Robotic Soldering System User Manual PDF

USER MANUAL, RSS-1000-CVSI
7000-5970 Rev. A
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Robotic Soldering System

RSS-1000-CVSI
User Manual
7000-5970 Rev. A
page 2 of 396
Copyright © 2018 OK International, Inc. 10800 Valley View Street, Cypress, CA 90630
Visit us on the web at www.okinternational.com/metcal
PROPRIETARY NOTICE: This document contains proprietary data of OK International, Inc. The
receipt or possession of this document does not convey any rights to reproduce it, disclose its
contents, or to manufacture the concepts and details disclosed by this document. This document
may not be copied or disclosed in whole or in part to anyone without written permission of an officer
of OK International, Inc.
All rights reserved.
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Table of Contents
SAFETY AND REGULATORY INFORMATION............................................................................................. 7
WARNING ......................................................................................................................................................... 7
OTHER SAFETY TIPS .................................................................................................................................... 8
SPECIFICATIONS ............................................................................................................................................... 9
INTRODUCTION AND GENERAL OVERVIEW ........................................................................................... 12
SYSTEM ARCHITECTURE ............................................................................................................................. 13
TIPS BEFORE SETTING UP ........................................................................................................................... 15
UNBOXING INSTRUCTIONS .......................................................................................................................... 16
CONTROLLER BOX CONNECTIONS .......................................................................................................... 20
ROBOT BASE CONNECTIONS ..................................................................................................................... 21
ROBOT GANTRY CONNECTIONS ............................................................................................................... 22
ROBOT HEAD CONNECTION........................................................................................................................ 22
CV POWER CABLE CONNECTION INSTRUCTIONS ........................................................................... 23
SOFTWARE NAVIGATION ............................................................................................................................. 24
LOGIN SCREEN ............................................................................................................................................ 24
MAIN SCREEN OVERVIEW ........................................................................................................................ 25
MAIN MENU BAR .......................................................................................................................................... 26
HEADER BAR................................................................................................................................................. 28
PROFILE OPTIONS ...................................................................................................................................... 31
ADVANCE PROFILE OPTIONS .................................................................................................................. 33
SOLDER FEEDER OPTIONS...................................................................................................................... 35
CAMERA TOOLS ........................................................................................................................................... 37
CONNECTION VALIDATION DISPLAY ..................................................................................................... 39
TOOLBAR ....................................................................................................................................................... 43
MOTION CONTROL ...................................................................................................................................... 45
REMAINING MENUS/ BUTTONS ............................................................................................................... 48
SYSTEM OPERATION ..................................................................................................................................... 50
POWERING UP THE UNIT .......................................................................................................................... 50
POWERING OFF THE UNIT........................................................................................................................ 51
REBOOTING SOFTWARE ........................................................................................................................... 54
LOGGING IN TO SOFTWARE .................................................................................................................... 57
UPDATING SOFTWARE .............................................................................................................................. 60
UPDATING USER MANUAL ........................................................................................................................ 65
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SAFETY FEATURES .................................................................................................................................... 69
Z-LIMIT SAFETY........................................................................................................................................ 69
CLEARANCE HEIGHT SAFETY............................................................................................................... 78
CONNECTION VALIDATION (CV) SAFETY FEATURES .................................................................... 82
CLEAR INDICATORS RADIO FREQUENCY IS ACTIVE ................................................................. 82
AUTOMATIC RF ACTIVATION/DEACTIVATION ............................................................................ 82
SAFETY COVER INSTALLATION & ACTIVATION ............................................................................. 84
COMPONENTS OF AC-RSS-1KSC ....................................................................................................... 85
SAFETY COVER INSTALLATION ....................................................................................................... 86
SAFETY COVER ACTIVATION ........................................................................................................... 98
CHANGING PASSWORD........................................................................................................................... 102
ADDING NEW USER .................................................................................................................................. 106
DELETING USER ........................................................................................................................................ 112
VIEWING USER LOGIN HISTORY........................................................................................................... 116
CHANGING TIME ZONE ............................................................................................................................ 118
CLEAR PATTERN PARAMETERS ........................................................................................................... 122
RESET TO FACTORY SETTINGS ........................................................................................................... 126
IOT SETTINGS ............................................................................................................................................. 129
PROFILE MANAGEMENT .......................................................................................................................... 130
PROFILE CREATION ............................................................................................................................... 130
SAVING A PROFILE ................................................................................................................................ 131
SAVING PROFILE TO EXTERNAL USB DEVICE ............................................................................... 134
PROFILE REMOVAL................................................................................................................................ 136
FOLDER CREATION ................................................................................................................................ 140
FOLDER REMOVAL ................................................................................................................................ 146
CONNECTION VALIDATION VS STANDARD SOLDERING .............................................................. 150
WHY USE CONNECTION VALIDATION? ............................................................................................ 150
FLOW CHARTS OF SOLDERING PROCESSES .................................................................................... 150
CV TIP SELECTION ................................................................................................................................. 151
CV STATE CODES ................................................................................................................................... 151
SOLDER PARAMETERS AND SETTINGS ............................................................................................. 153
SOLDER POINT ........................................................................................................................................ 153
SOLDER LINE ........................................................................................................................................... 158
FEEDING SOLDER ................................................................................................................................... 163
SOLDER FEEDER SETTINGS ................................................................................................................. 164
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WAY POINTS ............................................................................................................................................ 165
SOLDER WIRE FEEDER ADJUSTMENT ............................................................................................... 166
ADVANCED PROFILE FUNCTIONS........................................................................................................ 168
EDIT PROFILE .......................................................................................................................................... 168
EDIT PROFILE OVERVIEW ................................................................................................................ 168
SOLDER PARAMETER EDIT.............................................................................................................. 170
PROFILE EDIT ...................................................................................................................................... 175
Edit Transition Speed .......................................................................................................................... 180
Edit Parameter ..................................................................................................................................... 182
Editing a Point Coordinate .................................................................................................................. 183
Editing Line Coordinates .................................................................................................................... 185
