder area, upper and lower console areas when covers are taken out. The TSP must
to look for the related labels (next to the General Hazard Label) and read the safety
information before you try to service the equipment.
Color: Black on yellow background
Disconnect Power Label
Figure S-13: Disconnect Power Before Servicing Label
•
•
•
Installation Guide
Page S-16
Label: Disconnect Power Before Servicing Label
Description:
The label tells trained service personnel to disconnect the input power cord of the power
supply before they service the equipment in the lower console.
Color: White on blue background
Safety Information
Electrical Hazard Warning
98888-0000-006-04
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Power Series Ball Bonder
S.13.7
Equipment Grounding IEC
Figure S-14: Equipment Grounding IEC Label
•
•
•
S.13.8
Label: Equipment Grounding IEC Label
Description:
Label identifies the connection point for input power ground.
Color: Black on white background
Operator ESD Connection Point Label
Figure S-15: Operator ESD Connection Point Label
•
•
•
S.13.9
Label: Operator ESD Connection Point Label
Description:
Label identifies the connection point to attach the ESD wrist strap. This is to prevent
equipment damage from electrostatic discharge.
Color: Black on white background
Beryllium Product Warning
Figure S-16: Beryllium Product Warning Label
•
•
•
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Label: Beryllium Product Warning Label. “BERYLLIUM PRODUCT. HAZARDOUS
DUST PRODUCED WHEN MACHINED, FILED, OR GROUND.”
Description:
Trained service personnel are directed to manual for safety information with parts made
from Beryllium alloy, which can represent a health hazard under certain conditions.
During normal machine operations and maintenance actions, the Beryllium alloy does not
represent a hazard to machine users or service technicians. Refer to Power Series Ball
Bonder Maintenance Manual, chapter 5: bond head, for more data.
Color: Black on yellow background
Safety Information
Equipment Grounding IEC
Installation Guide
Page S-17
Power Series Ball Bonder
S.13.10 Hard Stop Caution
A
A
Hard Stop Limit Line
Figure S-17: Hard Stop Caution Label
•
•
•
Label: Hard Stop Caution Label. “HARD STOP CAUTION. Do not force beyond the hard
stop.”
Description:
Trained operators and service personnel are not to turn the work light beyond the hard
stop. This is because rotation beyond the hard stop will cause damage to the joint on the
goose neck. The hard stop location is denoted on the caution label.
Color: Black and white text on yellow, red, and gray background
S.13.11 Excessive Load Warning Against Scope Mount
Figure S-18: Excessive Load Warning Label (Against Scope Mount)
•
•
•
Installation Guide
Page S-18
Label: Excessive Load Warning Label (Against Scope Mount). “DO NOT LEAN OR
APPLY EXCESSIVE LOAD AGAINST SCOPE MOUNT ASSEMBLY.”
Description:
Trained operators and service personnel are not to lean or apply excessive force on the
scope mount assembly because this can cause damage to the locking screw and cause a
blockage to the linkage system. Do not use the scope mount assembly to push the bonder
during transport.
Color: Black text on yellow background
Safety Information
Hard Stop Caution
98888-0000-006-04
Revision G
Power Series Ball Bonder
S.14
Identification Label Descriptions
The sections below give descriptions of each identification label that includes label location,
color(s) and purpose, meaning, additional instructions, etc.
Select links below for more data:
S.14.1 EFO Box Ordering Notice Label
S.14.2 Equipment Configuration Tag
S.14.3 Equipment Identification/Manufacturer’s Identification Label
S.14.4 FDA Explanatory/Certification Label
S.14.1
EFO Box Ordering Notice Label
Figure S-19: EFO Box Ordering Notice Label
•
•
•
S.14.2
Label: EFO Box Ordering Notice Label
Description:
This label tells the trained service personnel to take note of the full part number that
includes the last two digits when ordering a new or replacement EFO Box. It also instructs
them to consult the customer service representative if necessary.
Color: Black on beige card stock
Equipment Configuration Tag
Figure S-20: Equipment Configuration Tag
•
•
•
98888-0000-006-04
Revision G
Label: Equipment Configuration Tag
Description: This tag gives Trained Service Personnel with the AC power configuration of
the equipment, as shipped. It also instructs them to refer to the Maintenance Manual if the
line voltage and frequency is out the specification.
Color: Red on White Card
Safety Information
Identification Label Descriptions
Installation Guide
Page S-19
Power Series Ball Bonder
S.14.3
Equipment Identification/Manufacturer’s Identification Label
Figure S-21: Equipment Identification Label
•
•
•
S.14.4
Label: Equipment Identification/Manufacturer's Identification Label
Description:
The label specifies the equipment and manufacturer's identification numbers (model
number, serial number, series and date manufactured), identifies the country of origin, and
indicates CE compliance. It shows data on the AC power configuration and tells trained
maintenance personnel of the expected maximum power consumption at listed nominal
voltages. It also directs trained maintenance personnel to consult the Machine Manuals
before you try to reconfigure the system.
Color: Black on gray
FDA Explanatory/Certification Label
Figure S-22: FDA Explanatory/Certification Label
•
•
•
Installation Guide
Page S-20
Label: FDA Explanatory/Certification Label
Description:
This label specifies that, with the use of Class 1 lasers in, the equipment is considered a
Class 1 Laser Product as specified per international standard EN/IEC 60825-1:2007. It
also specifies that the equipment complies with the US Food and Drug Administration/
Center for Devices and Radiological Health (FDA/CDRH) performance standards for
laser products except for deviations as documented in FDA/CDRH Laser Notice Number
50 published on June 24, 2007.
This label, in conjunction with the Equipment Identification Label (FDA/CDRH
Manufacturer's Identification Label), comprise the necessary US FDA/CDRH label
requirement for Class 1 Laser Products.
Color: Black on white
Safety Information
Equipment Identification/Manufacturer’s Identification Label
98888-0000-006-04
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Power Series Ball Bonder
S.15
Laser Safety
Note: The data below applies to K&S machines with serial numbers “@@E@-@@XXXXX”
where “@” is alpha configuration data and X is numeric.
LASER SAFETY INFORMATION: Mercury & Chip Encoder
These encoders contain an infrared laser diode or diodes. Emitted invisible laser radiation levels
have been measured to be in the CDRH Class 1 range, which is not considered hazardous.
However, to decrease exposure to the diverging beam, install the encoder sensor in its
operational configuration near the encoder scale before you apply power.
•
•
•
•
Invisible laser radiation
•
Wavelength: 850 nm
All maintenance procedures such as cleaning must be performed with the MicroE encoder
turned off.
Do not insert any reflective surface into the beam path when encoder is powered.
Do not attempt to service the encoder.
MicroE Systems
125 Middlesex Turnpike, Bedford, MA 01730
Serial # XXXXX
Model # Mercury II 1900XY/ZCRS
Manufactured Date: October 2011
CAUTION:
The use of controls or adjustments or performance of procedures other than those specified
herein may result in hazardous radiation exposure.
(1)
This laser product is designated as Class 1 during all procedures of operation.
•
Non-accessible Laser Parameter
•
Wavelength: 850 nm
(2)
The bond head Z-axis encoder and the XY table X and Y encoders contain a Class 1 laser.
While the encoders are mounted in the bonder, the laser poses no danger to the user or
maintenance technician. However, it is recommended that, unless specifically required for
the maintenance activity, you always turn off the machine power before you service the
equipment. Turn off the machine power before you remove the encoder from the bond
head or X and Y table.
(3)
Under normal usage, there is no user maintenance required or any scheduled maintenance
necessary to the laser encoders. The laser encoders should not be opened and no repair,
service or modification shall be done by customer. Only trained K&S service personnel or
K&S trained customer service engineers are able to service the encoders.
98888-0000-006-04
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Safety Information
Laser Safety
Installation Guide
Page S-21
Power Series Ball Bonder
(4)
If the X or Y encoder becomes faulty, send the complete X/Y table to the factory for repair
and/or replacement. This is due to the complexity and special tools required for the repair,
setup and recalibration. In some instances, and subject to the fault finding results, a trained
K&S service engineer may make the repairs on-site. You can service the Z-axis encoder at
a customer site but only by a trained K&S service engineer or K&S trained customer
service engineer.
(5)
A bonder with a faulty laser encoder should be taken out of service for repair by a
qualified service engineer as mentioned above.
(6)
For customer performed service functions, only K&S trained customer service engineers,
with K&S calibration tools and maintenance procedures in the equipment's Maintenance
Manual, are permitted.
Note: The data below applies to K&S machines with serial numbers “@@H@-@@XXXXX”
where “@” is alpha configuration data and X is numeric.
CAUTION:
The use of controls or adjustments or performance of procedures other than those specified
herein may result in hazardous radiation exposure.
(7)
This laser product is designated as Class 1 during all procedures of operation.
•
Non-accessible Laser Parameter
•
Wavelength: 850 nm
(8)
The bond head Z-axis encoder contains a class 1 laser. While the encoder is mounted in the
bonder, the laser poses no danger to the user or maintenance technician. However, it is
recommended that, unless specifically required for the maintenance activity, you always
turn off the machine power before you service the equipment. Turn off the machine power
before you remove the encoder from the bond head or X and Y table.
(9)
Under normal usage, there is no user maintenance required or any scheduled maintenance
necessary to the laser encoders. The laser encoders should not be opened and no repair,
service or modification shall be performed by customer. Only trained K&S service
personnel or K&S trained customer service engineers are allowed to service the encoders.
(10) You can repair and replace the Z-axis encoder at a customer site but only by a trained K&S
service engineer or customer service engineer.
(11) A bonder with a faulty laser encoder should be taken out of service for repair by a
qualified service engineer as mentioned above.
(12) For customer performed service functions, only K&S trained customer service engineers,
with K&S calibration tools and maintenance procedures in the equipment's Maintenance
Manual, are permitted.
Installation Guide
Page S-22
Safety Information
Laser Safety
98888-0000-006-04
Revision G
Power Series Ball Bonder
S.16
Declaration of Exemption
Kulicke & Soffa Pte Ltd declares that our products, i.e. ball bonders, wedge bonders, die bonders
and similar industrial equipment are exempt from the European RoHS (Restriction of Use of
Certain Hazardous Substances) and WEEE (Waste of Electrical and Electronics Equipment)
directives refered to the equipment under the not applicable category of “Large-scale, stationary
industrial tools” as referenced in EU Directive 2011/65/EU (RoHS) Article 2§4(d) and
Article 3§(3).
Examples of this type of equipment have previously been reviewed by third party evaluators (see
Note 1) who determined that the equipment reviewed meet the above criteria (see Note 2) and, as
such, are deemed to be outside the scope of both European Union (EU) RoHS and WEEE.
Note: 1) TUV Rheinland of North America, RoHS & WEEE – Official letter of exemption,
Kulicke & Soffa; September 26, 2005
Note: 2) TUV Rheinland of North America, WEEE and RoHS Directive Applicability to
Industrial Machinery; September 27, 2005
S.17
Shutdown and Start-up Procedures
In the event of a plant shutdown, bonders must be shut down. The machine shutdown and startup procedures are given below. Select links below for more data:
S.17.1 Machine Shutdown Procedure
S.17.2 Machine Start-up Procedure
S.17.1
Machine Shutdown Procedure
(1)
Turn “OFF” all heaters (pre-heat, bond site and post heat) from the GUI.
(2)
Remove all materials, units, magazines, wires, P-parts, etc from the bonder.
(3)
Re-initialize the workholder.
(4)
Save Bond Process Programs (if needed).
(5)
Save MDP to C:\ drive.
(6)
Push the machine off button to shut down the machine.
(7)
Disconnect clean dry air (CDA) supply line and AC power cord from the AC mains.
(8)
Wait for machine to cool down to room temperature. Place desiccants on the X/Y motors,
lower console (inside and outside) and heat block. Move the bond head above the heat
block.
(9)
Put a plastic sheet over the machine to prevent dust accumulation.
(10) At this juncture, inform the personnel in-charge of the site to shut down the HVAC
(heating, ventilating and air conditioning) system.
98888-0000-006-04
Revision G
Safety Information
Declaration of Exemption
Installation Guide
Page S-23
Power Series Ball Bonder
S.17.2
Machine Start-up Procedure
Note: Coordination with facilities is extremely important to make sure that there is smooth
transition of the bonders into production.
(1)
Wait for the production environment to stabilize to the these conditions:
•
•
•
Temperature ~77°F (25°C) or below
Relative humidity of 40-60%
Barometric pressure of 540 to 810 mm Hg (21.2 to 31.9” Hg)
(2)
Remove all desiccants from the bonder.
(3)
Purge the CDA supply (incoming facilities) before you connect the CDA supply line to the
bonder.
(4)
Check the supply (incoming) voltage with a multimeter. This is dependent on the AC
voltage requirement on the machine.
(5)
Connect the AC power cord to the AC mains.
(6)
Push the machine on button to power up the machine.
(7)
Load Bond Process Program.
(8)
Install the heat block & clamp insert.
(9)
Do the bonder dry cycle mode with pre-heat, bond site and post heat temperature setpoints turned “OFF”.
(10) Turn “ON” pre-heat, bond site and post heat heaters after successful completion of dry
cycle.
(11) Do the machine setup for production refered to customer’s standard procedure.
Installation Guide
Page S-24
Safety Information
Machine Start-up Procedure
98888-0000-006-04
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Power Series Ball Bonder
Chapter 1: Introduction
98888-0000-006-04
Revision G
Introduction
Installation Guide
Page 1-1
Power Series Ball Bonder
1.1
Installation Guide Contents
The Power Series Installation Guide gives site preparation, unpacking, installation, and power up
testing instructions for all Power Series Ball Bonder. The guide is divided into six sections:
•
Chapter 1: Introduction
Includes a general introduction, specification and installation sequence needed for
machine installation. Gives specific and general safety precautions that should be
reviewed before the machine installation.
•
Chapter 2: Site Preparation
Contains site requirements data needed to prepare the site where the machine will be
installed.
•
Chapter 3: Unpacking/Packing - Carton (Outside USA)
Contains instructions on:
•
•
•
Installation Guide
Page 1-2
(a)
How to do inspection on the machine carton for shipping damage or mishandling.
(b)
How to unpack the machine and its accessories from the shipping crate.
(c)
How to repack the machine are also included.
These will be helpful if there is ever a need to ship the machine to another location outside
USA.
Chapter 4: Unpacking/Packing (To or From USA)
Contains instructions on:
(a)
How to do inspection on the machine crate for shipping damage or mishandling.
(b)
How to unpack the machine and its accessories from the shipping crate.
(c)
How to repack the machine are also included.
Chapter 5: Machine Installation
Includes procedures that enable installation of the machine at its prepared site. The
procedures are:
(a)
How to move the machine to the site.
(b)
How to make the machine level.
(c)
How to install accessory items.
(d)
How to do checks on machine power supply configuration and facility air pressure.
(e)
How to connect the machine to facility electrical and air pressure supplies.
Chapter 6: Machine Power Up Tests
Power–up tests should be run to make sure the machine is ready to be set up for acceptance
test and production operations. These tests includes:
(a)
Start the machine.
(b)
Do checks on the power supply outputs to make sure that they are within their
specified ranges.
(c)
Make sure that the machine completes its initialization sequence.
Introduction
Installation Guide Contents
98888-0000-006-04
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Power Series Ball Bonder
1.2
Specification - Site Requirements
Select the links below to find the specific site requirement:
1.2.1 Electrical Requirement for Power Supply
1.2.2 Compressed Air Requirements
1.2.3 Nitrogen & Forming Gas Requirement (for Cu Wire Bonding)
1.2.4 Operating Environment
1.2.5 Machine Dimensions (approximate)
1.2.6 Machine Weight (approximate)
1.2.1
Electrical Requirement for Power Supply
CAUTION:
Operation Hazard.
To apply power to the machine below the specified voltage range may cause damage to the
machine. Do not connect the machine to the source power unless the source power is within
the range of 200 VAC to 240 VAC. If the source power is below this range, a step-up
transformer is required (see NOTE below).
•
Line Voltage: The power supply operates with the source AC line voltage of
200 to 240 VAC single phase and frequency of 47-63 Hz without additional configuration
•
Input Rush Current (estimated) at 200 to 240 VAC: 75 A for 100 msec
•
Power Consumption: 1.5 KVA (nominal), 2.6 KVA(maximum)
Note: If the source input voltage is within the range of 100 to 120 VAC, you need a step-up
transformer. The step-up transformer increases the input voltage to the 200 to 240 VAC
range.The transformer kit is installed between the source input voltage and the bonder
power supply. Call your local K&S sales representative for more data.
1.2.2
Compressed Air Requirements
Requirements
1.2.3
Dimension
Minimum Pressure
50 psi (3.52 kg/cm2)
Maximum Pressure
80 psi (5.62 kg/cm2)
Nominal Air Consumption (flow rate)
185 liters/min @4.6 kg/sq.cm (6.5 CFM @65 PSI)
Quality
Oil and acid gas free
Filtration
0.3 µm
Dew point
5°C @4.6 kg/cm2 (41°F @65 psi)
Nitrogen & Forming Gas Requirement (for Cu Wire Bonding)
The ball bonder feeds the customer-supplied nitrogen or forming gas to the bond site for copper
wire bonding. You must install a shut-off device (not supplied by K&S) for nitrogen and forming
gas to stop the supply to the ball bonder in case of emergency, machine maintenance or plant
shutdown.
1.2.4
Operating Environment
•
•
1.2.5
Temperature: 20°C - 30°C (68°F - 86°F)
Relative Humidity: 30 - 70% RH (non–condensing)
Machine Dimensions (approximate)
•
•
•
98888-0000-006-04
Revision G
Width: 889 mm (35 in.)
Depth: 1009 mm (39.7 in.)
Height: 1797 mm (70.75 in.) to the top of the monitor
Introduction
Specification - Site Requirements
Installation Guide
Page 1-3