Editing Coordinates Using Record Coordinate Function ................................................................... 188
Editing Coordinates Using Offset All Function.................................................................................. 192
Editing Feeder Settings ....................................................................................................................... 197
Edit Order of Features Within a Profile .............................................................................................. 199
Remove a Feature from a Profile ........................................................................................................ 200
MERGE PROFILE ..................................................................................................................................... 201
COMPONENT BASED MERGE........................................................................................................... 201
PRINTED CIRCUIT BOARD ASSEMBLY BASED MERGE ............................................................ 208
GENERATE ARRAY ................................................................................................................................ 216
Examples of Generate Array Settings ..................................................................................................... 218
Single Point Array................................................................................................................................... 229
Multiple Pattern Array ............................................................................................................................ 232
SET GO-TO LOCATION........................................................................................................................... 238
OFFSET PROFILE ..................................................................................................................................... 239
DRY RUN................................................................................................................................................... 243
TIP ALIGNMENT .......................................................................................................................................... 245
TIP ALIGNMENT ...................................................................................................................................... 245
CENTER POINT ALIGNMENT ............................................................................................................... 248
CAMERA CALIBRATION & FUNCTIONS ............................................................................................... 256
CALIBRATION ......................................................................................................................................... 256
POSITION VERIFICATION TEST ........................................................................................................... 268
FINE ADJUSTMENT AFTER CAMERA CALIBRATION .................................................................... 270
TAKING A SCREENSHOT....................................................................................................................... 273
OPENING AN IMAGE/SCREENSHOT/ DXF/ GERBER ....................................................................... 277
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IMAGE ZOOM ........................................................................................................................................... 278
ESTABLISHING FIDUCIAL POINTS (Future Feature, Not Present in this Release) ............................. 282
PATTERN RECOGNITION ...................................................................................................................... 286
Template Creation ................................................................................................................................... 287
Pattern Recognition Using Template ...................................................................................................... 289
Layout Creation ...................................................................................................................................... 305
Component Layout Creation ................................................................................................................... 311
Pattern Recognition Using Layout .......................................................................................................... 315
MECHANICAL ADJUSTMENT OF COMPUTER VISION CAMERA ................................................. 330
TIP CLEANING ............................................................................................................................................. 332
OVERVIEW ............................................................................................................................................... 332
TIP CLEANING PROFILE SET UP.......................................................................................................... 333
ADVANCE TIP CLEANING PROFILE ................................................................................................... 336
IMPLEMENTATION OF TIP CLEANING PROFILE ............................................................................. 341
TIP CLEANING TROUBLE SHOOTING ................................................................................................ 346
EDITING A CLEANING PROFILE .......................................................................................................... 347
CUSTOM CLEANING LOCATIONS ....................................................................................................... 354
BRUSH REPLACEMENT ......................................................................................................................... 356
INSTALLATION & USE OF FUME EXTRACTION & NITROGEN ......................................................... 359
FUME EXTRACTION .................................................................................................................................. 359
NITROGEN ................................................................................................................................................... 360
TROUBLESHOOTING .................................................................................................................................... 362
MAINTENANCE & INSPECTION ................................................................................................................. 367
REPLACING CV-H8-AV .............................................................................................................................. 369
CHANGING SOLDER WIRE FEEDER..................................................................................................... 381
REPLACING A FUSE .................................................................................................................................. 392
WHEN TO CHANGE SOLDERING CARTRIDGE .................................................................................. 396
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SAFETY AND REGULATORY INFORMATION
WARNING
 IN ORDER TO BE IN COMPLIANCE WITH REQUIREMENTS OF CE DIRECTIVES, THE
ROBOTIC SOLDERING SYSTEM MUST BE EQUIPPED WITH THE AC-RSS-1KSC SAFETY
COVER ACCESSORY. THE SAFETY INTERLOCK OF THE ENCLOSURE WILL
AUTOMATICALLY CEASE ALL MOVEMENT AND HOME THE SYSTEM ONCE AN
OPERATOR COMES IN CLOSE PROXIMITY OF THE WORKING ENVELOPE.
 THIS PRODUCT IS HIGH VOLTAGE! MAKE SAFETY THE NUMBER ONE PRIORITY
WHEN OPERATING THIS UNIT.
 TO PREVENT FIRE OR SHOCK HAZARD, DO NOT EXPOSE SYSTEM TO MOISTURE OR
OPERATE UNIT WITH WET HANDS.
 TO PREVENT FIRE OR SHOCK HAZARD, DO NOT USE FLAMMABLE SOLVENTS NEAR
OR ON THE SYSTEM WHILE CONNECTED TO A POWER SOURCE.
 FAMILIARIZE ONESELF WITH EMERGENCY STOP BUTTON’S LOCATION AND HOW TO
USE IT.
 TO PREVENT POSSIBILITY OF INJURY OR DAMAGE TO THE SYSTEM:
o DO NOT USE THE UNIT IF THERE ARE ANY VISIBLE BROKEN OR DAMAGED
WIRES/CABLES.
o DO NOT OPERATE WITH ANY COVERS OR PANELS REMOVED.
o DO NOT MOVE THE ROBOT IN ANY AXES BY HAND
o ALWAYS USE THE SILICONE REMOVAL PAD WHEN CHANGING OUT
CARTRIDGES
o ALWAYS CHECK FOR AND REMOVE OBSTRUCTIONS FROM THE WORKING
ENVELOPE OF THE ROBOT
o ALWAYS USE THE ROBOT WITHIN THE STANDARD REQUIREMENTS (SUCH AS
VOLTAGE, AIR PRESSURE, POWER FREQUENCY, ETC.) AS DETAILED IN THE
SPECIFICATIONS ON PAGE 9
 CHANGES OR MODIFICATIONS MADE TO THIS PRODUCT WITHOUT EXPRESS
CONSENT FROM OK INTERNATIONAL WILL VOID THE USERS AUTHORITY TO
OPERATE THE EQUIPMENT.
 DO NOT PLACE ANY MAGNETS ON THE CONTROLLER BOX OF THE ROBOT, AS THIS
WILL PRODUCE UNDESIREABLE EFFECTS ON THE SYSTEM
 Read and understand the entire User’s Manual before installation or operation of the Robotic
Soldering System. Heed ALL warnings on the system and in the operating instructions.
 The Robotic Soldering System is only for point to point and line soldering of printed circuit
board assemblies. If you are not familiar with the proper and safe operation of the unit, do not
operate it until properly trained.
 Operate the unit from the type of power source indicated on the serial number label.
 Use only the supplied power cord. Avoid damage to the power cord. If damage should occur,
replace it with the approved OK International replacement power cord.
 This CAUTION symbol on the equipment refers the user to the user guide for additional
important information. This symbol appears next to the relevant information in the manual.
 This HOT symbol on the equipment warns the user of a hot surface and potential injury if
touched. This symbol appears next to the relevant information in the manual.
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 This HEAVY LIFTING symbol on the packaging warns the user to team lift the Robotic
Soldering System during removal from packaging and installation on the workbench. This
symbol appears next to the relevant information in the manual.
 This PINCH POINT symbol on the equipment warns the user of a potential injury. This symbol
appears next to the relevant information in the manual.
 This EYE PROTECTION symbol on the equipment warns the user of potential injury due to
flying debris. This symbol appears next to the relevant information in the manual.
OTHER SAFETY TIPS
 Once the unit has been unboxed, inspect unit and remove any obstructions that may have
been put in place to ship the unit securely.
 Unplug the unit before cleaning or performing any maintenance. Clean the exterior of the
system with a damp cloth. Do not use solvent-based cleaners.
 Slots and openings in the system are provided for ventilation and to ensure reliable operation
as well as protection from overheating. The openings should never be blocked or covered.
 Do not overload power outlets and extension cords. This can result in fire or electric shock.
 Unit to comply with CE, UL, & CSA standards.
 When operating this equipment, please exercise caution. If this unit is used in a manner in
which it is not intended for, serious personal injury may occur. Please read this user manual
thoroughly prior to use.
 The main power cord is a means for disconnecting the equipment from an operating energy
source. Position the equipment in a way that impedes the disconnection of the main power
cord in case of an emergency.
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SPECIFICATIONS
Microprocessor
64-bit Intel® Atom™ E3826 Series SoC
Core Logic Integrated Intel HD Graphics with Open Source Hardware-
Accelerated Drivers for Linux OS
2GB DDR3L RAM - System Memory
Memory
8 MB SPI Flash - System Firmware Memory
Intel HD Graphics (1920x1080 max resolution)
Video
HDMI 1.4a (micro HDMI connector)
Audio Digital via HDMI
Micro SDSDIO
SATA2 3Gb/sec
USB 3.0 (host)
USB 2.0 (host)
Serial debug via FTDI cable
I/O 1 GB Ethernet RJ-45 connector
8 x Buffered GPIO pins (2 pins support PWM)
I2C & SPI bus
2 x 16550 HS UARTs, one with CTS/RTS
System Firmware Flash Programming Header (compatible with
Dedi-Prog programmer)
Board Dimensions 99 x 74mm (2.9 x 3.9in)
Temperature Range 0 – 40 °C
Power 5V (min 2.5A) DC
Operating System Linux O/S