Power Series Ball Bonder
1.2.6
Machine Weight (approximate)
•
•
Installation Guide
Page 1-4
Machine: 590 kg (1300 lbs)
Machine and Shipping Crate: 670 kg (1477 lbs)
Introduction
Machine Weight (approximate)
98888-0000-006-04
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Power Series Ball Bonder
1.3
Safety Considerations
You must obey the warnings (see Safety Information chapter) and general safety precautions (see
section 1.3.1 General Safety Precautions). Other WARNINGS and CAUTIONS are added
where appropriate throughout the text of this manual and in the other manuals.
You must read the Safety Information in the safety chapter before you operate the machine.
1.3.1
General Safety Precautions
You must obey the general safety precautions when you operate, adjust, or service this
equipment. Read below:
(1)
Read all the Safety Information supplied with the manual set before you operate the
machine. Be sure to obey all WARNINGS and CAUTIONS.
(2)
Be sure to comply with all approved and established safety precautions while working
around powered machinery.
(3)
Components of the workholder are VERY HOT! Do not allow fingers, or any material
with a low melting point to contact heated areas.
(4)
Hands or tools must NEVER be put on the Material Handling System (MHS) area or near
other moving parts when the system is in operation. Push the MOTOR STOP keys before you
work on the powered components.
(5)
Always operate equipment with covers installed.
(6)
Standard precautions apply when you work with live electrical circuits during adjustments
or maintenance.
(7)
Obey manufacturer’s safety precautions and disposal procedures when you work with
chemical substances. Refer to the Manufacturer’s Safety Data Sheet (MSDS) for guidance.
98888-0000-006-04
Revision G
Introduction
Safety Considerations
Installation Guide
Page 1-5
Power Series Ball Bonder
1.4
Machine Installation Sequence
Step
Installation Guide
Page 1-6
Action
Reference
1
Prepare site for machine:
Chapter 2: Site Preparation
1. Make sure that facilities are present and will meet
requirements (electrical power and air pressure
source).
2. Make sure that the operating environment is suitable.
3. Make sure there is sufficient area for machine
operation and maintenance.
4. Make sure floor will support machine.
2
Unpack machine:
1. Do a check for shipping damage/mishandling.
2. Disassemble crate. Make sure that the inventory
contents and serial number are correct.
3. Detach and lift machine off from the carton/crate
pallet. Install leveling feet.
4. Remove shipping restraints/packing materials.
5. Move machine to prepared site.
Chapter 3: Unpacking/Packing Carton (Outside USA)
3
Install machine:
1. Position and level machine at prepared site.
2. Mount accessory items and assemblies removed for
shipping. Install power plug on machine power cord.
3. Make sure that the setting of input voltage range
switch and facility air pressure level are correct.
4. Connect power and air pressure to machine.
Chapter 5: Machine Installation
4
Perform power-up tests:
1. Set machine power to ON.
2. Do Emergency Off Switch test.
3. Do power supply DC outputs check.
4. Make sure that initialization is completed.
Chapter 6: Machine Power Up Tests
Introduction
Machine Installation Sequence
Chapter 4: Unpacking/Packing (To or
From USA)
98888-0000-006-04
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Power Series Ball Bonder
1.5
Storage and Transport
Select the links below for the necessary storage and transportation needed to keep the machine:
1.5.1 Short Term Storage
1.5.2 Long Term Storage
1.5.3 Packing and Shipping
1.5.1
Short Term Storage
The Power Series Ball Bonder may be stored within the facility for an indefinite period of time.
Make sure that it remains in an environment where temperature and humidity do not exceed the
limits listed in the 1.2.4 Operating Environment section. During storage:
•
The machine has a vapor barrier to prevent dust
•
The leveling feet are adjusted to lift the machine off of from the casters
1.5.2
Long Term Storage
If the machine is to be stored for an extended period of time at a location where the environment
may not be strictly controlled, pack the machine in its shipping crate. Refer to the chapter
4.1 Unpacking/Packing (To or From USA) for data.
In transit to and while in storage, temperature, humidity, and shock must be in accordance with
the requirements listed below:
•
Storage and Shipping Requirements
Note: Storage and shipping environmental specifications are for a machine packed in its
shipping carton/crate.
•
Temperature : -40 °C to 55 °C (-40 °F to 131°F)
•
Relative Humidity: 30 % to 70 % RH (non-condensing)
•
Shock: Maximum impulse ≤ 10 g
CAUTION:
Operation Hazard!
Allow a minimum of 12 hours for machine temperature to become stable in its operating
environment before you remove the vapor barrier. If the machine is cooler than ambient
temperature when the vapor barrier is opened, moisture from the air will condense on the
machine. Condensation will cause immediate failures in the electronic control system.
1.5.3
Packing and Shipping
If it is necessary to ship the machine to another location, install the shipping restraints and other
packing material. Then pack the machine in its original shipping carton/crate. Refer to
4.1.3 Pack Machine for Reshipment chapter in this guide. During transport, temperature, relative
humidity, and shock must not exceed the limits of the storage and shipping requirements.
98888-0000-006-04
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Introduction
Storage and Transport
Installation Guide
Page 1-7
Power Series Ball Bonder
1.6
Decommissioning and Disposal
Decommissioning is a process to put the machine out of service permanently and to prepare the
machine for its final disposition. In general, you should follow the site procedures for
decommissioning. No special cleaning or decontamination procedures are required for the Power
Series, but make sure that you review the items below:
(1)
(2)
(3)
1.6.1
Before the machine power is off:
(a)
Make sure that all process programs on the storage drive have been transferred to a
permanent storage.
(b)
Remove the bonding wire and materials that may be on the MHS.
(c)
Remove the capillary.
After the machine power is off:
(a)
Disconnect the power cord from the source power.
(b)
Wind the power cord and attach it to the lower console rear cover.
(c)
Disconnect the earth ground cable from the lower console frame.
(d)
Disconnect the air pressure hose from the machine.
(e)
Clean the machine to remove dust, dirt, bits of gold wire.
(f)
Raise the four leveling feet to make the machine stand on its casters.
(g)
Move the machine to the desired location.
Storage, shipping, or disposal:
(a)
To put the machine into storage or ship to another location, refer to the Installation
Guide.
(b)
To dispose the machine, refer to section 1.6.1 Disposal.
Disposal
There are three options to dispose the decommissioned machine:
(1)
Re-manufacturing/Refurbishment
K&S operates a re-manufacturing/refurbishment program that repairs and updates K&S
bonding machines. Call K&S for more data. If this is the option, put the machine into
storage in the shipping crate immediately after it is decommissioned. Refer to the
Installation Guide.
(2)
Resale
K&S re-manufactures and resells used K&S equipment. K&S may be interested in the
purchase of a decommissioned Power Series machine or some of its parts/assemblies. Call
K&S for more data. If this is the option, put the machine into storage in the shipping crate
immediately after it is decommissioned. Refer to the Installation Guide.
(3)
Removal and Scrap
Remove the items that require special use in accordance with the local environmental
protection regulations. The table below lists the items and assemblies that may be
classified as hazardous waste based on local regulations within the local jurisdiction. Items
not listed may be classified as ordinary solid waste and their disposal must agree with the
local regulations.
Note: Call K&S before you discard the machine assemblies and parts. K&S may be interested
to purchase some machine assemblies or parts for its re-manufacturing/refurbishment
program. Assemblies most often needed include bond head assemblies, electrical
assemblies, MHS assemblies, high-value components and some structural parts
(castings, frames).
Installation Guide
Page 1-8
Introduction
Decommissioning and Disposal
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Revision G
Power Series Ball Bonder
Note: If there are similar machines (or variant) in operation that share the same parts as the
decommissioned machine, you may keep the assemblies for use as spares. Assemblies
suitable for reuse include: PCB assemblies, bond head/optics, power supply assembly,
major MHS assemblies, and other items listed in the table below. If you have doubts
with the reusable item or similar part with the same base number and later revision
(different “dash” number), call K&S customer support for assistance.
Part/Assembly
Material(s)
Safe Usage
Bond Head
(bond head link, flexure stiffeners)
Aluminum-Beryllium alloy
Storage: Wrap the parts in a plastic bag,
and seal the plastic bag for storage.
Disposal: Recycle or discard in
accordance with local regulations. Refer
also to the Material Safety Data Sheet for
Beryllium, which is available from K&S
upon request.
Refurbish: Return the bond head to K&S
for refurbishment. Call K&S customer
support for instructions.
Printed Circuit Boards (PCB)
Lead (in solder), Copper,
batteries, other metals
Storage: Keep the PCB in the static
protective containers.
Disposal: Recycle to reclaim metals or
discard in accordance with local
regulations.
Refurbish: Return the PCBs to K&S for
refurbishment. Call K&S customer
support for instructions.
Cable Assemblies
Copper, plating alloys,
other metals
Storage: No special requirements
Disposal: Recycle to reclaim metals or
discard in accordance with local
regulations.
Original Equipment Manufacturer
(OEM) Electrical Assemblies:
Power supply, vision system,
personal computer, XY power
amplifier, Z node, UPS, LCD
monitor, video camera
Copper, plating alloys,
lead, batteries, other
metals
Storage: No special requirements
Disposal: Recycle to reclaim metals or
discard in accordance with local
regulations.
Refurbish: Return the power supply,
vision system unit, and power amplifiers
to K&S for refurbishment. Call K&S
customer support for instructions.
Copper, plating alloys,
Lead, Chromium, Nickel,
other metals
Storage: No special requirements
Disposal: Recycle to reclaim metals or
discard in accordance with local
regulations.
Electrical Parts:
Solenoid valves motors, heater
assembly, thermocouples, fans
switches.
98888-0000-006-04
Revision G
Introduction
Disposal
Installation Guide
Page 1-9
Power Series Ball Bonder
Chapter 2: Site Preparation
Installation Guide
Page 2-2
Site Preparation
98888-0000-006-04
Revision G
Power Series Ball Bonder
2.1
Site Requirements
A site must be prepared for the machine before it is unpacked. The site must have electrical and
air pressure facilities required for machine operation as specified in sections:
1.2.1 Electrical Requirement for Power Supply
1.2.2 Compressed Air Requirements
This site must agree to the operating environment requirements specified in section
1.2.4 Operating Environment.
The site requirements for the all Power Series Ball Bonder are shown below.
3 ft. (1 m)
Electrical
Connection
(See Detail below)
Air Connection
(See Detail below)
”
(mm)
2 ft.
(.6 m)
2 ft.
(.6 m)
”(mm)
3 ft. (1 m)
Regulator
Facility Air Input
Pressure Gauge
Air Filter/
Moisture Trap
Air Input Location
(Hidden - see
DETAIL)
Frame Ground
Terminal
Drain Valve (Drain
Hose not attached
Power Supply Receptacle
(End of the Cord)
REAR VIEW OF MACHINE
DETAIL - AIR INPUT (SIDE VIEW)
Figure 2-1: All Power Series Ball Bonder Site Requirements
There must be sufficient space at the front, rear, and sides of the machine for maintenance and
operation. The rear view of the machine shows the locations of the input power cord, earth
ground connection, and input air pressure fitting.
98888-0000-006-04
Revision G
Site Preparation
Site Requirements
Installation Guide
Page 2-2
Power Series Ball Bonder
The floor at the site must be able to support the weight of the machine. The figure below shows
the center of gravity (C.G.) of the machine.
358mm
Rear
346mm
Base Pad (4x)
Wheel (4x)
Left
Right
Approximate CG Location
Front
Z=551MM
Z=551MM
Machine Base Diagram
Approximate CG Location
Approximate CG Location
Figure 2-2: Power Series Center of Gravity
Installation Guide
Page 2-3
Site Preparation
Site Requirements
98888-0000-006-04
Revision G
Power Series Ball Bonder
2.2
Power, Earth Ground, and Compressed Air
Connections
A power connector that mates with the facility power receptacle may need to be given by the user
(See NOTE below). The connector must meet or exceed the specifications listed in section
2.2.1 Power Connector Requirements. Facility power source wiring should meet the minimum
specifications below:
•
Rating: 264 Volts, 15 Amperes (minimum)
Note: Facility power wiring is usually defined by local electrical codes. The K&S ball
bonder is rated to operate up to 264VAC and up to 10 Amps depending on the
operating line voltage (see reference machine equipment label). Thus, the voltage
rating of the facilities power would be dictated by the local codes to meet the
electrical load of our ball bonder.
•
Conductors: 3 + PE (14 AWG, min.)
•
High-temperature insulation
K&S will install an input power cord connector (from Hubbell HBL2621) to mate with facility
receptacles if this is requested at time of sale. If the input power connector is not supplied, the
user must supply and install a power cord connector that will mate with facility receptacles.
Alternatively, the input power cord can, at the user’s option, be wired directly to the facility
electrical mains. If the input power cord is wired directly to the facility electrical mains, the user
must supply an AC power disconnect device to disconnect the power to the machine. Do this
before maintenance and emergency power removal.
Note: The input power cord can be disconnected at the power supply.
Select the links below for the necessary connections needed to prepare the site for machine
installation:
2.2.1 Power Connector Requirements
2.2.2 Earth Ground Cable
2.2.3 Air Pressure Supply Hose
2.2.4 Overcurrent Protection Device Requirements
98888-0000-006-04
Revision G
Site Preparation
Power, Earth Ground, and Compressed Air Connections
Installation Guide
Page 2-4
Power Series Ball Bonder
2.2.1
Power Connector Requirements
•
•
•
2.2.2
Rating: 264 Volts (minimum), 15 Amperes
Ground Contact: Connector ground contact must make connection before the line contacts
make connection
Conductor Terminals: Must accept #14 AWG conductors
Earth Ground Cable
The ground cable supplied connects the machine frame to the facility ground.
The ground connection is made at the lower rear left side of the lower console frame (viewed
from rear of machine). A ring terminal supplied with the ground cable is attached by an M6
screw and a lock washer.
Figure 2-3: Frame Ground Cable (Lower Console)
Installation Guide
Page 2-5
Site Preparation
Power Connector Requirements
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Revision G
Power Series Ball Bonder
2.2.3
Air Pressure Supply Hose
A connector for the compressed air input hose is installed in the air input connector at the right
side (viewed fromthe front of machine) of the upper console. This connector should be fitted to a
hose that will connect the facility air supply to the machine. The air input hose must be sized to
allow the flow rate and pressure specified in section 1.2.2 Compressed Air Requirements. A 3/8”
(9.5 mm) inside diameter (ID) hose is recommended. It is the customer's responsibility to give an
isolation device to isolate the facility air supply to the machine for maintenance or emergency off
conditions.
2.2.4
Overcurrent Protection Device Requirements
The overcurrent protection device (in the source power line connected to the machine) must be
selected in accordance with local electrical codes for equipment with these electrical
specifications:
Requirements
Current Limit
Rating
200-240 VAC
15 Amperes (minimum) for all Power Series except ATPremier Plus
20 Amperes (minimum) for ATPremier Plus
100-120 VAC 30 Amperes
Power–on Peak Inrush Current
75 Amperes peak for 100 ms after application of input power
Rated Breaking Capacity
Minimum 10,000 Ampere Interrupted Current (AIC) at 300 VAC
If the facility voltage is within 100 to 120VAC, a 30 Ampere circuit breaker is needed. Also, a
transformer kit is required to step-up the source input voltage to 200 to 240 VAC. The
transformer kit is installed between the source input voltage and the bonder power supply. Call
your local K&S sales representative for more data.
98888-0000-006-04
Revision G
Site Preparation
Air Pressure Supply Hose
Installation Guide
Page 2-6
Power Series Ball Bonder
2.3
Anchorage and Vibration Damping
Select the links below on the anchorage and vibration damping of the machine:
2.3.1 Anchorage
2.3.2 Vibration Damping
2.3.1
Anchorage
The Power Series bonder is a stand-alone unit that requires no external anchorage. The machine
is fixed in place if you adjust the leveling feet to lift the machine off from the casters.
In the areas of potential seismic (earthquake) hazards, however, K&S will install the earthquake
tie-down hardware to the machine if this is requested at the time of sale. The earthquake tie-down
hardware are installed at the left and right sides of the lower console shown below.
You must supply and install the correct seismic restraint hardware to prevent the machine
movement when an earthquake occurs. For proper installation methods, refer to the local codes
for more details.
Earthquake Tie-down
See Detail A
Detail A
Left Side of Lower
Console
See Detail A
Right Side of Lower
Console
Figure 2-4: Earthquake Tie-down
Installation Guide
Page 2-7
Site Preparation
Anchorage and Vibration Damping
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Revision G
Power Series Ball Bonder
2.3.2
Vibration Damping
Elastomer pads in the leveling feet and vibration isolators can be found under the machine table.
The purpose of elastomer pads and vibration isolators is to prevent interference to the machine
functions when damp vibrations is present in the machine environment. These items also stop
vibrations caused by machine operations from being coupled to surrounding equipment through
the facility floor.
Make sure that the machine is fixed in place and not subject to ambient vibrations:
•
Situate the machine as shown in Figure 2-1
The machine must not contact facility walls or other equipment.
•
All four leveling feet have been adjusted:
Make sure that the machine is level and does not rest on its casters. Refer to Chapter 3:
Unpacking/Packing - Carton (Outside USA)or Chapter 4: Unpacking/Packing (To or
From USA) of this guide.
98888-0000-006-04
Revision G
Site Preparation
Vibration Damping
Installation Guide
Page 2-8
Power Series Ball Bonder
2.4
Checklist: Site Preparation
Machine Serial Number:___________________
Date:_____________
Note: Copy this checklist. Use it to make sure that all required site preparation actions have
been taken before you unpack and install the machine.



1. Site selected has sufficient floor space. See section 2.1 Site Requirements.
2.
Floor at installation site can support machine. See section 2.1 Site Requirements.
3.
Electrical power and air pressure supplies available at installation site. See sections
1.2.1 Electrical Requirement for Power Supply and 1.2.2 Compressed Air Requirements for
power and pneumatic specifications.

4.
User–supplied power cord connector on hand that mates with facility power receptacle (if
required). See section 2.2.1 Power Connector Requirements.

5.
Earth ground cable supplied on hand for connection to machine frame ground. See section
2.2.2 Earth Ground Cable.

6.
User–supplied input air hose on hand that will supply air at the required pressure and flow
rate. See section 2.2.3 Air Pressure Supply Hose .

7.
User–supplied overcurrent protection device installed in electrical power supply line from the
facility. See section 2.2.4 Overcurrent Protection Device Requirements.

8.
Safety precautions have been read and understood. See section 1.3 Safety Considerations.
Installation Guide
Page 2-7
Site Preparation
Checklist: Site Preparation
98888-0000-006-04
Revision G
Power Series Ball Bonder
Chapter 3: Unpacking/Packing - Carton (Outside USA)
98888-0000-006-04
Revision G
Unpacking/Packing
Installation Guide
Page 3-1
Power Series Ball Bonder
3.1
Unpacking/Packing - Carton (Outside USA)
This section tells you how to unpack/pack the Power Series Ball Bonder from its shipping carton
and move the machine to the operational area (outside USA). Instructions are also included for
repacking the machine for shipment to another location or for long–term storage. There are two
checklists at the end of this section. One is for use when you unpack the machine, and the other
one is for use when you pack the machine for reshipment.
Select the links below for the unpacking and repacking procedures:
3.1.1 Unpack Machine
3.1.2 Checklist: Unpack Machine
3.1.3 Pack Machine for Reshipment
3.1.4 Checklist: Pack Machine for Reshipment
3.1.1
Unpack Machine
Tools, Materials, and Equipment
Part Number
Supplier
Pry Bar
None
Local Purchase
Fork Lift
None
Local Purchase
Utility Knife
None
Local Purchase
Hand Tools
None
Local Purchase
Power Drill with Philips Bit
None
Local Purchase
CAUTION:
Operation Hazard!
Allow a minimum of 12 hours for machine temperature to stabilize in its operating
environment before you remove the vapor barrier. If the machine is cooler than ambient
temperature when the vapor barrier is opened, moisture from the air will condense on the
machine. Condensation will cause immediate failures in the electronic control system.
3.1.1.1
Inspect Machine Shipping Carton
(1)
Do a check on the shipping crate for shipping damage.
(2)
Do a check on the tip, tilt, and shock indicators on the shipping crate for activation.
(3)
If any damage is found or if a tip/tilt/shock indicator shows that the shipping carton has
been mishandled (dropped or tipped), do the steps follow:
Installation Guide
Page 3-2
(a)
Take note of the tip/tilt/shock indicator activation and/or any visible shipping carton
damage on the bill of lading.
(b)
Immediately notify the shipping company and the local K&S Sales and Service
Representative.
Unpacking/Packing
Unpacking/Packing - Carton (Outside USA)
98888-0000-006-04
Revision G
Power Series Ball Bonder
(c)
Do not unpack the machine and continue with the installation.
Blue in arrowhead indicates
crate was tipped
Tip Indicator
Red indicates possible
shock damage
Shock Indicator
Red circle indicates excessive tilt
during shipping
Tilt Indicator
Figure 3-1: Shock, Tilt and Tip Indicators on the Shipping Carton
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Revision G
Unpacking/Packing
Unpack Machine
Installation Guide
Page 3-3
Power Series Ball Bonder
3.1.1.2
Disassemble Shipping Carton (See CAUTION above)
(1)
Cut the shipping straps and remove them from the shipping carton.
(2)
Remove the top cover of shipping carton.
(3)
Use a pry to remove all the nails around the bottom of shipping carton.
(4)
Remove three screws on the vertical edge on one side of the shipping carton panel.
(5)
Carefully remove the shipping carton panel.
(6)
Remove the separate shipping carton. Remove the four (4) leveling pads from the shipping
carton.
(7)
At the pallet, carefully cut through the plastic vapor barrier. Lift the vapor barrier up and
out of the machine. DO NOT DISCARD THE VAPOR BARRIER.
Note: The machine is attached to the pallet with bolts. There are no other internal
restraints.
(8)
Remove all accessories, etc. packed with the machine. Inventory the contents of the
shipping crate and verify that all parts and accessories listed on the packing list have been
received.
(9)
Do a check on the machine serial number to make sure that it matches the serial number on
the packing list. If it doesn’t, notify your local K&S Sales and Service representative
immediately.
Installation Guide
Page 3-4
Unpacking/Packing
Unpack Machine
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Revision G
Power Series Ball Bonder
3.1.1.3
Remove Machine from Crate Pallet
(1)
Remove the four (4) 19 mm hex nuts with flat washers that attach the four (4) isolation
mounts to the pallet.
Carton Top Cover
Vapor Barrier
Carton Panel
Bonding Machine
See “Detail B”
Isolation Mount (4 places)
See “Detail A”
Pallet
19mm Hex Nut, Lock Washer, Flat
Washer (4 Places)
Figure 3-2: Disassemble Shipping Carton
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Revision G
Unpacking/Packing
Unpack Machine
Installation Guide
Page 3-5
Power Series Ball Bonder
(2)
Use the forklift to lift the machine approximately 3 feet (1 meter) off of the floor. Lift
machine only from the rear, as shown below. Do not insert forks under the front or under
either side of the machine. Make sure the forks pass between the bonder and bottom of the
vapor barrier. The pallet will remain on the floor as the machine is lifted.
CAUTION:
Injury Hazard!
Put the forks of the forklift under the machine from the rear as shown below. Do not lift the
machine any other way.
Rear of Machine
Forks
Isolation Mounts (4 Places)
Forks
Forkslift
Figure 3-3: Machine on Fork Lift
(3)
Remove the pallet under the machine.
(4)
While the machine is on the forklift, remove the four (4) isolation mounts from the bottom
of the machine.
Installation Guide
Page 3-6
Unpacking/Packing
Unpack Machine
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Revision G
Power Series Ball Bonder
Note: Before shipment, a foam plug is put in position in each M20 thread hole below the
lower console frame. This is to keep the threads from contamination during shipment.
Lower Console Frame
Foam Plug
(Flush with Bottom Surface)
M20 Thread Hole
Foam Plug
(08888-0011-010-00)
Caster Wheel
Figure 3-4: Lower Console - Foam Plug Location
WARNING:
Injury Hazard!
Do not push the foam plug up with your finger. Thread holes may have sharp edges.
(5)
Before you install the leveling feet, use a hand tool to push the foam plug up into the
console frame and release the foam plug internally. Do not pull the foam plug down
because this causes the dust particles in the frame to fall into the thread hole.