Language Unicode supported
Motion Control 4-Axis
Programming Methodology Icon Driven / Graphical Programming Language
Motion Interpolation 2D, 3D and 4D
Interface with Solder Iron &
Required
Feeder Control
File Importing DXF, GER, JPEG
Teach Mode Display / Solder Coordination in Real Time
Run Mode Display / Solder Coordination in Real Time
Setup Mode Vector speed, acceleration, delay, unit measurement,
programmable cleaning & origin location, relative snap distance
and continuous jog, programmable retract height, programmable
dot & line.
Operating Temperature 0 – 55° C
ESD housing 109 ohms – 1011 ohms
Lighting Minimum 3W LED
Communication Protocol USB 2.0/3.0
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Power Supply & Soldering Iron

Metcal CV-PS5200-R with Communications Port
Application Dependent CV Cartridges
Ambient Operating Temp. 10 to 40 °C
Max. Enclosure Temp. 55 °C
Input Line Voltage 100 – 240 VAC, Grounded Circuit
Input Line Frequency 50/60 Hz
Rated Power Consumption 125 W
Output Power 80 W Max.
Output Frequency 13.56 MHz
Heating Method Induction
Communications USB
Power Supply Dimensions
121 x 130 x 235 mm
WxDxH
Power Supply Weight 3.35 kg
Certification / Marking CE TUV
Potential <2 mV
Tip-to-Ground
Resistance <2 Ohms
Idle Temp. Stability ±1.1°C in Still Air
Tip Temp. Accuracy Meets or exceeds IPC J-STD-001 Standard
Soldering Iron Cable Length 183 cm (72”), Burn Proof, ESD Safe
Radio Freq.
F-type Power Connector
Soldering Iron Connector
Connectors Power
6 pin DIN
Connector
Touch Screen Monitor

Diagonal Size 396.24 mm [15.6”]
Aspect Ratio 16:9
Native (Optimal) Resolution 1366 x 768
Response Time 10 ms
Computer Vision Camera

Megapixels 3.2 MP
Resolution 2048 x 1536
Power Consumption <3 W maximum
Interface USB 3.0
Witness Camera
Resolution 720 x 480
Power Consumption <1 W maximum
Interface Wire Harness
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Solder Wire Feeder

Solder Feeder Required
Solder Feeder Speed 1.0mm/sec – 50mm/sec
Solder Diameter 0.8mm
Solder Feeder Resolution ± 1.5mm or ± 5% of value (whichever is greater)
Options
Nitrogen Optional, Plumbed
Fume Extraction Optional, Plumbed
Safety Curtain Optional
Ready Indicator Optional
General Requirements
Power Input 115/230 VAC, 200W, 50/60Hz
Operating Temperature 0 – 40 °C
Relative Humidity 20% - 90%, no condensation.
Communication Protocol UART & TTL
Motor driver Integrated

Motor Stepper Motor
Encoder N/A
X, Y, Z 0.01 mm
Resolution Theta
0.01°
(
X, Y 400 mm x 400 mm (±0.02%)
Operation Range Z 100 mm (±0.02%)
300° (±0.02%)
X, Y Up to 100 mm/s Max
Vector Z Up to 80 mm/s Max
Up to 100 °/s Max
Speed Interpolation Z Up to 150 mm/s Max
Up to 150 °/s Max
Space Z Up to 300 mm/s Max
Up to 300 °/s Max
X, Y, Z ± 0.2 mm
Repeatability
± 0.2°
Program Capacity Up to 2100 Programs*
Memory Capacity @ 5,000 Points / Program*
Weight 83 kg
Dimensions (W x D x H) 1055 x 775 x 820 mm (±1%)
Communication Protocol UART, TTL
*Storage can be expanded with the addition of an external flash drive or when connected to a network.
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INTRODUCTION AND GENERAL OVERVIEW
Metcal soldering systems have led the way with SmartHeat® technology for 35 years.
SmartHeat® senses the thermal load and instantly delivers Power on Demand directly to the joint.
The embedded, self-regulating heater delivers the right amount of power based on the requirements
of the solder joint. This provides a fast, safe and repeatable process with no calibration required.
Metcal raised the bar by introducing Connection Validation. Connection Validation evaluates the
quality of the solder joint by calculating the intermetallic compound formation and provides closed
loop feedback to the operator of hand soldering applications.
This systemic and objective approach provides repeatability and a measurable standard to the
soldering process. For this reason, Metcal has raised the bar yet again by incorporating their
revolutionary technology into a robotic platform to provide an automated solution with intelligence.
The Robotic Soldering System with Connection Validation & Smart Interface, or RSS-1000-CVSI for
short, is a desktop robot designed as a rapid, automated solution for soldering applications. The
system is a fully automated, high-precision soldering control system with soldering capabilities in 4
axes (X, Y, Z, & R.) Coupled with Connection Validation, the RSS-1000-CVSI takes the risk
associated with the variables involved in soldering activity and removes the success and failure
determination of a good solder joint out of the hands of the operator.
In addition to Connection Validation, the RSS-1000-CVSI includes Smart Interface System.