X
X
Figure 3-5: Foam Plug Release “Dos and Don’ts”
Note: It is not necessary to take out the foam plug. Keep it inside the lower console frame.
(6)
Make sure that all four foam plugs are released from the four M20 thread holes and into
the internal hollow region of the lower console frame.
(7)
Attach the four leveling feet to the bottom of the machine.
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Unpacking/Packing
Unpack Machine
Installation Guide
Page 3-7
Power Series Ball Bonder
(8)
Make sure that the leveling feet are fully retracted so that the machine will rest on its
casters. Lower the machine to the floor.
WARNING:
Injury Hazard!
The leveling feet support the machine. Make sure that the leveling feet are fully retracted
before you lower the machine to the floor.
CAUTION:
Operation Hazard!
Do not move the machine up or down any ramp that is at an inclined angle greater than
7 degrees to the horizontal. The leveling feet can touch the floor and cause damage to the
leveling feet, even if the feet are fully retracted.
(9)
Store the shipping carton, vapor barrier bag and hardware for later repacking/shipping.
(10) Carefully move the machine to its prepared site.
3.1.1.4
(a)
Move the machine to the location where it will be installed.
(b)
Put the machine at its prepared site. Make sure that there is sufficient space at the
front, rear, and sides of the machine for operation and maintenance.
Assemble the modules
Remove shipping restraints and other packing material from the machine. See the figures below
for locations.
Note: Store all the packing material for later repacking/shipping: shipping restraint with
hardware, foam blocks, cardboard pads. The other packing material may be discarded
(shipping straps, bubble wrap, tie–wraps, adhesive tape, rubber band).
(1)
(2)
Signal light tower:
(a)
Cut and remove the shipping strap that attachs the signal light tower to the rear of
the lower console. Remove the bubble wrap around the signal light tower.
(b)
Remove the upper console rear cover.
(c)
Install the signal light tower to the signal light tower bracket on the upper console
rear structure with the hardware given.
(d)
Adjust the signal light tower height until the top of the signal light tower is on the
same level as the top of the monitor. Tighten the stopper screw to hold the signal
light tower at this height.
(e)
Connect the signal light tower cable connector to J48 on the BITS board.
LCD Monitor (Step a: Standard Power Series Model or Step b: ConnX Plus, IConn Plus,
IConn ProCu Plus and related LA versions only)
(a)
(b)
Installation Guide
Page 3-8
For Standard Power Series Model
1.
Cut and remove the shipping straps that attach the LCD monitor to its mount
on the upper console.
2.
Remove the L-shaped foam blocks (4 places) from the monitor and bubble
wrap. Keep the foam blocks and bubble wrap for re-use.
3.
Hold the monitor then tilt it to the front.
For ConnX Plus, IConn Plus, IConn ProCu Plus and related LA versions only
1.
Loosen the shipping straps that attach the LCD monitor to the upper console.
2.
Remove the two L-shaped foam blocks and bubble wrap from the monitor.
Keep the foam blocks and bubble wrap for reshipment if necessary.
Unpacking/Packing
Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
3.
Loosen the screws on the opening slot of left and right adjustment monitor
brackets.
4.
Carefully lift the monitor with brackets from the opening slot of the
adjustment monitor brackets.
Adjustment Monitor Bracket
Monitor With Bracket
Opening Slot
Figure 3-6: Monitor with Brackets
5.
Put the monitor with brackets against the sides of the top upper console cover,
near to the adjustment monitor brackets.
6.
Remove the bottom screws at the left and right monitor brackets. Keep the
screws for later use.
Monitor Bracket
Remove Screw
Figure 3-7: Remove Screw
98888-0000-006-04
Revision G
7.
Hold and tilt the monitor to the front.
8.
Carefully lift the left monitor bracket.
Unpacking/Packing
Unpack Machine
Installation Guide
Page 3-9
Power Series Ball Bonder
9.
Attach the top screw of the monitor bracket to the top opening slot of left
adjustment monitor bracket.
Top Screw
Top Opening Slot
Adjustment Monitor
Bracket
Attach Screw
Figure 3-8: Install the LCD Monitor
Installation Guide
Page 3-10
10.
Align the mounting hole of left monitor bracket to the mounting hole of left
adjustment monitor bracket, then attach the screw removed before.
11.
Carefully lift the right monitor bracket.
12.
Attach the top screw of the monitor bracket to the top opening slot of right
adjustment monitor bracket.
13.
Align the mounting hole of right monitor bracket to the mounting hole of
right adjustment monitor bracket, then attach the screw removed before.
14.
Remove the top cover of upper console.
15.
Remove the shipping straps.
16.
Attach the top cover to the upper console.
Unpacking/Packing
Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
(3)
(4)
(5)
Indexer assembly:
(a)
Remove pieces of adhesive tape with foam pad that hold the index gripper, eject
grippers and force tucker blade to the front rail.
(b)
Remove foam block between indexer motor mount and the left side of eject gripper
mount bracket. Keep the foam block for re-use.
(c)
Remove foam block between force tucker assembly and output magazine wall.
Keep the foam block for re-use.
(d)
Cut and remove the cable tie that attach the foam block to the rear rail, between the
wire clamp assembly and the rear rail.
Bond head and optics assembly:
(a)
Remove the foam pad between the bond head assembly and wire clamp assembly.
(b)
Remove the foam blocks located at the diffuser assembly, next to the bond head and
optics assembly. Keep the foam blocks for re-use.
(c)
From the left side of the machine, remove one screw on the X slide hard stop that
attach the shipping restraint (yellow) to X slide. Remove the shipping strap. Keep
the shipping strap and one screw for re–use.
(d)
From the rear of the machine, remove one screw on the rear Y slide that attach two
shipping restraints (yellow) to the Y hard stop. Remove two screws on the Y hard
stop that attach the two shipping straps (yellow). Remove the shipping straps. Keep
the shipping straps and three screws for re-use.
Man Machine Interface (MMI):
(a)
(6)
Remove foam pads with tapes from the MMI control panel. Remove the bubble
wrap from the mouse.
Remove bubble wrap around the spool wire cover, microscope, scope mount and work
light. Remove the form block between the scope mount and the work light.
Tape with foam pad
Bubble Wrap
Mouse
Figure 3-9: Unpacking Material (Front View)
(7)
98888-0000-006-04
Revision G
Swing the scope to the left for access to the Material Handling System (MHS) and bond
head. Flip over the MHS workholder cover. Keep the foam block for re-use.
Unpacking/Packing
Unpack Machine
Installation Guide
Page 3-11
Power Series Ball Bonder
Bubble Wrap
Spool Wire Assembly
Foam Blocks
Tape with foam pad
Microscope
Foam Block
Work Light
Index Gripper
Eject Gripper
Shipping Restraints
XY Table
XY Table
Bond Head
Shipping Restraints
Cable Tie
Foam Blocks
Tape with foam pads
Figure 3-10: Shipping Restraint and Packing Material Locations (Front View)
Installation Guide
Page 3-12
Unpacking/Packing
Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
Shipping Strap
LCD Monitor
Pad (4 Places)
Bubble Wrap
Signal Light Tower
Signal Light Tower
Bubble Wrap
Shipping Strap
Bubble Wrap
Figure 3-11: Packing Material Locations (Rear View)
3.1.1.5
Install Machine at Prepared Site
Refer to section 5.1 Machine Installation.
98888-0000-006-04
Revision G
Unpacking/Packing
Unpack Machine
Installation Guide
Page 3-13
Power Series Ball Bonder
3.1.2
Checklist: Unpack Machine
Machine Serial Number:___________________
Date:_____________
Note: Copy this checklist and use it while you unpack the machine. Make sure that all
required actions have been taken and that the procedure has been done in the specified
order.
CAUTION:
Immediately report shipping damage or any other indication of mishandling (tilt, tip, or shock
indicator activated) to the shipping company and to your local K&S sales and service
representative.


1. All required tools on hand. Refer to section 3.1.1 Unpack Machine for list.
2.
Done the shipping damage check. All tilt, tip, and shock indictors checks done. See Figure 31 to identify indicators.

3.
Carton top and bottom blocks removed. Vapor barrier removed. Blocks and vapor barrier
retained for later use. See Figure 3-2.

4.
Box(es) of accessories removed. The check between serial number on machine and contents
of box(es) and bill of lading is done. Refer to section 3.1.1 Unpack Machine, step 3.1.1.3.

5.
Machine removed from crate pallet. Leveling feet installed. Feet adjusted so that machine
rests on casters. Refer to section 3.1.1 Unpack Machine, step 3.1.1.3.

6.
XY–axes shipping restraint removed. Shipping restraint and attaching hardware kept for later
use. Refer to section 3.1.1 Unpack Machine, step 3.1.1.4 and Figure 3-10.

7.
All shipping material removed (plastic foam, bubble wrap, cable ties, shipping straps, etc.).
Refer to section 3.1.1 Unpack Machine, step 3.1.1.4 and Figure 3-10.

8.
Following items stored for possible later use: shipping carton, carton top and bottom blocks,
vapor barrier, XY-axes shipping restraint and attaching hardware, cardboard pads (monitor),
foam blocks. Refer to section 3.1.1 Unpack Machine, step 3.1.1.4.

9.
Signal light tower installed. Refer to section 3.1.1 Unpack Machine, step 3.1.1.4(1).
Installation Guide
Page 3-14
Unpacking/Packing
Checklist: Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
3.1.3
Pack Machine for Reshipment
•
Specification
Note: Storage and shipping environmental specifications are for machine packed in its
shipping carton.
•
Temperature: -40° to 55°C (-40° to 131°F)
•
Relative Humidity: 30 to 70% RH (non–condensing)
•
Shock: Maximum Impulse ≤ 10g
Tools, Materials, and Equipment
Shipping Carton
Part Number
Supplier
None
Local Purchase
Plastic Vapor Barrier Bag
None
Local Purchase
Plastic or Metal Straps
None
Local Purchase
Isolation Mounts with 19 mm Hex Nuts/Flat
Washers
None
Local Purchase
XY- axes Shipping Restraint with three M4
Screws
None
Local Purchase
Tie Wraps
None
Local Purchase
Bubble Wrao
None
Local Purchase
Plastic Foam
None
Local Purchase
Adhesive Tape
None
Local Purchase
Heat Sealer
None
Local Purchase
Nailing Gun (or Hammer and Nails)
None
Local Purchase
Industrail Vacuum Cleaner
None
Local Purchase
Fork Lift
None
Local Purchase
Rubber Band (1/4” wide x 3” lg.)
None
Local Purchase
Utility Knife
None
Local Purchase
Hand Tools
None
Local Purchase
Power Drill with Philips Bit
None
Local Purchase
Note: Make sure that the shipping carton is not damaged.
(1)
Disconnect the machine from facility power and air pressure.
(2)
Remove the wire spool from the machine. Remove any leadframes and magazines from
the machine. Remove the clamp plate and heat block insert from the MHS workholder,
then set them aside for separate packaging.
(3)
Remove the leveling feet so that the machine rests on its casters. Roll the machine to the
area where it will be packed for shipment.
CAUTION:
Operation Hazard!
Do not move the machine up or down any ramp that is at an inclined angle greater than
7 degrees to the horizontal. The leveling feet can touch the floor and cause damage to the
leveling feet, even if the feet are fully retracted.
98888-0000-006-04
Revision G
Unpacking/Packing
Pack Machine for Reshipment
Installation Guide
Page 3-15
Power Series Ball Bonder
3.1.3.1
Prepare Machine for Packing
(1)
(2)
Attach signal light tower as follows:
(a)
Remove the upper console rear cover.
(b)
Disconnect the signal light tower cable connector from connector J48 on the BITS
board.
(c)
Loosen the stopper screw that holds the signal light tower to the bracket on the
upper console rear structure. Remove the signal light tower.
(d)
Wrap the bubble wraps around the signal light tower.
(e)
Put the signal light tower at the top rear of lower console. Install the shipping straps
to attach the signal light tower to the top rear of lower console.
(f)
Attach the rear cover on the upper console.
Attach the LCD Monitor as follows (Step a: Standard Power Series Model or Step b:
ConnX Plus, IConn Plus, IConn ProCu Plus and related LA versions only):
(a)
(b)
For Standard Power Series Model
1.
Wind the LCD monitor in bubble wrap.
2.
Pivot the LCD monitor towards the rear of the machine. The screen points up.
3.
Put L-shaped foam blocks on the LCD monitor.
4.
Install two (2) shipping straps around the monitor and monitor mount to hold
the monitor in place. Make sure to put foam blocks under the straps at all
points where the strap contacts the monitor case.
For ConnX Plus, IConn Plus, IConn ProCu Plus and related LA versions only
1.
Wind the LCD monitor in bubble wrap.
2.
Remove the top cover from the upper console.
3.
Find the monitor cables at the top of the upper console.
4.
Move the monitor cables a small distance away from the monitor bracket.
5.
Move the cable near to the side wall of the upper console .
6.
Attach the shipping straps to the side walls of the upper console.
7.
Attach the top cover to the top of the upper console.
Note: Make sure that the shipping straps hang outside at each side of the side
wall and the top cover.
8.
Loosen the screw at the top of the left adjustment monitor bracket.
Loosen Screw
Left Adjustment
Monitor Bracket
Remove Screw
Figure 3-12: Left Adjustment Monitor Bracket
Installation Guide
Page 3-16
Unpacking/Packing
Pack Machine for Reshipment
98888-0000-006-04
Revision G
Power Series Ball Bonder
9.
Remove the screw at the bottom of the left adjustment monitor bracket. Keep
the screw for later use.
10.
Hold the monitor with bracket, then loosen three screws at the right
adjustment monitor bracket.
Loosen Screws (x3)
Right Adjustment
Monitor Bracket
Remove Screw
Figure 3-13: Right Adjustment Monitor Bracket
11.
Remove the screw at the bottom of the right adjustment monitor bracket.
Keep the screw for later use.
12.
Hold the monitor with bracket, then tilt the monitor to the rear.
13.
Put the monitor on top of the upper console. Make sure that the monitor
screen points up.
14.
Attach the screw removed before from the adjustment brackets to each of the
left and right monitor brackets.
Monitor Bracket
Attach Screw
Figure 3-14: Monitor Bracket
98888-0000-006-04
Revision G
Unpacking/Packing
Pack Machine for Reshipment
Installation Guide
Page 3-17
Power Series Ball Bonder
15.
Top Screw
Hold the left monitor bracket with screws, then put the top screw against the
opening slot of left adjustment monitor bracket.
Opening Slot
Top Screw Against Opening
Slot
Figure 3-15: .Top Screw in Opening Slot
CAUTION:
Operation Hazard!
Incorrect installation can cause the monitor cables to kink. Install the left adjustment monitor
bracket carefully.
16.
Hold the right monitor bracket with screws, then put the top screw in the
opening slot of the right adjustment monitor bracket.
17.
Adjust the right adjustment monitor bracket until the monitor is set on the
correct position on top of upper console.
18.
Tighten two screws loosened before on the right adjustment monitor bracket .
19.
Tighten the screws on the opening slots of left and right adjustment monitor
brackets.
20.
At each side of the monitor, put two L-shaped foam blocks between the
monitor and the top cover.
L-shaped Foam Blocks (x2)
Figure 3-16: L-shaped Foam Blocks
(3)
Wind the shipping straps around the L-shaped foam blocks to attach the
monitor to the upper console.
22.
Tighten the shipping strap.
Install the XY–axes shipping restraint:
(a)
Installation Guide
Page 3-18
21.
On the left side of the machine, put the XY–axes shipping restraint (painted yellow)
on the X slide. Install one (1) screw on the X slide hard stop to attach the shipping
restraint.
Unpacking/Packing
Pack Machine for Reshipment
98888-0000-006-04
Revision G
Power Series Ball Bonder
(b)
(4)
At the rear of the machine, put two (2) XY–axes shipping restraints (painted yellow)
on the rear Y slide. Install one (1) screw on the rear Y slide that attach the shipping
restraints to the Y hard stop. Install the another two (2) screws on the Y hard stop to
attach the shipping straps.
Attach the MHS workholder components as follows:
(a)
Move the gripper assembly to its left–side limit, next to the input magazine wall.
(b)
Put a foam block (kept during machine unpacking) between the indexer motor
mount and the left side of eject gripper mount bracket.
Index Gripper
Eject Gripper
Figure 3-17: Foam Block Positions
(c)
Move the gripper assembly to the left until the foam block is held between the
indexer motor mount and the left side of eject gripper mount bracket.
(d)
Put a foam block (kept during machine unpacking) between the force tucker
assembly and output magazine wall.
(e)
Use adhesive tape with foam pad to hold down the index gripper, eject grippers and
force tucker blade to the front rail.
(f)
Put a small piece of foam block (kept during machine unpacking) between the wire
clamp assembly and rear rail. Install a cable tie to attach the foam block to the rear
rail.
(g)
Put a small piece of foam pad between the optics assembly and wire clamp
assembly.
(h)
Put three foam blocks (kept during machine unpacking) on the left hand X shield
cover of integrated table assembly, between the input magazine wall and bond head
and optics assembly.
(5)
Wind the mouse in bubble wrap. Attach the mouse and the MMI drawer using foam pads
with adhesive tape to the MMI.
(6)
Attach the microscope as follows:
(a)
Move the microscope to its operating position.
(b)
Move the scope mount to the farthest left position.
(c)
Put the foam block between the microscope and the scope mount shaft.
(d)
Put the bubble wrap around the microscope and the scope mount shaft, then put the
adhesive tape around to prevent the scope mount from movement.
(7)
Wind bubble wrap around the spool wire cover and the work light, and tape it in place.
(8)
Put a foam block between the microscope and work light.
98888-0000-006-04
Revision G
Unpacking/Packing
Pack Machine for Reshipment
Installation Guide
Page 3-19
Power Series Ball Bonder
(9)
At the input magazine handler, loosen the leadframe retainer at the tray assembly and
move them fully to the right. Tighten the screw to attach the leadframe retainer.
(10) At the output magazine handler, loosen the leadframe retainer at the tray assembly and
move them fully to the left. Tighten the screw to attach the leadframe retainer.
(11) Put the machine on the crate pallet.
(a)
Put the pallet on the floor. Orient the pallet so that holes for the isolation mounts are
aligned with the tapped holes at the bottom of the machine. Make sure that the rear
side of the pallet points to the front of the machine. When the machine is moves
over the pallet, the rear side of the machine will be at the rear side of the pallet.
(b)
Use forklift to lift up the machine from the floor. Move the forks under the rear of
the machine as shown in the figure below. Do not try to lift the machine from the
front or at either side.
WARNING:
Injury Hazard!
Put the forks of the forklift under the machine from the rear as shown below. Do not lift the
machine any other way.
Rear of Machine
Forks
Isolation Mounts (4 Places)
Forks
Forkslift
Figure 3-18: Machine on Fork Lift
Installation Guide
Page 3-20
(c)
Make sure that all four (4) leveling feet stay retracted.
(d)
Install the isolation mounts to the tapped holes at the bottom of the machine.
(e)
Put the machine over the pallet. Make sure the threaded stud of each isolation mount
is above a mounting hole in the pallet. Slowly lower the machine onto the pallet,
making sure the threaded studs of the isolation mounts pass through the holes in the
pallet.
(f)
From the underside of the pallet, install a flat washer and 19 mm hex nut on each of
the isolation mount threaded studs. Fully tighten the four (4) hex nuts.
(g)
Pack all of the loose parts (power cord, microscope eyepieces, clamp plate, heat
block insert) in a cardboard box.
(h)
Put the box at any convenient location on the machine.
(i)
Use a shipping strap to attach the box to the machine.
Unpacking/Packing
Pack Machine for Reshipment
98888-0000-006-04
Revision G
Power Series Ball Bonder
(j)
Put the vapor barrier bag over the machine.
(k)
Heat seal the vapor barrier to the piece of plastic sheeting on the pallet with a small
opening unsealed.
(l)
Use an industrial vacuum to remove air from under the vapor barrier.
(12) When done, heat seal the remaining opening in the vapor barrier. Assemble the shipping
carton panel around the machine. Nail the panel to the pallet.
(13) Install three screws to the vertical edge on one side of the shipping carton panel.
Screws 3x
Vertical Edge of Shipping
Carton Panel
Figure 3-19: Three Screws
(14) Install the top cover on the shipping carton panel.
(15) Install two (2) shipping straps vertically around the carton and pull them tight.
98888-0000-006-04
Revision G
Unpacking/Packing
Pack Machine for Reshipment
Installation Guide
Page 3-21
Power Series Ball Bonder
3.1.4
Checklist: Pack Machine for Reshipment
Machine Serial Number:___________________
Date:_____________
Note: Copy this checklist and use it while you pack the machine for reshipment. Make sure
that all required actions have been taken and that the procedure has been done in the
specified order.

1. All required tools and materials on hand. Refer to section 3.1.3 Pack Machine for
Reshipment for list.

2.
Machine disconnected from compressed air and power. Refer to section 3.1.3 Pack Machine
for Reshipment step (1).

3.
All material removed from machine (magazines, device, wire spool). Clamp insert and heat
block insert removed from machine and set aside for separate packaging. Refer to section
3.1.3 Pack Machine for Reshipment, step (2).

4.
Leveling feet removed so that machine rests on casters. Machine moved to packing area.
Refer to section 3.1.3 Pack Machine for Reshipment, step (3).

5.
Signal light tower attached to the rear of the machine. Refer to section 3.1.3 Pack Machine for
Reshipment, step 3.1.3.1(1) and Figure 3-11.

6.
XY–axes shipping restraint installed. Refer to section 3.1.3 Pack Machine for Reshipment,
step 3.1.3.1(3) and Figure 3-10.

7.
Foam blocks and cable ties installed to prevent MHS workholder movement. Refer to section
3.1.3 Pack Machine for Reshipment, step 3.1.3.1 and Figure 3-10.

8.
Adhesive tape installed to hold down index gripper arm, eject gripper arm and force tucker
blade on front rail. Refer to section 3.1.3 Pack Machine for Reshipment, step 3.1.3.1 and
Figure 3-10.

9.
Foam block and cable tie installed to prevent bond head link movement. Refer to section
3.1.3 Pack Machine for Reshipment, step 3.1.3.1and Figure 3-10.

10. Scope covered with bubble wrap. Bubble wrap installed around scope mount shaft to prevent
scope movement on shaft. Scope mount attached with shipping strap. Refer to section
3.1.3 Pack Machine for Reshipment, step 3.1.3.1and Figure 3-10.

11. Bubble wrap installed around signal light tower, spool wire cover and work light. Refer to
section 3.1.3 Pack Machine for Reshipment, step 3.1.3.1 and Figure 3-10 and Figure 3-11.

12. Shipping strap installed to attach video monitor to monitor mount. Refer to section 3.1.3 Pack
Machine for Reshipment, step 3.1.3.1 and Figure 3-11.

13. Mouse bubble wrapped. Control panel taped to attach drawer. Refer to section 3.1.3 Pack
Machine for Reshipment, step 3.1.3.1 and Figure 3-10.

14. Leadframe retainer on input and output magazine handlers moved fully inward (toward
machine) and locked in place. Refer to section 3.1.3 Pack Machine for Reshipment, step
3.1.3.1.

15. Leveling feet removed. Levelling feet set aside for separate packaging. Refer to section
3.1.3 Pack Machine for Reshipment, step (11).

16. Machine mounted on crate pallet. Hardware installed and fully tightened to attach isolation
mounts to pallet. Refer to section 3.1.3 Pack Machine for Reshipment, step (11), Figure 3-2.

17. Leveling feet, clamp insert, heat block insert, and power cord packed in box. Box placed on
machine and attached. Refer to section 3.1.3 Pack Machine for Reshipment, step (11).

18. Vapor barrier installed over machine. Refer to section 3.1.3 Pack Machine for Reshipment,
step (11).

19. Vapor barrier partially heat-sealed to plastic sheet on pallet. Air exhausted from under barrier
and vapor barrier/plastic sheet seal completed. Refer to section 3.1.3 Pack Machine for
Reshipment, step (11).

20. Shipping carton panel assembled onto and nailed to pallet. Three screws installed to one side
of vertical edge of carton panel. Refer to section 3.1.3 Pack Machine for Reshipment, step
(12) and Figure 3-2.
Installation Guide
Page 3-22
Unpacking/Packing
Checklist: Pack Machine for Reshipment
98888-0000-006-04
Revision G
Power Series Ball Bonder

21. Carton top mounted on carton panel. Refer to section 3.1.3 Pack Machine for Reshipment,
step (12) and Figure 3-2.

22. Two shipping straps installed vertically around crate and pulled tight. Refer to section
3.1.3 Pack Machine for Reshipment, step (12).
98888-0000-006-04
Revision G
Unpacking/Packing
Checklist: Pack Machine for Reshipment
Installation Guide
Page 3-23
Power Series Ball Bonder
Chapter 4: Unpacking/Packing (To or From USA)
Installation Guide
Page 4-1
Unpacking/Packing
98888-0000-006-04
Revision G
Power Series Ball Bonder
4.1
Unpacking/Packing (To or From USA)
This section tells you how to unpack/pack a Power Series Ball Bonder from its shipping crate
and move the machine to the operational area (To or From USA). Instructions are also included
on how to repack the machine for shipment to another location or for long–term storage. There
are two checklists at the end of this section. One is for use when you unpack the machine, and the
other one is for use when you pack the machine for reshipment.
Select the links below for the unpacking and repacking procedures:
4.1.1 Unpack Machine
4.1.2 Checklist: Unpack Machine
4.1.3 Pack Machine for Reshipment
4.1.4 Checklist: Pack Machine for Reshipment
4.1.1
Unpack Machine
Tools, Materials, and Equipment
Part Number
Supplier
Pry Bar
None
Local Purchase
Fork Lift
None
Local Purchase
Utility Knife
None
Local Purchase
Hand Tools
None
Local Purchase
Power Drill with Philips Bit
None
Local Purchase
CAUTION:
Operation Hazard!
Allow a minimum of 12 hours for machine temperature to stabilize in its operating
environment before you remove the vapor barrier. If the machine is cooler than ambient
temperature when the vapor barrier is opened, moisture from the air will condense on the
machine. Condensation will cause immediate failures in the electronic control system.
4.1.1.1
Inspect Machine Shipping Crate:
(1)
Do a check on the shipping crate for shipping damage.
(2)
Do a check on the tip, tilt, and shock indicators on the shipping crate for activation.
(3)
If any damage is found or if a tip/tilt/shock indicator shows that the shipping crate has
been mishandled (dropped or tipped), do the steps follow:
98888-0000-006-04
Revision G
(a)
Take note of the tip/tilt/shock indicator activation and/or any visible shipping crate
damage on the bill of lading.
(b)
Immediately notify the shipping company and the local K&S Sales and Service
Representative.
Unpacking/Packing
Unpacking/Packing (To or From USA)
Installation Guide
Page 4-2
Power Series Ball Bonder
(c)
Do not unpack the machine and continue with the installation.
Blue in arrowhead indicates
crate was tipped
Tip Indicator
Red indicates possible
shock damage
Shock Indicator
Red circle indicates excessive tilt
during shipping
Tilt Indicator
Figure 4-1: Shock, Tilt and Tip Indicators on the Shipping Crate
Installation Guide
Page 4-3
Unpacking/Packing
Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
4.1.1.2
Disassemble Shipping Crate (See CAUTION above)
(1)
Cut the shipping straps and remove them from the shipping crate.
(2)
Remove the screws that attach the top cover of the crate. Remove the top cover.
(3)
Remove the crate side panels, one at a time. At each of the side panels:
(a)
Remove the screws in the vertical edges of the panel first.
(b)
Remove the screws from the bottom of the side panel. Hold the panel in place while
you remove the last screw.
(c)
Remove the side panel from the crate.
(4)
Remove the separate shipping carton. Remove the four (4) leveling pads from the shipping
carton.
(5)
At the pallet, carefully cut through the plastic vapor barrier. Lift the vapor barrier up and
out of the machine. DO NOT DISCARD THE VAPOR BARRIER.
Note: The machine is attached to the pallet with bolts. There are no other internal
restraints.
(6)
Remove all accessories, etc. packed with the machine. Inventory the contents of the
shipping crate and verify that all parts and accessories listed on the packing list have been
received.
(7)
Do a check on the machine serial number to make sure that it matches the serial number on
the packing list. If it doesn’t, notify your local K&S Sales and Service representative
immediately.
98888-0000-006-04
Revision G
Unpacking/Packing
Unpack Machine
Installation Guide
Page 4-4
Power Series Ball Bonder
4.1.1.3
Remove Machine from Crate Pallet
(1)
Remove the four (4) 19 mm hex nuts with flat washers that attach the four (4) isolation
mounts to the pallet.
Figure 4-2: Disassemble Shipping Crate
Installation Guide
Page 4-5
Unpacking/Packing
Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
(2)
Use the forklift to lift the machine approximately 3 feet (1 meter) off of the floor. Lift
machine only from the rear, as shown below. Do not insert forks under the front or under
either side of the machine. Make sure the forks pass between the bonder and bottom of the
vapor barrier. The pallet will remain on the floor as the machine is lifted.
WARNING:
Injury Hazard!
Put the forks of the forklift under the machine from the rear as shown below. Do not lift the
machine any other way.
Rear of Machine
Forks
Isolation Mounts (4 Places)
Forks
Forks Lift
Figure 4-3: Machine on Fork Lift
(3)
Remove the pallet under the machine.
(4)
While the machine is on the forklift, remove the four (4) isolation mounts from the bottom
of the machine.
98888-0000-006-04
Revision G
Unpacking/Packing
Unpack Machine
Installation Guide
Page 4-6
Power Series Ball Bonder
Note: Before shipment, a foam plug is put in position in each M20 thread hole below the
lower console frame. This is to keep the threads from contamination during shipment.
Lower Console Frame
Foam Plug
(Flush with Bottom Surface)
M20 Thread Hole
Foam Plug
(08888-0011-010-00)
Caster Wheel
Figure 4-4: Lower Console - Foam Plug Location
WARNING:
Injury Hazard!
Do not push the foam plug up with your finger. Thread holes may have sharp edges.
(5)
Before you install the leveling feet, use a hand tool to push the foam plug up into the
console frame and release the foam plug internally. Do not pull the foam plug down
because this causes the dust particles in the frame to fall into the thread hole.