The Smart Interface System does away with the archaic programming method of using a teach
pendant and provides an easy to use touch screen interface to program the robot. This in turn cuts
down programming time to a fraction of the time it used to take using traditional methods. To further
ease programming, Smart Interface System utilizes machine vision features to provide operators
invaluable tools such as Fiducial Point Auto-Alignment, Pattern Recognition, and Profile Merging.
Smart Interface System not only provides an arsenal of software tools but also offers
convenient, customizable methods for adjustment of a multitude of parameters within each solder
profile. The Edit Profile function allows for quick modification to a solder profile in a matter of
seconds, minimizing downtime. From adjusting solder wire feed by volume or length to personalized
solder tip cleaning patterns, Smart Interface software allows operators to tailor each profile down to
their individual application’s need.
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SYSTEM ARCHITECTURE
1 17
2 16
15
3 14
7 8 9 10 11 12 13
1 Computer Vision Camera 10 Emergency Stop Button

2 Tip Alignment Fixture 11 Pause Button (N/A)
3 CCD Witness Camera 12 Solder Tip Cleaner
4 Solder Wire Feeder Tube Adjustment Assembly 13 Smart Interface Display
5 Power “On” LED 14 Fume Extraction Tube
6 CCD Camera Power Switch & Lighting Controls 15 CCD Witness Camera Display
7 Main Power Switch 16 Nitrogen Outlet Tube
8 Camera Calibration Fixture 17 Solder Wire Feeder
9 End Effector Cartridge Lock
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18
24
19
30
29
28
20 21 22 23 25 26 27
18 CV Power Supply Power Switch 25 Nitrogen Inlet

19 Monitor Adjustment Thumb Screws 26 CCD Witness Camera 12V Power Connection
20 Controller Box Power Connection 27 Micro HDMI Connection
21 Solder Wire Feeder Connection 28 Ethernet Connection
22 CCD Witness Camera Connection 29 6x USB Connections
23 Inlet Power Connection 30 Communications Cable
24 Nitrogen Air Regulator
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TIPS BEFORE SETTING UP
The unit is very heavy! Please uncrate the unit
with at least 2 people and using best lifting
practices.
DO NOT LIFT THE MAIN UNIT BY THE GANTRY
OR TOP PLATE. LIFTING BY THE GANTRY OR
TOP PLATE MAY DAMAGE THE ASSEMBLY!
Before Setting Up Your Equipment...
• Ensure your Robotic Soldering System has arrived complete
• Provide a location that allows the user to operate this
machine in a comfortable, well‐spaced environment
Every Selective Soldering Robot has been factory
assembled and calibrated.
• Recalibration is not necessary after initial setup.
• Verifying calibration and product functionality is strongly
recommended prior to initial use.
Power‐Up Sequence
• Plug in all harnesses provided with unit.
• Plug in all all power cords provided with unit.
• Once all harnesses have been plugged in, you may power on
unit.
Be Mindful of Lighting!
• Lighting can affect various camera functions within the
software.
• Choose an installation location which will minimize uneven
illumination of a workpiece
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UNBOXING INSTRUCTIONS
1. With proper Personal Protection Equipment (PPE), use an 8mm (5/16”) socket to remove all of the
screws (16X) at the bottom of the crate.
2. With the assistance of a coworker or a mechanical lifting device, carefully lift lid of crate vertically
and evenly using proper lifting techniques.
3. Remove accessory box

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4. Use a spanner wrench to remove the 4X 8mm hex nuts.
5. With the assistance of a coworker or a mechanical lifting device, carefully lift unit off pallet using
proper lifting techniques.
5.1. Warning: Weight of unit is not evenly distributed. The back of the unit is heavier than the
front. Please be mindful of this when lifting.
6. Loosen nuts of unit’s feet to remove shipping brackets.
7. Remove shipping foam from the following locations:
7.1. Top Plate

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7.2. Calibration Slider Block Assembly
7.3. End Effector
7.4. Head/Gantry
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7.5. Connection Validation Housing
7.5.1. Warning: Failure to remove foam from Connection Validation Housing may result
in the overheating of the Connection Validation Power Supply
8. Replace Connection Validation Housing Cover once foam is removed
Unboxing Complete!
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CONTROLLER BOX CONNECTIONS
 
 
 (Optional)
 
(Optional) (Optional)
OPEN
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ROBOT BASE CONNECTIONS
  
 
N₂
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ROBOT GANTRY CONNECTIONS

 *
ROBOT HEAD CONNECTION

*Plug into an external outlet, see next page for instructions

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CV POWER CABLE CONNECTION INSTRUCTIONS
For units all units ordered, regardless of the configuration, please use an external outlet for
powering the CV Power Supply at the rear of the unit. Outlet of which the CV Power Supply is to be
plugged in to will vary depending on region. If unsure of what outlet to use, please contact the
facility’s maintenance department of which the unit is to be installed in for assistance.
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SOFTWARE NAVIGATION
LOGIN SCREEN
Firmware
Version
Software
Version
Power Off Restart

Cancel
Controller Controller
Admin Engineer Operator

Login Login Login
Main
Login/Enter Power
Button
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MAIN SCREEN OVERVIEW
Header Solder Feeder

Advance Bar Options
Camera Profile Options
Tools
Profile
Options
Connection
Validation
Display
Main Toolbar
Menu Bar
Motion
Controls
Global Coordinate
Display
Status
Bar
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MAIN MENU BAR
Main
Menu Bar
Create New
Edit Profile Open Profile Save Profile
Profile
Pause Profile
(Available only
Run Profile Stop Profile Global Settings
after run profile is
activated.)
Eject USB Emergency Stop

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Description of Functions
Function Permissions Description
The Create New Profile function allows the user to create a brand-new
profile. Once this function is activated, the workspace will be cleared of
any unsaved work.
The Edit Profile function allows the operator to modify any existing
profile or the current profile that is being created. Adjustments in the X,
Y, Z, and Theta axes are available. This function allows the user to
edit other parameters such as speed, retract height, and solder feeder
parameters. More details provided in the System Operation section.
The Open Profile function allows the user to open any previously
created profile, either from the on-board memory or from an external
memory device.
The Save Profile function saves all programmed parameters. This

includes all point to point and line soldering commands within the
workspace, solder feeder parameters, desired cleaning profile, go-to
positions, etc.
The Run Profile function will start the profile active in the workspace.
This can be a profile saved on the onboard memory, profile from an
external memory device, or an unsaved work in progress profile.
At any point in time, the user may hit the pause button to stop all robot
movement and maintain its position. Upon clicking the pause button,
the icon will change to the play button again, to be pressed to resume
operation.
The Stop Profile function immediately stops the active profile and
sends the unit back to the home position.
The Global Settings function gives users access to system settings,

camera settings, software updates and debugging support. More
details provided in the System Operation section.
The Eject USB function must be activated to safely remove any

external device. Use of this button aids in the prevention of data loss
or corruption when removing devices.
The E-Stop function is a virtual option of an emergency stop to halt the

unit in its entirety. Unlike the Stop Profile function, the unit will freeze
entirely to allow for the removal of any obstructions or to prevent any
damage to the unit or workpiece. A pop-up will appear noting that the
E-Stop has been activated. This pop-up must be disabled before the
unit returns home.
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HEADER BAR
Header
Bar
Name of Profile CV Cartridge of

Active in Workspace Profile
Profile names and/or status of the profile will be displayed on the left of the header bar.
CV cartridge name and/or status of the cartridge with respect to the profile will be displayed on
the right of the header bar.
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Profile Status Indicators
Profile Display – New Profile Creation
Appears when the Create New Profile function is utilized.
Appears after any points are programmed into a profile.