X
X
Figure 4-5: Foam Plug Release “Dos and Don’ts”
Note: It is not necessary to take out the foam plug. Keep it inside the lower console frame.
(6)
Make sure that all four foam plugs are released from the four M20 thread holes and into
the internal hollow region of the lower console frame.
(7)
Attach the four leveling feet to the bottom of the machine.
Installation Guide
Page 4-7
Unpacking/Packing
Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
(8)
Make sure that the leveling feet are fully retracted so that the machine will rest on its
casters. Lower the machine to the floor.
WARNING:
Injury Hazard!
The leveling feet hold the machine. Make sure that the leveling feet are fully retracted before
you lower the machine to the floor.
CAUTION:
Operation Hazard!
Do not move the machine up or down any ramp that is at an inclined angle greater than
7 degrees to the horizontal. The leveling feet can touch the floor and cause damage to the
leveling feet, even if the feet are fully retracted.
(9)
Store the shipping crate, vapor barrier bag and hardware for later repacking/shipping.
(10) Carefully move the machine to its prepared site.
4.1.1.4
(a)
Move the machine to the location where it will be installed.
(b)
Put the machine at its prepared site. Make sure that there is sufficient space at the
front, rear, and sides of the machine for operation and maintenance.
Assemble Modules
Remove shipping restraints and other packing material from the machine. See the figures below
for locations.
Note: Store all the packing material for later repacking/shipping: shipping restraint with
hardware, foam blocks, cardboard pads. The other packing material may be discarded
(shipping straps, bubble wrap, tie–wraps, adhesive tape, rubber band).
(1)
(2)
Signal light tower:
(a)
Cut and remove the shipping strap that attachs the signal light tower to the rear of
the lower console. Remove the bubble wrap from the signal light tower.
(b)
Remove the upper console rear cover.
(c)
Install the signal light tower to the signal light tower bracket on the upper console
rear structure with the hardware given.
(d)
Adjust the signal light tower height until the top of the signal light tower is at the
same level as the top of the monitor. Tighten the stopper screws to hold the signal
light tower at this height.
(e)
Connect the signal light tower cable connector to J48 on the BITS board.
(f)
Attach the upper console rear cover to the machine.
LCD Monitor (Step a: Standard Power Series Model or Step b: Plus model only)
(a)
(b)
98888-0000-006-04
Revision G
For Standard Power Series Model
1.
Cut and remove the shipping straps that attach the LCD monitor to its mount
on the upper console.
2.
Remove the L-shaped foam blocks (4 places) from the monitor and bubble
wrap. Keep the foam blocks and bubble wrap for re-use.
3.
Hold the monitor then tilt it to the front.
For Plus model only
1.
Loosen the shipping straps that attach the LCD monitor to the upper console.
2.
Remove the two L-shaped foam blocks and bubble wrap from the monitor.
Keep the foam blocks and bubble wrap for reshipment if necessary.
Unpacking/Packing
Unpack Machine
Installation Guide
Page 4-8
Power Series Ball Bonder
3.
Loosen the screws on the opening slot of left and right adjustment monitor
brackets.
4.
Carefully lift the monitor with brackets from the opening slot of the
adjustment monitor brackets.
Adjustment Monitor Bracket
Monitor With Bracket
Opening Slot
Figure 4-6: Monitor with Brackets
5.
Put the monitor with brackets against the sides of the top upper console cover,
near to the adjustment monitor brackets.
6.
Remove the bottom screws at the left and right monitor brackets. Keep the
screws for later use.
Monitor Bracket
Remove Screw
Figure 4-7: Screw Removal
Installation Guide
Page 4-9
7.
Hold and tilt the monitor to the front.
8.
Carefully lift the left monitor bracket.
Unpacking/Packing
Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
9.
Attach the top screw of the monitor bracket to the top opening slot of left
adjustment monitor bracket.
Top Screw
Top Opening Slot
Adjustment Monitor
Bracket
Attach Screw
Figure 4-8: Install the LCD Monitor
(3)
(4)
98888-0000-006-04
Revision G
10.
Align the mounting hole of left monitor bracket to the mounting hole of left
adjustment monitor bracket, then attach the screw removed before.
11.
Carefully lift the right monitor bracket.
12.
Attach the top screw of the monitor bracket to the top opening slot of right
adjustment monitor bracket.
13.
Align the mounting hole of right monitor bracket to the mounting hole of
right adjustment monitor bracket, then attach the screw removed before.
14.
Remove the top cover of upper console.
15.
Remove the shipping straps.
16.
Attach the top cover to the upper console.
Indexer assembly:
(a)
Remove pieces of adhesive tape with foam pad that hold the index gripper, eject
grippers and force tucker blade to the front rail.
(b)
Remove foam block between indexer motor mount and the left side of eject gripper
mount bracket. Keep the foam block for re-use.
(c)
Remove foam block between force tucker assembly and output magazine wall.
Keep the foam block for re-use.
(d)
Cut and remove the cable tie that attach the foam block to the rear rail, between the
wire clamp assembly and the rear rail.
Bond head and optics assembly:
(a)
Remove the foam pad between the bond head assembly and wire clamp assembly.
(b)
Remove the foam blocks located at the diffuser assembly, next to the bond head and
optics assembly. Keep the foam blocks for re-use.
(c)
From the left side of the machine, remove one screw on the X slide hard stop that
attaches the shipping restraint (yellow) to the X slide. Remove the shipping strap.
Keep the shipping strap and one screw for reuse.
(d)
From the rear of the machine, remove one screw on the rear Y slide that attaches
two shipping restraints (yellow) to the Y hard stop. Remove the two screws on the Y
hard stop that attaches the two shipping straps (yellow). Remove the shipping
straps. Keep the shipping straps and three screws for future use.
Unpacking/Packing
Unpack Machine
Installation Guide
Page 4-10
Power Series Ball Bonder
(5)
(6)
Man Machine Interface (MMI)
(a)
Remove the foam pad and the adhesive tape from the man-machine interface (MMI)
control panel.
(b)
Remove the bubble wrap from the mouse.
Remove bubble wrap around the spool wire cover, microscope, scope mount and work
light.
Bubble Wrap
Tape with foam pad
Mouse
Figure 4-9: Unpacking Material (Front View)
(7)
Remove the form block between the scope mount and the work light.
(8)
Swing the scope to the left for access to the Material Handling System (MHS) and bond
head.
(9)
Flip over the MHS workholder cover. Keep the foam block for reuse.
Installation Guide
Page 4-11
Unpacking/Packing
Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
Bubble Wrap
Foam Blocks
Tape with foam pad
Spool Wire Assembly
Microscope
Foam Block
Work Light
Index Gripper
Eject Gripper
Shipping Restraints
XY Table
XY Table
Bond Head
Shipping Restraints
Cable Tie
Foam Blocks
Tape with foam pads
Figure 4-10: Shipping Restraint and Packing Material Locations (Front View)
98888-0000-006-04
Revision G
Unpacking/Packing
Unpack Machine
Installation Guide
Page 4-12
Power Series Ball Bonder
Shipping Strap
LCD Monitor
Pad (4 Places)
Bubble Wrap
Signal Light Tower
Signal Light Tower
Bubble Wrap
Shipping Strap
Bubble Wrap
Figure 4-11: Packing Material Locations (Rear View)
4.1.1.5
Install Machine at Prepared Site
Refer to section 5.1 Machine Installation.
Installation Guide
Page 4-13
Unpacking/Packing
Unpack Machine
98888-0000-006-04
Revision G
Power Series Ball Bonder
4.1.2
Checklist: Unpack Machine
Machine Serial Number:___________________
Date:_____________
Note: Copy this checklist and use it while you unpack the machine. Make sure that all
required actions have been taken and that the procedure has been done in the specified
order.
CAUTION:
Immediately report shipping damage or any other indication of mishandling (tilt, tip, or shock
indicator activated) to the shipping company and to your local K&S sales and service
representative.



1. All required tools on hand. Refer to section 4.1.1 Unpack Machine for list.

4. Box(es) of accessories removed. The check between serial number on machine and
contents of box(es) and bill of lading is done. Refer to section 4.1.1 Unpack
Machine, step 4.1.1.3.

5. Machine removed from crate pallet. Leveling feet installed. Feet adjusted so that
machine rests on casters. Refer to section 4.1.1 Unpack Machine, step 4.1.1.3.

6. XY–axes shipping restraints removed. Shipping restraints and attaching hardware
kept for later use. Refer to section 4.1.1 Unpack Machine, step 4.1.1.4.

7. All shipping material removed (plastic foam, bubble wrap, cable ties, shipping
straps, etc.). Refer to section 4.1.1 Unpack Machine, step 4.1.1.4.

8. Following items stored for possible later use: shipping crate, crate top and bottom
blocks, vapor barrier, XY-axes shipping restraints and attaching hardware,
cardboard pads (monitor), foam blocks. Refer to section 4.1.1 Unpack Machine,
step 4.1.1.4.

9. Signal light tower installed. Refer to section 4.1.1 Unpack Machine, step 4.1.1.4(1).
98888-0000-006-04
Revision G
2. Done the shipping damage check. All tilt, tip, and shock indictors checks done.
3. Crate top and bottom blocks removed. Vapor barrier removed. Blocks and vapor
barrier kept for later use.
Unpacking/Packing
Checklist: Unpack Machine
Installation Guide
Page 4-14
Power Series Ball Bonder
4.1.3
Pack Machine for Reshipment
•
Specification
Note: Storage and shipping environmental specifications are for machine packed in its
shipping crate.
•
Temperature: -40° to 55°C (-40° to 131°F)
•
Relative Humidity: 30 to 70% RH (non–condensing)
•
Shock: Maximum Impulse ≤ 10g
Tools, Materials, and Equipment
Part Number
Supplier
Shipping Crate
None
Local Purchase
Plastic Vapor Barrier Bag
None
Local Purchase
Plastic or Metal Straps
None
Local Purchase
Isolation Mounts with 19 mm Hex Nuts/Flat
Washers
None
Local Purchase
XY- axes Shipping Restraint with three M4
Screws
None
Local Purchase
Tie Wraps
None
Local Purchase
Bubble Wrap
None
Local Purchase
Plastic Foam
None
Local Purchase
Adhesive Tape
None
Local Purchase
Heat Sealer
None
Local Purchase
Nailing Gun (or Hammer and Nails)
None
Local Purchase
Industrail Vacuum Cleaner
None
Local Purchase
Fork Lift
None
Local Purchase
Rubber Band (1/4” wide x 3” lg.)
None
Local Purchase
Utility Knife
None
Local Purchase
Hand Tools
None
Local Purchase
Power Drill with Philips Bit
None
Local Purchase
Note: Make sure that the shipping crate is not damaged.
(1)
Disconnect the machine from facility power and air pressure.
(2)
Remove the wire spool from the machine. Remove any leadframes, and magazines from
the machine. Remove the clamp plate and heat block insert from the MHS workholder,
then set them aside for separate packaging.
(3)
Remove the leveling feet so that the machine rests on its casters. Roll the machine to the
area where it will be packed for shipment.
CAUTION:
Operation Hazard.
The machine cannot be rolled up or down any ramp that is at an incline angle greater than 7
degrees to the horizontal. The leveling feet will contact the floor and can be damaged, even if
the feet are fully retracted.
Installation Guide
Page 4-15
Unpacking/Packing
Pack Machine for Reshipment
98888-0000-006-04
Revision G
Power Series Ball Bonder
4.1.3.1
Prepare the machine for packing
(1)
(2)
Attach the signal light tower as follows:
(a)
Remove the upper console rear cover.
(b)
Disconnect the signal light tower cable connector from connector J48 on the BITS
board.
(c)
Loosen the stopper screw that holds the signal light tower to the bracket on the
upper console rear structure. Remove the signal light tower.
(d)
Wrap the bubble wraps around the signal light tower.
(e)
Put the signal light tower at the top rear of lower console. Install the shipping straps
to attach the signal light tower to the top rear of lower console.
(f)
Attach the rear cover to the upper console.
Attach the LCD Monitor as follows (Step a: Standard Power Series Model or Step b: Plus
model only):
(a)
(b)
For Standard Power Series Model
1.
Wind the LCD monitor in bubble wrap.
2.
Pivot the LCD monitor towards the rear of the machine. The screen points up.
3.
Place L-shaped foam blocks on the LCD monitor.
4.
Install two (2) shipping straps around the monitor and monitor mount to hold
the monitor in place. Make sure to put foam blocks under the straps at all
points where the strap contacts the monitor case.
For Plus model only
1.
Wind the LCD monitor in bubble wrap.
2.
Remove the top cover from the upper console.
3.
Find the monitor cables at the top of the upper console.
4.
Move the monitor cables a small distance away from the monitor bracket.
5.
Move the cable near to the side wall of the upper console.
6.
Attach the shipping straps to the side walls of the upper console.
7.
Attach the top cover to the top of the upper console.
Note: Make sure that the shipping straps hang outside at each side of the side
wall and the top cover.
8.
Loosen the screw at the top of the left adjustment monitor bracket.
Loosen Screw
Left Adjustment
Monitor Bracket
Remove Screw
Figure 4-12: Left Adjustment Monitor Bracket
98888-0000-006-04
Revision G
Unpacking/Packing
Pack Machine for Reshipment
Installation Guide
Page 4-16
Power Series Ball Bonder
9.
Remove the screw at the bottom of the left adjustment monitor bracket. Keep
the screw for later use.
10.
Hold the monitor with bracket, then loosen three screws at the right
adjustment monitor bracket.
Loosen Screws (x3)
Right Adjustment
Monitor Bracket
Remove Screw
Figure 4-13: Right Adjustment Monitor Bracket
11.
Remove the screw at the bottom of the right adjustment monitor bracket.
Keep the screw for later use.
12.
Hold the monitor with bracket, then tilt the monitor to the rear.
13.
Put the monitor on top of the upper console. Make sure that the monitor
screen points up.
14.
Attach the screw removed before from the adjustment brackets to each of the
left and right monitor brackets.
Monitor Bracket
Attach Screw
Figure 4-14: Monitor Bracket
Installation Guide
Page 4-17
Unpacking/Packing
Pack Machine for Reshipment
98888-0000-006-04
Revision G
Power Series Ball Bonder
15.
Top Screw
Hold the left monitor bracket with screws, then put the top screw against the
opening slot of left adjustment monitor bracket.
Opening Slot
Top Screw Against Opening
Slot
Figure 4-15: .Top Screw in Opening Slot
CAUTION:
Operation Hazard!
Incorrect installation can cause the monitor cables to kink. Install the left adjustment monitor
bracket carefully.
16.
Hold the right monitor bracket with screws, then put the top screw in the
opening slot of the right adjustment monitor bracket.
17.
Adjust the right adjustment monitor bracket until the monitor is set on the
correct position on top of upper console.
18.
Tighten two screws loosened before on the right adjustment monitor bracket .
19.
Tighten the screws on the opening slots of left and right adjustment monitor
brackets.
20.
At each side of the monitor, put two L-shaped foam blocks between the
monitor and the top cover.
L-shaped Foam Blocks (x2)
Figure 4-16: L-shaped Foam Blocks
(3)
Wind the shipping straps around the L-shaped foam blocks to attach the
monitor to the upper console.
22.
Tighten the shipping strap.
Install the XY–axes shipping restraint:
(a)
98888-0000-006-04
Revision G
21.
On the left side of the machine, put the XY–axes shipping restraint (painted yellow)
on the X Slide. Install one (1) screw on the X slide hard stop to attach the shipping
restraint.
Unpacking/Packing
Pack Machine for Reshipment
Installation Guide
Page 4-18
Power Series Ball Bonder
(b)
(4)
At the rear of the machine, put two (2) XY–axes shipping restraints (painted yellow)
on the rear Y slide. Install one (1) screw on the rear Y slide that attach the shipping
restraints to the Y hard stop. Install the another two (2) screws on the Y hard stop to
attach the shipping straps.
Attach the MHS workholder components as follow:
(a)
Move the gripper assembly to its left–side limit, next to the input magazine wall.
(b)
Put a foam block (kept during machine unpacking) between the indexer motor
mount and the left side of eject gripper mount bracket. Move the gripper assembly
to the left until the foam block is held between the indexer motor mount and the left
side of eject gripper mount bracket as shown below.
Index Gripper
Eject Gripper
Figure 4-17: Foam Blocks Positions
(c)
Put a foam block (kept during machine unpacking) between the force tucker
assembly and output magazine wall.
(d)
Use adhesive tape with foam pad to hold down the index gripper, eject grippers and
force tucker blade to the front rail.
(e)
Put a small piece of foam block (kept during machine unpacking) between the wire
clamp assembly and rear rail. Install a cable tie to attach the foam block to the rear
rail.
(f)
Put a small piece of foam pad between the optics assembly and wire clamp
assembly.
(g)
Put three foam blocks (kept during machine unpacking) on the left hand X shield
cover of integrated table assembly, between the input magazine wall and bond head
and optics assembly.
(5)
Wind the mouse in bubble wrap. Attach the mouse and the MMI drawer using foam pads
with adhesive tape to the MMI.
(6)
Attach the microscope as follows:
(a)
Move the microscope to its operation position.
(b)
Move the scope mount to the farthest left position.
(c)
Put the foam block between the microscope and the scope mount shaft.
(d)
Put the bubble wrap around the microscope and the scope mount shaft, then put the
adhesive tape around to prevent the scope mount from movement.
(7)
Wind bubble wrap around the spool wire cover and the work light, and tape it in place.
(8)
Put a foam block between the microscope and work light.
(9)
At the input magazine handler, loosen the leadframe retainer at the tray assembly and
move them fully to the right. Tighten the screw to attach the leadframe retainer.
Installation Guide
Page 4-19
Unpacking/Packing
Pack Machine for Reshipment
98888-0000-006-04
Revision G
Power Series Ball Bonder
(10) At the output magazine handler, loosen the leadframe retainer at the tray assembly and
move them fully to the left. Tighten the screw to attach the leadframe retainer.
(11) Put the machine on the crate pallet.
(a)
Put the pallet on the floor. Orient the pallet so that holes for the isolation mounts are
aligned with the tapped holes at the bottom of the machine. Make sure that the rear
of pallet is toward the front of the machine so that when the machine is moved over
the pallet, the rear of the machine will be at the rear of the pallet.
(b)
Use forklift to lift up the machine from the floor. Move the forks under the rear of
the machine as shown in the figure below. Do not try to lift the machine from the
front or at either side.
WARNING:
Injury Hazard!
Put the forks of the forklift under the machine from the rear as shown below. Do not lift the
machine any other way.
Rear of Machine
Forks
Isolation Mounts (4 Places)
Forks
Forks Lift
Figure 4-18: ATPremier Plus Packing
98888-0000-006-04
Revision G
(c)
Remove the four leveling feet and put them in the carton box (with the monitor
bracket).
(d)
Install the isolation mounts to the tapped holes at the bottom of the machine.
(e)
Put the machine over the pallet. Make sure the threaded stud of each isolation mount
is above a mounting hole in the pallet. Slowly lower the machine onto the pallet.
Make sure that the threaded studs of the isolation mounts pass through the holes in
the pallet.
(f)
From the underside of the pallet, install a flat washer and 19 mm hex nut on each of
the isolation mount threaded studs. Fully tighten the four (4) hex nuts.
(g)
Pack all of the loose parts (leveling feet, power cord, microscope eyepieces, clamp
plate, heat block insert) in a cardboard box.
(h)
Put the box at any convenient location on the machine.
(i)
Use a shipping strap to attach the box to the machine.
(j)
Put the vapor barrier bag over the machine.
Unpacking/Packing
Pack Machine for Reshipment
Installation Guide
Page 4-20
Power Series Ball Bonder
(k)
Heat seal the vapor barrier to the piece of plastic sheeting on the pallet with a small
opening unsealed.
(l)
Use an industrial vacuum to remove air from under the vapor barrier.
(m)
When done, heat seal the remaining opening in the vapor barrier.
(12) Assemble the crate sides, front, and back panels around the machine. Nail the panel to the
pallet.
(13) Nail the front and back panels to the crate sides. Mount the crate top on the panels and nail
it in place.
(14) Install two (2) shipping straps vertically around the crate and pull them tight.
Installation Guide
Page 4-21
Unpacking/Packing
Pack Machine for Reshipment
98888-0000-006-04
Revision G
Power Series Ball Bonder
4.1.4
Checklist: Pack Machine for Reshipment
Machine Serial Number:___________________
Date:_____________
Note: Copy this checklist and use it while you pack the machine for reshipment. Make sure
that all required actions have been taken and that the procedure has been done in the
specified order.
 1. All required tools and materials on hand. Refer to section
 2.
 3.
 4.
 5.
 6.
 7.
 8.
 9.
 10.
 11.
 12.
 13.
 14.
 15.
 16.
 17.
 18.
 19.
98888-0000-006-04
Revision G
4.1.3 Pack Machine for Reshipment for list.
Machine disconnected from compressed air and power. Refer to section
4.1.3 Pack Machine for Reshipment step (1).
All material removed from machine (magazines, device, wire spool). Clamp insert and
heat block insert removed from machine and set aside for separate packaging. Refer
to section 4.1.3 Pack Machine for Reshipment, step (2).
Leveling feet removed so that machine rests on casters. Machine moved to packing
area. Refer to section 4.1.3 Pack Machine for Reshipment, step (3).
Signal light tower attached to the rear of the machine. Refer to section
4.1.3 Pack Machine for Reshipment, step 4.1.3.1(1).
XY–axes shipping restraint installed. Refer to section
4.1.3 Pack Machine for Reshipment, step 4.1.3.1(3).
Foam blocks and cable ties installed to prevent MHS workholder movement. Refer to
section 4.1.3 Pack Machine for Reshipment, step 4.1.3.1.
Adhesive tape installed to hold down index gripper arm, eject gripper arm and force
tucker blade on front rail. Refer to section 4.1.3 Pack Machine for Reshipment, step
4.1.3.1.
Foam block and cable tie installed to prevent bond head link movement. Refer to
section 4.1.3 Pack Machine for Reshipment, step 4.1.3.1.
Scope covered with bubble wrap. Bubble wrap installed around scope mount shaft to
prevent scope movement on shaft. Scope mount attached with shipping strap. Refer
to section 4.1.3 Pack Machine for Reshipment, step 4.1.3.1.
Bubble wrap installed around signal light tower, spool wire cover and work light. Refer
to section 4.1.3 Pack Machine for Reshipment, step 4.1.3.1.
Shipping strap installed to attach video monitor to monitor mount. Refer to section
4.1.3 Pack Machine for Reshipment, step 4.1.3.1.
Mouse winded with bubble wrap. Control panel taped to attach drawer. Refer to section
4.1.3 Pack Machine for Reshipment, step 4.1.3.1.
Leadframe retainer on input and output magazine handlers moved fully inward (toward
machine) and locked in place. Refer to section 4.1.3 Pack Machine for Reshipment,
step 4.1.3.1.
Leveling feet removed. Levelling feet set aside for separate packaging. Refer to
section 4.1.3 Pack Machine for Reshipment, step (11)
Machine mounted on crate pallet. Hardware installed and fully tightened to attach
isolation mounts to pallet. Refer to section 4.1.3 Pack Machine for Reshipment, step
(11).
Leveling feet, clamp insert, heat block insert, and power cord packed in box. Box
placed on machine and attached. Refer to section
4.1.3 Pack Machine for Reshipment, step (11).
Vapor barrier installed over machine. Refer to section
4.1.3 Pack Machine for Reshipment, step (11).
Vapor barrier partially heat-sealed to plastic sheet on pallet. Air removed from under
barrier and vapor barrier/plastic sheet seal completed. Refer to section
4.1.3 Pack Machine for Reshipment, step (11).
Unpacking/Packing
Checklist: Pack Machine for Reshipment
Installation Guide
Page 4-22
Power Series Ball Bonder
 20. Crate sides assembled onto and nailed to pallet. Crate front and rear sides nailed to


Installation Guide
Page 4-23
crate sides and pallet. Refer to section 4.1.3 Pack Machine for Reshipment, step (11).
21. Crate top mounted on crate sides. Crate top nailed to sides. Refer to section
4.1.3 Pack Machine for Reshipment, step (12).
22. Two shipping straps installed vertically around crate and pulled tight. Refer to section
4.1.3 Pack Machine for Reshipment, step (12).
Unpacking/Packing
Checklist: Pack Machine for Reshipment
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Power Series Ball Bonder
Chapter 5: Machine Installation
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Machine Installation
Installation Guide
Page 5-1
Power Series Ball Bonder
5.1
Machine Installation
This section tells you how to install the machine, set the machine to level, and make connections
to the electrical and compressed air supplies.
Select the links below for the machine installation procedures:
5.1.1 Position And Level The Machine
5.1.2 Check Input Line Facilities
5.1.3 Facility Air/Electrical Connections
5.1.1
Position And Level The Machine
The machine must be lifted off of its casters by the four levelling feet and the machine table is set
to level. Additionally, extend the leveling feet helps to isolate the machine from ambient
vibrations and fixes the machine firmly in place.
Tools, Materials, and Equipment
Part Number
Supplier
Measuring Tape
None
Local Purchase
Spirit Level
None
Local Purchase
(1)
Move the machine to its prepared site (if this has not done).
CAUTION:
Operation Hazard.
The machine cannot be rolled up or down any ramp that is at an incline angle greater than 7
degrees to the horizontal. The leveling feet will contact the floor and can be damaged, even if
the feet are fully retracted.
(2)
(a)
Move the machine to the location where it will be installed.
(b)
Put the machine at its prepared site. Make sure that there is sufficient space at the
front, rear, and sides of the machine for operation and maintenance.
Set the machine to level.
CAUTION:
Operation Hazard!
The machine must be on its leveling feet. Make sure that the machine is carefully set to level!
Otherwise, the machine may not operate to its specifications.
Installation Guide
Page 5-2
(a)
Lower the leveling feet at the four corners of the machine base to lift the machine
off from the casters.
(b)
Adjust the jacking screws on the leveling feet so that the machine is set to level. Use
the spirit level to check level front–to–back and side–to–side.
Machine Installation
Machine Installation
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5.1.2
Check Input Line Facilities
Select the links below to do a check on the input line facilities for machine installation:
5.1.2.1 Check Facility AC Line Voltage
5.1.2.2 Check Facility Air Pressure Source
5.1.2.1
Check Facility AC Line Voltage
The facility AC line voltage must be within the range of 200 VAC to 240 VAC. Make sure that
the facility gives the required voltage range before you continue. The facility input voltage
frequency difference (within the range of 200VAC to 240VAC) are handled automatically by the
power supply.
CAUTION:
If you apply power to the machine that is below the specified voltage range, the machine
equipment may be damaged. Do not connect the machine to facility power unless the facility
power is within the range of 200 VAC to 240 VAC. If the facility power is below this range, a
step-up transformer is required (see NOTE below).
Note: If the source input voltage is within the range of 100 to 120 VAC, you need a step-up
transformer. The step-up transformer increases the input voltage to the 200 to 240 VAC
range.The transformer kit is installed between the source input voltage and the bonder
power supply. Call your local K&S sales representative for more data.
5.1.2.2
Check Facility Air Pressure Source
The facility must give clean, dry, and non-lubricated compressed air at 50 PSI (minimum) for
machine operation. Do the inspection the facility air supply before you connect air pressure to the
machine. Adjust air pressure and/or clean the air filtration system as needed.
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Machine Installation
Check Input Line Facilities
Installation Guide
Page 5-3
Power Series Ball Bonder
5.1.3
Facility Air/Electrical Connections
Select the links below to install and connect the air and electrical connections procedures:
5.1.2.1 Check Facility AC Line Voltage
5.1.3.2 Install Power Cord Plug
5.1.3.3 Connect Machine to Electrical Power
5.1.3.4 Connect Machine to Air Pressure
5.1.3.1
Install Frame Ground Cable to Facility Building Ground
Note: A #12 AWG ground cable is supplied with machine. If the local electrical code requires
a different earth ground wire such as different conductor cross–sectional area or have
other characteristics (a specific insulation color, for example), then obey the local
electrical code requirements.
A #12 American Wire Gauge (AWG) safety earth ground cable (permanent connection) must be
connected between the frame ground screw (rear of lower console) and the facility building
ground. The ground cable is supplied by K&S.
Tools, Materials, and Equipment
5.1.3.2
Part Number
Supplier
Hex Wrench Set
None
Local Purchase
Star Washer
None
Local Purchase
M6 Screw
None
Local Purchase
Install Power Cord Plug
Note: If the machine comes with a power plug installed on the power cord, skip this procedure
and go to section 5.1.3.3 Connect Machine to Electrical Power. If you want to connect
the supplied machine power cord directly to the facility power mains (not
recommended), refer to bullet 2 below for wire insulation color coding.
A plug that mates with the facility power receptacle may need to be supplied by and installed on
the input power cord of the machine by the user (see NOTE above.) When installing the plug:
•
Power Plug:
The plug must meet or exceed the following power handling specifications: 264 Volts, 15
Amperes (minimum). The power plug terminals must accept #12 AWG conductors. The
plug must attach to the ground connection first before either line connection is made when
the plug is connected to the facility power receptacle.
•
Color coding of power cord wire insulation is as follows:
•
BROWN: AC Line
•
BLUE: AC Neutral
•
GREEN/YELLOW: Ground
(1)
Follow the plug manufacturer’s instructions when you install the plug. After installation,
make sure that all connections are tight and there are no loose strands of wire found around
the plug terminals.
(2)
Do a continuity check before you use the cord. Make sure there is continuity along each
cord conductor and its contact in the plug. Make sure there is an open circuit between
conductors.
(3)
Install the plug back shell. Make sure the power cord jacket is properly attached in the plug
strain relief.
Installation Guide
Page 5-4
Machine Installation
Facility Air/Electrical Connections
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Power Series Ball Bonder
5.1.3.3
Connect Machine to Electrical Power
(1)
Connect the plug on the power cord to the facility power receptacle.
(2)
Do the test on the emergency off circuit:
WARNING:
Operation Hazard. Do not use the machine if the Emergency Off Switch test fails. Turn off the
machine power and arrange for servicing immediately.
(a)
Latch the Emergency Off Switch (red mushroom switch on front of upper console).
(b)
Push the upper push button (green) on the Start/Stop switch. Make sure that the
machine power can’t be set to on.
(c)
Reset the Emergency Off Switch to the OUT position (turn switch to right to
release).
(d)
If the Emergency Off Switch did not pass the test in steps (a) and (b), turn off
machine power and disconnect the machine power cord. Arrange for service
immediately. Do not use the machine until after the Emergency Off switch has been
repaired.
Start/Stop Switch
Emergency Off Switch
Power OFF (Red)
Power Indicator
Power ON (Green)
Figure 5-1: Power Control
(3)
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To power up the bonder after an emergency power down, do this:
(a)
Release the emergency OFF switch.
(b)
Push the stop (red) button from the start/stop switch.
(c)
Push the start (start) button from the start/stop switch to turn on machine power. The
machine power comes on and noise from the cooling fans should be audible. The
power indicator lamp in the Start/Stop switch should be on.
If there is no power, remove the rear cover from lower console. Do not disconnect
the power cord plug from the facility power receptacle.
Machine Installation
Facility Air/Electrical Connections
Installation Guide
Page 5-5
Power Series Ball Bonder
(d)
Installation Guide
Page 5-6
Check indicator LEDs located on the left edge of the PDU PCB (mounted at the
lower console left cover see the figure below for location.). If all lamps are dark:
1.
Disconnect power cord and do a check for power at the facility power
receptacle.
2.
Do a continuity check through plug contact and power cord wires.
3.
Do a check for shorts between power plug contacts.
4.
If source power is good and the power cord plug is good, stop the installation.
Call your nearest K&S Sales and Service office to arrange for service.
(e)
The PSOK (green) should be ON on the left edge of the PDU PCB. While the
DISABLE (yellow) should be on when the INH or PFA signals are active. The four
other LEDs (ERR1 to ERR4) should be OFF.
(f)
If any of the indicator LEDs ERR1 to ERR4 are lit (red), the power supply probably
requires service. Push the right push button (red) in the Start/Stop switch to turn off
machine power. Disconnect the power cord and contact K&S Sales and Service to
arrange for service.
Machine Installation
Facility Air/Electrical Connections
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Power Series Ball Bonder
Battery Box
Power Distribution Unit (PCU) PCB
Power Supply Unit (PSU)
Lower Console Rear View (Without Rear Panel Cover)
Connect to J6 of PDU
PCB (15V & 12V)
Connect to J4 (P3) of
PDU PCB
See (PDU) PCB below
for details.
Power Supply Unit (PSU)
Status Light LEDs
Fuse Region
Test Points
Power Distribution (PDU) PCB
Figure 5-2: Power Supply Indicator LEDs
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Machine Installation
Facility Air/Electrical Connections
Installation Guide
Page 5-7
Power Series Ball Bonder
5.1.3.4
Connect Machine to Air Pressure
(1)
Remove the supplied male pipe connector from the air input fitting mounted at the right
side of the lower console (viewed from front of machine).
(2)
Install the male connector on the air hose from the facility air pressure source.
(3)
Verify that facility air pressure is set within the 65 psi (345 kPa) to 80 psi (552 kPa) range.
(4)
Connect the facility air pressure hose to the air input fitting on the machine.
CAUTION:
Operation Hazard!
Do not set the machine system pressure regulator until the machine pressure is above 50 psi or
345 kPa (indicated on the digital air gauge at the rear of upper console. The pressure switch
(input air low sensor, part of the air gauge/sensor assembly) is easy to damage.
(5)
Check the digital air gauge below the front face of the machine upper console. It should
read 55 psi. If not, adjust the air regulator knob until the gauge reads 55 psi.
CAUTION:
Operation Hazard!
Make sure that the pressure is not more than 65 psi when you adjust the regulator.
(6)
Installation Guide
Page 5-8
If machine air pressure cannot be adjusted to 55 psi (380 kPa):
(a)
Make sure air hose connector is fully engaged in the air input connector on the
lower console side cover.
(b)
Do a check for air leaks at all hose connections. Do a check on hose for kinks,
blocks, and breaks.
Machine Installation
Facility Air/Electrical Connections
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Power Series Ball Bonder
5.2
Checklist: Machine Installation
Machine Serial Number:___________________
Date:_____________
Note: Copy this checklist and use it while you install the machine. Make sure that all required
actions have been taken and that the procedure has been done in the specified order.