Upon completion of a run of the profile (live or dry run,) the robot will remain in the X, Y, and Θ
coordinates of the last programmed point but shall move to the upper limit of the Z-Axis.
Profile Display – Open Existing Profile
Appears when an existing profile is opened.

Upon completion of a run of the profile (live or dry run,) the robot will return to the home
position (0,0,0,0 in the X, Y, Z & Θ axes respectively.)
Appears when an existing profile is opened, and changes have been made to the profile.
coordinates of the last programmed point but shall move to the upper limit of the Z-Axis.
Appears when a new profile is saved or when changes have been saved to an existing profile.
coordinates but shall move to the upper limit of the Z-Axis.
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CV Cartridge Status Indicators
RF must be cycled On/Off once in order to activate this feature.
Cycling the RF On/Off initializes the connection between the CV Power Supply and the robot
after a complete power cycle of the unit.
The default state upon bootup or when the new profile button has been tapped.
Appears when RF has yet to be cycled On/Off after a power down or reboot of the system.
The CV Cartridge that was used to program the profile will appear on the right-hand side of the
header bar to notify operators of the correct cartridge for the job.
If the installed cartridge does not match the programmed cartridge, then the display will
highlight the installed cartridge’s name in red, within the CV display (as shown below.)
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PROFILE OPTIONS
Profile
Options
Solder Point
Merge Profile Waypoint (Toggled under
Waypoint)
Solder Line Space Move
Interpolation
(Toggled under (Toggled under
Move
Waypoint) Interpolation)
Undo Waypoint/ Redo Waypoint/

Record Point
Pattern/ Line Pattern/ Line
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Merge profile allows users to insert previously programmed profiles into
a new profile in locations defined by the user.
Waypoints are user defined locations that can be programmed before

or after a solder joint. Typically used to avoid obstacles. When this
icon is active, pressing the record button programs the point saving in
the X, Y, Z, and Theta Axes.
The Solder Point icon appears after one click of the waypoint icon.
When this icon is active, pressing the record button programs the point
saving the location in the X, Y, Z, and Theta Axes.
The Solder Line icon appears after two clicks of the waypoint icon.
When this icon is active, pressing the record button programs the point
saving in the X, Y, Z, and Theta Axes. Two points must be
programmed to form the line.
Interpolation Move is the first of two types of transition movements that

can be selected. A transition movement is the movement that occurs
from one programmed point to another, after the programmed retract
has been completed. Interpolation Move provides the ability to move in
a straight line from the first point to the next. In other words, all axes
will be move simultaneously during the movement. Transition speed
has a max velocity of 150 mm/s. When icon is active, movement
commands on workspace will be executed at this speed setting.
Space Move is the second of two types of transition movements that
can be selected. A transition movement is the movement that occurs
from one programmed point to another, after the programmed retract
has been completed. Space Move allows for a max velocity of 300
mm/s but the path from the first point to the next is determined by the
software and will move in one axis at a time. When icon is active,
movement commands on workspace will be executed at this speed
setting.
Record button is used to program waypoints, solder points, and solder
lines. This saves X, Y, Z, and Θ positions, travel speeds, and the
current solder feeder parameters.
Undo removes the last programmed point or line. There is no limitation

to how many removals the user can do.
Redo replaces the last removed point or line. This can be used as
many times as possible until the last programmed point has been
reached.
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ADVANCE PROFILE OPTIONS
Advance
Profile Options
Set Go-To
Generate Array
Location
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Go-To Location allows users to record any position (X, Y, Z, & Θ)
within the working envelope as a location for the robot to go to after
each profile is complete. Every subsequent profile will start from this
location as well.
The Generate Array function allows users to instantly create an array of
solder points, lines, and waypoints. This function is fully customizable
to allow establishment of array direction, path type, and instance
skipping.
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SOLDER FEEDER OPTIONS
Solder Feeder
Options
Pulse Solder
Pulse Solder
Feeder Test Solder Feed
Feeder Forward
Backward
Solder Feeder Dry Run Toggled Dry Run Toggled

Settings Off On
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Pulses solder forward for the duration of the button press.
Pulses solder backward for the duration of the button press.
The Test Solder Feed button will feed the amount of solder at the
speed that is set in the solder feeder parameters menu.
Solder Feeder Parameters allow users to toggle between feeding

solder by a specified length (in mm) or by volume. When feeding by
volume, the user programs the solder wire diameter used along with
the desired volume and the system automatically calculates the
equivalent solder feed length. This length can then be entered within
the solder feed parameter window. In addition, users can select the
ratio of solder between pre-tin and the solder event, the solder feed
delay, and the speed at which the solder is fed.
Although not directly related to solder feeding, Dry Run is a very useful
tool that not only disables solder feeding but will also disable any
programmed delays, disable the soldering cartridge RF (which in turn
cools the iron,) and disable access to the RF Power On/Off & CV
Settings buttons to prevent accidental powering ON of the iron. This
function is used to test a program to ensure all points have been
programmed to the user’s expectations.
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CAMERA TOOLS
Camera
Tools
Enable/Disable
Take Screenshot
Camera
Open Image/ Pattern

DXF/ Gerber Recognition
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Enables or Disables Camera. The teal icon signifies when the camera
is in an enabled state, the grey icon signifies when the camera is in its
disabled state. Upon shipment or during unboxing, the camera lens
may lose focus. Please refer to the diagram below for focus
adjustment
Takes screenshot of the active work area. This function is only

available once the camera is active. Taking a screenshot can ease the
programming process as it allows the user to program on a still image
rather than on the live camera image. The teal icon signifies when the
function is available (camera in an enabled state,) the grey icon
signifies when the function is not available (camera is in its disabled
state.)
Opens various file types such as .PNG, .DXF, and Gerber files (.ART
file extension). .DXF and Gerber files must be imported whereas
.PNG files can either be created from a screenshot of the workspace
or imported from another unit.
With the camera enabled, Pattern Recognition allows users to select a

desired feature and the system will identify all other similar features
within the viewing area. The user can then insert a pattern on each of
these features if they so choose. The teal icon signifies when the
function is available (camera in an enabled state,) the grey icon
signifies when the function is not available (camera is in its disabled
state.)
Focus Adjustment
Ring
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CONNECTION VALIDATION DISPLAY
Connection
Validation
Display
Tip Cartridge
Installed on Robot Connection
Validation Power
Meter (Watts)
Active Temperature Connection

Display Validation Time-Out
Counter
Proper Grounding Connection Connection

Indicator Validation Status Validation Time-Out
Counter
Toggle CV RF
CV Graph CV Settings
On/Off
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Connection Validation Settings include toggling between the
temperature displayed in either degrees Celsius or degrees Fahrenheit
and toggling the connection validation sound on/off.
Connection Validation Graph button toggles between Net Power Meter

(featured on previous page) and the Power Graph screen. The graph
displays the amount of power (in watts) used over a given time period
(in seconds.) Information displayed includes number of joints soldered
with installed cartridge, peak power usage, current temperature,
cartridge serial number and cartridge lot code (see example below.)
The graph must be toggled on by an engineer or admin, prior to a
profile being run by an operator.
Toggle On/Off radio frequency (RF) current for Connection Validation.

Essentially this will turn the turn the iron on, enabling it for soldering or
put the iron to “sleep mode” when in the off position.
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Connection Validation Graph
Number of Joints
Current Temperature
Soldered with Peak Power on Joint
of Solder Tip
Installed Cartridge
Cartridge Serial Cartridge Production

Number Lot Code
Connection Validation Settings
Celsius Toggled Fahrenheit

Exit
On Toggled On
CV Audio CV Audio Solder Station Solder Station

Toggled On Toggled Off Link Toggled On Link Toggled Off
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Displays the tip temperature in degrees Celsius.
Displays the tip temperature in degrees Fahrenheit.
Exits the screen
Enables Connection Validation audio. Good joints are designated with

a short beep while bad joints are designated with an extended chirping
noise.
Disables Connection Validation audio.
Enables the Solder Station Link feature. When active, the user can
program a delay before any movement commands are executed.
Typically used for tips with a larger geometry, this feature allows for full
and even heat distribution to the soldering tip as well as allowing it to
reach its maximum temperature. The delays can be programmed from
0-10 seconds. A programmed delay of 0 allows for the system to
automatically turn on the iron at the beginning of a profile and
automatically turn it off at the end of a profile.
Disables the Solder Station Link feature. When disabled, the system
will run in its current state. For example, if the RF is turned on, the
program will run with RF on. If RF is turned off, the program will run
with a cold iron.
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TOOLBAR
Toolbar
Motion Control
(Fine & Coarse
Absolute Position Home Speed Settings
Adjustment
Toggle)
Tip Cleaning
Offset Camera Zoom Nitrogen
Parameters
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Motion control main menu is a directional pad for jogging and coarse
adjustment. The button can be toggled for user defined fine
adjustment. The icon will become gold when the menu is active, grey
when another menu is active.
Allows users to move to an absolute position as defined by user. If

pressed at any position other than the home position, the current
coordinates will be populated within their respective axes.
Sends end effector to home position (0,0,0,0) or in other words, the

end effector fully retracted into the head, the head positioned to the left
of the gantry, the top plate positioned in the forward position, and the
end effector graduation marks facing the operator.
Speed settings allow the user to customize speeds for each axis.
1-100 mm/s for the X & Y axes and 1-200 mm/s for the Transition
speed. The Z-axis to a maximum of 1-80 mm/s & Θ can be adjusted
from 1-100°/s. The icon will become gold when the menu is active,
grey when another menu is active. If the system does not detect any
mouse movement for 10 seconds, the system will default to the motion
control main menu.
Offset allows users to offset any previously programmed profiles in the

X, Y, and Z axes. This offset will shift the entire program in the axes
specified.
Tip cleaning parameters consist of tip cleaning movement profile, dot

cleaning interval, line solder cleaning interval, and cleaning profile start
location. The icon will become gold when the menu is active, grey
when another menu is active.
Camera zoom menu allows users to digitally zoom up to 3X the original

image size. There is a directional pad for image adjustment, and a
restore button to revert to 1X zoom.
Nitrogen button toggles the flow of nitrogen on and off when nitrogen is
connected to the unit (sold separately.)
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MOTION CONTROL
Motion
Controls
Jog Top Plate

Jog Head Left Jog Head Right Jog Top Plate Up
Down
Rotate Counter Jog End Effector Jog End Effector

Rotate Clockwise
Clockwise Up Up
Θ Quick-Snap: Θ Quick-Snap: Θ Quick-Snap: Θ Quick-Snap:

0° 90° 180° 270°
Z-Limit Up Z-Limit Down

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Jogs head left. This is a coarse adjustment and the distance travelled
is dependent on the speed settings and how long of a button press
occurs.
Jogs head right. This is a coarse adjustment and the distance travelled
is dependent on the speed settings and how long of a button press
occurs.
Jogs top plate towards user. However, with the camera activated, it
will appear as though the end effector is moving up the workpiece.
This is a coarse adjustment and the distance travelled is dependent on
the speed settings and how long of a button press occurs.
Jogs top plate away from user. However, with the camera activated, it
will appear as though the end effector is moving down the workpiece.
This is a coarse adjustment and the distance travelled is dependent on
the speed settings and how long of a button press occurs.
Rotates end effector clockwise. This is a coarse adjustment and the

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

and the distance travelled is dependent on the speed settings and how
long of a button press occurs.
Jog end effector up. This is a coarse adjustment and the distance
travelled is dependent on the speed settings and how long of a button
press occurs.
Jog end effector down. This is a coarse adjustment and the distance
travelled is dependent on the speed settings and how long of a button
press occurs.
The Z-Limit Up function automatically drives head to the 0mm position.

This function can be utilized to solely drive up to the 0mm position
without moving in any other axis.
The Z-Limit Down function automatically drives head to the user-

defined Z-Limit. This function can be utilized to immediately drive
down to the fixture height without any further commands. This
command should be used with CAUTON in order to avoid
accidental crashing of the end effector.
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Θ Quick-Snap rotates end effector to the 0° position. 0° is defined as
the position in which the end effector graduation marks are visible to
the operator. This is an absolute command, or in other words, will
automatically rotate to the 0° position, regardless of its current position.
Θ Quick-Snap rotates end effector to the 90° position. The 90° position
is counterclockwise to the 0° position. This is an absolute command,
or in other words, will automatically rotate to the 90° position,
regardless of its current position.
Θ Quick-Snap rotates end effector to the 180° position. The 180°

position is counterclockwise to the 0° position. This is an absolute
command, or in other words, will automatically rotate to the 180°
position, regardless of its current position.
Θ Quick-Snap rotates end effector to the 270° position. The 270°

position is counterclockwise to the 0° position. This is an absolute
command, or in other words, will automatically rotate to the 270°
position, regardless of its current position.
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REMAINING MENUS/ BUTTONS
Programmed Pts
Loading Icon
Global Coordinate
Display
Status
Bar
Y-Axis Position Z-Axis Position
X-Axis Position Θ Position
Sticky Note
Unit Status
Log Out Permission Level Time Firmware Version
Manual Current User Software Version

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Description of Privileges
Admin - Tapping on the icon brings up the Administrative Menu. Privileges

include: Add/Delete Users, View All Users, Login History, Time Zone Settings, and
Reset to Factory Defaults
Engineer/Operator - Tapping on the icon brings up the Change Password Menu.