1. Site prepared for machine. Refer to Chapter 2: Site Preparation .


3. Machine leveled. Refer to section 5.1.1 Position And Level The Machine.
2. Machine put at installation site. Sufficient space at sides and rear for maintenance.
Sufficient space at front for operation. Refer to section 5.1.1 Position And Level The
Machine.
4. Facility AC line voltage checked. Line voltage verified to be within 200 VAC to 240
VAC (refer to section 5.1.2.1 Check Facility AC Line Voltage). For Voltage within 100
VAC to 115VAC: K&S transformer is installed between the line voltage and the
power supply.
• Local line voltage: __________ Vac
• HI/LO Switch: LO (115) HI (230)

5. Facility air pressure supply checked. Air pressure level verified to be within 55 psi 80 psi range (refer to section 5.1.2.2 Check Facility Air Pressure Source):

6. Safety ground cable connected between facility ground and machine frame ground
terminal (refer to section 5.1.3.1 Install Frame Ground Cable to Facility Building
Ground).

7. Plug for facility receptacle installed on AC power cord. Power cord continuity check
done (refer to section 5.1.3.2 Install Power Cord Plug).

8. Machine connected to facility power (refer to section 5.1.3.3 Connect Machine to
Electrical Power).

9. Test for TOP circuit done. EOFF switch reset to out position (refer to section
5.1.3.3 Connect Machine to Electrical Power).

10. Main Power circuit breaker set to ON (refer to section 5.1.3.3 Connect Machine to
Electrical Power). Power supply operates correctly (power supply PSOK and
DISABLE indicator lamps on).

11. Facility air pressure connected to machine (refer to section 5.1.3.4 Connect Machine
to Air Pressure). Machine air pressure successfully adjusted to 55 psi.
• Facility Air Pressure: __________ psig
• Machine Air Pressure: ____________ psig
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Machine Installation
Checklist: Machine Installation
Installation Guide
Page 5-9
Power Series Ball Bonder
Chapter 6: Machine Power Up Tests
Installation Guide
Page 6-1
Machine Power Up Tests
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Revision G
Power Series Ball Bonder
6.1
Machine Power Up Tests
This section contains instructions on how to turn on the machine power, initialize the machine,
and do the check for power supply outputs. When done, the machine will be ready for the
detailed setup procedures outlined in Maintenance Manual and the configuration/calibration
procedures in Operator’s Guide.
Select the links below for the machine power up test procedures:
6.1.1 Power Up Machine
6.1.2 Initialize Machine
6.1.3 Continue Setup
6.1.1
Power Up Machine
Select the links below to power up the machine procedures:
6.1.1.1 Apply Power to Machine
6.1.1.2 Check Power Supply Outputs
6.1.1.1
Apply Power to Machine
(1)
Make sure the machine is connected to facility power. Make sure that all covers are on the
machine. If not, install the covers now.
(2)
Make sure the Emergency Off Switch (on the front of the upper console) is out (inactive).
If it is latched down, turn the switch knob to the right (clockwise) to release the switch.
(3)
Push the left push button (green) of the Start/Stop switch.
(4)
The machine will perform its power–up self tests.
Start/Stop Switch
Power OFF (Red)
Power Indicator
Motor-Stop Mode dialog - appears after
power up sequence is complete.
Emergency OFF Switch
Control Panel
Power ON (Green)
Figure 6-1: Power Series Power Controls
Note: Red FAULT lamps on PC boards in the Distributed Material Handling System (DMHS)
chassis (behind monitor) will be lit during the power up tests. This does not indicate a
problem with the PC boards. The FAULT lamps will go off later during machine
initialization.
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Machine Power Up Tests
Machine Power Up Tests
Installation Guide
Page 6-2
Power Series Ball Bonder
6.1.1.2
(5)
If the password protection function is active, a dialog shows for password entry
immediately after the video monitor display comes on. Push ENTER on the MMI to bypass
password entry if this dialog appears. The machine will then enter motor-stop mode. If the
function is inactive, the machine will enter standby mode. No user password entry is
necessary.
(6)
Check power supply outputs before the machine initialization. Refer to section
6.1.1.2 Check Power Supply Outputs.
Check Power Supply Outputs
You must check the power supply outputs before the machine is initialized and set up for
operation. You use a digital multimeter to check the outputs at the test points on the rear face of
the power supply (see Figure 6-2).
Tools, Materials, and Equipment
Digital Multimeter
Part Number
Supplier
None
Local Purchase
WARNING:
Electric Shock Hazard. Some tasks are necessary with electrical power on. Be careful when
you work within the lower console.
(1)
Make sure that you connect the machine power cord to facility power.
(2)
Make sure that you power up the machine. If not, use a quick motion, push the Power Start
Button to start the machine.
(3)
Remove the rear cover of the lower console and the protective cover (if any) of the DC test
points as shown in the figure below.
Note: Refer to the table shown below for minimum and maximum voltages for each output
under Regulation in the table. The table also identifies the test point for each output.
Voltage
Output Current (A)
Regulation
Assignments
Min.
Norm.
Max.
Min.
Max.
+5VDC
3.5
22
23.6
4.9
5.25
Digital Electronics
+12VDC
1.19
14.0
16.0
11.6
12.4
Analog Electronics, Relays, Lamps
-12VDC
0.19
0.60
0.67
-11.6
-12.4
Analog Electronics
+24VDC
0.15
3.4
5.7
23.8
25.2
Electronics, DC fans
+48VDC
0.5
4.00
7.00
45 (43)
48.5
Electronics, Stepper Motor (Backup Battery)
+57VDC
0.07
3.45
6.75
55.5 (43)
57.0 (57.0) Set nominal to 56.3VDC [+0.7/-0.8V] DC
Servomotor, Heaters (Backup Battery)
+57VH
0
11
12
55.0 (43)
57.0 (57.0) Heaters (Backup Battery)
+420VD
0.06
1.50
1.66
380
430
DC Servo motor
24VSW
0
2.1
2.3
17.0
26.4
ZTC Heater
(4)
Use a digital multimeter to do checks on the DC voltages at test points (see the table
shown above for test point locations and output ratings):
Note: It is not necessary to do the DC voltage check for +420 VDC. Look for the red
safety light LED on the power supply for the +420 VDC. When lit, it indicates the
voltage is above +60 VDC. Make sure that this safety LED is off before you
disconnect the power supply, XY amp, or X and Y motors.
(a)
Installation Guide
Page 6-3
Use the GND as the reference (multimeter black or ground lead attached to GND) to
do the checks for +5 V, +12 V, and -12 V.
Machine Power Up Tests
Power Up Machine
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Power Series Ball Bonder
(b)
Push MOTOR ON on MMI keypad.
(c)
Use the PGND as the reference (multimeter black or ground lead attached to
PGND) to do the checks for +48 V and +57 V.
WARNING:
Electric Shock Hazard. For voltages above +60 V, do not do the DC voltages check at test
points.
Note: 1. High voltage test point are one–tenth (1/10) of actual voltage. Multiply
the reading at the test point by 10.
Note: 2. These test points are meant for multimeter measurements. If an
oscilloscope is used to record the voltage waveforms, the waveforms may
show high frequency noise, due to the low impedance of PGND and
DGND.
Note: 3. The +5 V requires a connection to the machine backplane in order to
read within the regulation range. If during debugging, backplane
connections are removed, the +5 V will read close to +5.7 V.
(5)
Do the checks for PSOK, PFA, and POC referenced to DGND (PSOK, PFA, and POC
should measure approximately +5 V (logic high).
(6)
If any DC output is outside of its specified range (see note 3 above), do the steps follow:
(a)
Turn off machine power. Disconnect the machine power cord from the facility
receptacle. Do not attempt to use the machine until the power supply problem has
been resolved.
WARNING:
Electric Shock Hazard. The voltages inside the power supply modules can cause electric
shocks or burns. Do not attempt to repair or adjust the power supply module.
(b)
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If the machine is under warranty, notify the local K&S Sales/Service office
immediately. If the machine is not under warranty, remove and replace the power
supply assembly. There are no user–serviceable or adjustable components within the
power supply assembly.
Machine Power Up Tests
Power Up Machine
Installation Guide
Page 6-4
Power Series Ball Bonder
(7)
If all DC outputs are good, install back the protective cover and the rear panel on the lower
console.
+420 V Safety
Light LED
Connect to J6 of PDU
PCB (15V & 12V)
Connect to J4 (P3) of
PDU PCB
See (PDU) PCB below
for details.
Power Supply Unit (PSU)
Status Light LEDs
Fuse Region
Test Points
Power Distribution (PDU) PCB
Figure 6-2: Output Voltage Test Points
Installation Guide
Page 6-5
Machine Power Up Tests
Power Up Machine
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Power Series Ball Bonder
6.1.2
Initialize Machine
(1)
The Motor-Stop mode dialog should be shown on the monitor. If not, push MOTOR STOP on
the control panel. Select OK in the dialog (use the mouse and mouse button B1) or push
ENTER on the control panel.
(2)
The XYZ limit seek dialog appears on the monitor. Make sure the shipping restraints and
all packing material has been removed from the bond head and upper XY table. Select OK
(or push ENTER) to start bond head X, Y and Z servo axis limit seek sequence.
Note: You can select Cancel to continue initialization without the XYZ limit seek sequence. In
this case, the machine will set default software limits.
(3)
After XYZ limit seek is completed, the MHS Home Sequence dialog appears on the
monitor. The software limits for the X-Y table (derived from home sensor positions) are
indicated by the red areas in the device graphic window of the display.
(4)
Make sure that the all shipping material have been removed from the MHS workholder
and magazine handlers. Select OK (or push ENTER) to start MHS home sequence.
(5)
After the MHS home positions are found, a dialog will tell you to do the calibrations,
update the machine dependent parameters (MDPs), or continue with no change. Refer to
Power Series User Guides and Power Series Maintenance Manual for machine setup and
preparation.
Note: If a dialog tells you that the MDPs could not be loaded, then you must load the MDPs
from disk or do all the machine calibrations.
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Machine Power Up Tests
Initialize Machine
Installation Guide
Page 6-6
Power Series Ball Bonder
PRESS START/STOP
TO TURN ON POWER
SOFTWARE LOADS
TEST & INITIALIZATIONS;
VIDEO ON
BONDER
ININ
BONDER
STANDBY MODE
SELECT OK
START XYZ LIMIT SEEK
SEQUENCE
SELECT OK
XYZ LIMIT SETTING
PERFORMED
START MHS HOME
SEQUENCE
SELECT OK
MHS HOME SENSORS
LOCATED
MODE/FUNCTION
VIDEO DISPLAY
CALIBRATION DIALOG
BOX DISPLAYED
(SEE VOLUME 1)
CALIBRATE, RESTORE
MDPs, OR SKIP
CONFIGURE MHS
AND BONDER
(SEE VOLUME 1)
Figure 6-3: Normal Power Up and Initialization Sequence
6.1.3
Continue Setup
Continue to do the setup tasks listed in chapter 1 of Maintenance Manual. Along with the
required tasks for machine setup, the table gives specifications, references to maintenance
procedures, and lists required tools/materials.
Installation Guide
Page 6-7
Machine Power Up Tests
Continue Setup
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Power Series Ball Bonder
6.2
Checklist: Machine Power Up Tests
Machine Serial Number:___________________
Date:_____________
Note: Copy this checklist and use it while you turn on the power and initialize the machine.
Make sure that all required actions have been taken and that the procedure has been
done in the specified order.

1. Machine connected to facility power and air pressure. All covers installed. Refer to
section 6.1.1.1 Apply Power to Machine.


2. Emergency Off switch pulled OUT.

4. Power supply DC outputs and interface signals (PDU PCB) within specification.
Refer to section 6.1.1.2 Check Power Supply Outputs. Record measurements:
3. Machine power comes on when Start/Stop switch pressed. Machine enters standby
mode after password entry is bypassed.
Nominal (Min/Max)
Measured Voltage
Nominal (Min/Max)
+5VDC (4.90/5.25)
Standard models
+54VH (52/57)
Plus models
+57VH (55.0/57.0)
+12VDC (11.6/12.4)
24VSW (17.0/26.4)
-12VDC (-11.6/12.4)
PSOK (+5V)
+24VDC (23.8/25.2)
PFA (+5V)
+48VDC (45/48.5)
POC (+5V)
Measured Voltage
Standard Models
+54VDC (52/57)
Plus Models
+57VDC (55.5/57.0)

5. Machine completes initialization successfully. Refer to section 6.1.2 Initialize
Machine.
Go to Previous View
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Machine Power Up Tests
Checklist: Machine Power Up Tests
Installation Guide
Page 6-8