This menu allows the user to change password as needed.
Sticky-Note Tool
The Sticky-Note tool is a convenient method of communication between users for the Robotic
Soldering System. This can be used to pass messages between users from one shift to the next, for
instructions from engineer to operator, to notify an operator that the unit is being accessed remotely,
or simply a safety reminder from management to the operator. When not in use, the icon resides in
the bottom right of the screen. To access the Sticky-Note tool, simply tap on the icon within the
Status Bar to bring up the Sticky-Note pad. This same action can be used to hide the Sticky-Note
when not in use.
Tap on the enlarged Sticky-Note pad to bring up the keyboard and begin typing the desired
message.
The intended use for this tool is for short, concise messages. Words cannot be longer than 14
characters long. A space is required after 14 characters for word wrap to function. The Sticky-Note
tool allows for around 14 characters per line (including spaces) for a total of six lines. These values
may slightly vary, depending on the characters used, number of capitalized letters within the word,
etc.
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SYSTEM OPERATION
POWERING UP THE UNIT
1. Verify installation location meets system general requirements.

1.1. Reference specifications.
2. Verify all cables have been plugged into the appropriate locations.
2.1. Reference System Architecture, Controller Box Connections, and Robot Base Connections for
cable routing locations.
3. Follow all safety and regulatory information.
4. Plug in IEC 60320 C-13 connector into its corresponding receptacle.
5. Toggle the power switch to the “ON” position
ON
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POWERING OFF THE UNIT
1. Tap the Logout button

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2. Tap the Power Button

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3. Tap the Power Off Button.
4. Once the screen has gone black, signaling that the system has shut down, toggle the main power
switch to the “OFF” position.
OFF
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REBOOTING SOFTWARE
1. Tap the Logout button

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2. Tap the Power Button

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3. Tap the Restart button
The system will reboot, returning to this screen upon completion.

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LOGGING IN TO SOFTWARE
1. Power-On unit.
2. Once the main screen has booted up, tap on the icon for the appropriate permission level
2.1. There are three levels of permissions: Admin, Engineer, and Operator.
Admin Engineer Operator

Login Login Login
2.2. Admin
2.2.1. Unlimited access to features with the sole ability to add/remove users, view login
history, change system time zone, reset factory settings and revert to factory settings.
2.2.2. *Note*: Only one admin allowed per system.
2.3. Engineer
2.3.1. Unlimited access to all features with the exception of admin privileges (see 2.2.1).
2.3.2. Can create a custom password/ change password.
2.4. Operator
2.4.1. Can open, start, and stop a profile. In addition, operator can open manual, press the
emergency stop, use the sticky note feature, as well as eject USB’s.
2.4.2. Can create a customer password/ change password.
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3. After tapping on the icon, tap the white space to bring up the keyboard to type in the password.
4. Upon initial startup, there will only be an Admin Login available. The Password for the Admin
Login is 1000. This password can be changed after initial Log in*.
*Note: In the event the Admin forgets their password, contact the Metcal™ Technical Service Department for a
password reset.
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5. After the password has been entered, tap to complete log in.
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UPDATING SOFTWARE
Periodically, Metcal™ will provide software updates for the RSS-1000-CVSI via the Software
Download Section of the company website, found at the following link:
http://www.okinternational.com/metcal/english/globalnavigation/resources/software-download
Complete the following steps to successfully update the Smart Interface Software to the latest
revision.
1. Navigate to the Solder Robot Section of the Software Download Page at the link previously
provided.
2. Download the software.
2.1. The file is downloaded within a Zip File
3. Extract the file: okirobot
4. Copy the file to the Main Directory of a flash drive
5. Eject the flash drive from the computer.

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6. Insert flash drive into an available USB port on the rear of the controller box at the rear of the unit.
7. Tap the Global Settings Button

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8. Tap the Software Update Menu
9. Tap the USB icon next to Update Application (USB) to update the software
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9.1. Tap Yes on the Prompt
9.2. Note the screen will turn white and the system reboot.
10. Upon bootup, confirm the version number displayed matches that which is shown on the website
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11. Tap on the appropriate permission and enter password. After password has been entered, tap
to proceed with log-in.
12. Tap to eject USB.

Software Update Complete!
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UPDATING USER MANUAL
Periodically Metcal™ will create updated user manuals to that will correspond with software
updates, typically detailing new/improved features made in the software for the RSS-1000-CVSI.
Please note that a new manual may or may not be released with each new version of software that is
released.
The latest manuals can be downloaded via the User Manual Download Section of the
company website, found at the following link:
http://www.okinternational.com/metcal/english/globalnavigation/resources/user-manuals
Although not required, the user manual can then be uploaded to the unit for an environmentally
friendly way to access the manual. Complete the following steps to successfully update the User
Manual for the Smart Interface Software to the latest revision.
1. Navigate to the Solder Robot Section of the User Manual Download Section at the link previously
provided.
2. Download the software.
2.1. The file is downloaded within a Zip File
3. Extract the file: UserManual.pdf
4. Copy the file to the Main Directory of a flash drive
5. Eject the flash drive from the computer.

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6. Insert flash drive into an available USB port on the rear of the controller box at the rear of the unit.

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8. Tap the Software Update Menu
9. Tap the USB icon to next to User Manual Update (USB)

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10. Tap Yes on the Prompt
10.1. Tap the user manual button to confirm the update has taken place.
10.2. If the following message displays, check to make sure the USB is completed seated
within the controller box and redo steps 7-10
User Manual Update Complete!

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SAFETY FEATURES
Z‐LIMIT SAFETY
The Z-Limit Safety is a user-defined feature that will prevent the robot from going below a
designated height. This feature is used to prevent crashing and causing damage to PCBA’s,
soldering cartridges, the robot, and most importantly, the customer. The Z-Limit Safety function will
prevent the user from using any of the motion controls to go beyond this point. The default setting is
for 100mm, or in other words, the full range of travel in the Z-Axis. Values are calculated from the
home position. The home position for the Z-Axis is the location when the end effector is fully
retracted into the head. Therefore, any measurements should be with respect to the home position.
Values set DO NOT correlate to a given height off the board. Complete the following steps to set
the safety limit.
1. Tap the Global Settings button
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2. Tap the System Settings Menu
3. In the last row of the menu, tap the yellow box next to Z-Limit
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4. Input the value in millimeters.
4.1. In this example, the value was set at 45 mm. This means that the software will prevent any
travel that is greater than 45 mm in the Z-Axis from the home position (see diagram below.)
45mm
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4.2. This in turn would mean there is a 55mm clearance from the board.
4.3. If unsure of what height to set for the Z-Limit safety, complete the following steps. Otherwise,
skip to step 5.
4.3.1. Install PCBA fixture onto top plate in a desired location.
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4.3.2. Install PCBA onto fixture.
4.3.3. Using the jog controls, jog to an open location on the PCBA, clear of any leads.
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4.3.4. As the soldering cartridge nears the PCBA, switch from coarse to fine movement by
tapping the motion controls button once to toggle to fine movement.
4.3.5. Adjust the value of each fine adjustment movement to 0.10mm in the X, Y, and Z
directions by tapping the box in between the arrows to bring up the keypad and entering
the value.
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4.3.5.1. Please note that these values are not required and can be adjusted as needed.
They will however minimize the chance of inadvertent crashing of the board.
4.3.6. Carefully drive the end effector down to the board until the tip slightly contacts PCB.
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4.3.7. Record the Z-Value listed in the Global Coordinate Display
4.3.8. Then complete steps 1-4 from this procedure, using the value recorded in step 4.4.7.
4.3.9. Please note that the accuracy of this information is dependent on the fixture that is used
in these steps and can vary due to machining tolerances, variations in board height,
flatness of the fixture surface, among other factors. Please consult ASME Y14.43-2003
when designing a fixture for design rules and assigning the appropriate tolerances. For
design constraints of fixture design associated with the RSS-1000-CVSI, please refer the
Camera Calibration section of the manual.
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5. Once the desired value has been entered, tap the Enter button to clear the keypad
6. Tap the Close button to save the new Z-Limit value and exit the global settings menu.
Z-Limit set! This value can be changed at any time at the Admin and Engineer permissions levels.
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CLEARANCE HEIGHT SAFETY
Where Z-Limit is used to prevent crashing in the Z-Axis, Clearance Height is a user-defined feature
set to prevent collisions in the X and Y-axes during programming of the RSS-1000-CVSI. The
system’s touchscreen is extremely responsive and the slightest brush of skin or conductive rubber on
the work area on the screen will send the robot moving to that location. For this reason, the
Clearance Height Safety function has been made available. When set, any command to move via
touch on the work area will result in the system driving up in the Z-Axis before executing any
commands in the X and Y-axes. The system default is 0mm, meaning the unit will drive all the way
up before moving in the X or Y-axes. The system will then remain at this height until the user sends a
command to move down to a desired height. Please note that values are calculated from the home
position. The home position for the Z-Axis is the location when the end effector is fully retracted into
the head. Therefore, any measurements should be with respect to the home position. Values set
DO NOT correlate to a given height off the board. In addition, please note that this feature will only
prevent collisions resulting from inadvertent touches to the work area. This feature will not prevent
collisions that can occur from the following:
 Deliberately tapping and holding of jog commands, driving end effector into object.
 Setting a fine adjustment value larger than what is required.
 Selecting an absolute move coordinate in which the resulting vector passes through an object.
 Creating an offset to an existing profile that offsets the profile on top of an object.
 Any collision as a result of an incorrect orientation (theta value.)
 Or any other movement command other than tapping on the workspace.
Complete the following steps to set the Clearance Height:
1. Tap the Global Settings button
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2. Tap the System Settings Menu
3. In the second to last row of the menu, tap the yellow box next to Clearance Height (Touch Screen)
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4. Input the value in millimeters.
4.1. The default Z-Limit is 0mm or in other words, the end effector fully retracted up into the head.
5. Once the desired value has been entered, tap the Enter button to clear the keypad
6. Tap the Close button to save this value and close the Global Settings menu.
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6.1. In the event one wishes to turn this feature off, one may do so by tapping the check mark.
6.2. Followed by tapping the Close button.
Clearance Height Set!

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CONNECTION VALIDATION (CV) SAFETY FEATURES
In addition to the collision protection features previously listed, the Smart Interface System also
provides built-in features that protect users from accidental burns from the soldering iron as well as
prolong tip life. A built-in feature means that no activation is required by the user!
CLEAR INDICATORS RADIO FREQUENCY IS ACTIVE
The default state of the Robotic Soldering System is with the Radio Frequency (RF) in the off
position. In other words, the soldering iron is in a cool-to-the-touch state. The CV Display should be
displayed as shown below.
When the iron is active, the CV display brightly and boldly displays that the RF button is
illuminated in an eye catching green, signifying RF is in the ON position, the Power Bar meter is
displayed as well as the current temperature, as shown below:
This will let users know from a distance that the iron is hot and to take the necessary
precautions (PPE, avoiding hot surfaces, etc.) when operating around the unit.
AUTOMATIC RF ACTIVATION/DEACTIVATION
When running a profile, RF will automatically turn ON at the beginning of a profile and turn
OFF at the close of a profile. This not only protects the user from burning themselves when operating
on the unit when the robot is not in use, but it also extends the life of tip cartridge by minimizing
oxidation. This also is a built-in function, requiring no activation from the user.
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In addition, the Smart Interface System will automatically deactivate RF when any of the
following functions are utilized by the user:
Home
New Profile
Stop
Emergency Stop
Furthermore, upon logging out of the software, the system will automatically deactivate RF.
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SAFETY COVER INSTALLATION & ACTIVATION
Metcal™ offers the 1000 Safety Cover accessory or AC-RSS-1KSC as a means of both
protecting operators from accidents and protecting the Robotic Soldering System from environmental
obstructions. The AC-RSS-1KSC encloses the Robotic Soldering System in acrylic, allowing for
maximum visibility of the unit at all times while preventing unintended access. The front of the system
is open for operator access to the unit but is protected with a light curtain. This curtain emits an
infrared light beam across the opening that is always active. When this beam is broken, all motion
will be stopped immediately. This would be similar to the behavior of activating the emergency-stop
button. The system will remain in this suspended mode until the beam is no longer broken and the
emergency-stop pop-up message is cleared.
In addition, the bottom of the rear panel is open for cable routing access. Lastly, there is an
access hole on the right-hand side of the unit for emptying the solder cleaner tray and an access door
for tending to the solder feeder. The door comes with a locking mechanism to further prevent
unintended access to the solder feeder and spool to prevent theft or injury.
When equipped, the following will describe the components of the Safety Cover, as well as
procedures on how to install and activate the Safety Cover after installation.
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COMPONENTS OF AC‐RSS‐1KSC
1 13
12
2
11
10
3 9
6 8
4 5
7
Item Description
2 Light Curtain Transmitter

3 USB Extension
4 Locking Bar
5 Light Curtain Receiver
6 Splice Box
7 3’ RCA Extension Cable
8 DC Power 2.1MM Barrel Plug Extension
9 Monitor Mounting Hardware
10 Solder Tip Cleaner Tray Access Hole
11 Extension Cable Access Hole
12 Light Curtain Relay
13 Solder Wire Feeder Access Door
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SAFETY COVER INSTALLATION
WARNING: Do NOT attempt to install cover alone. Ask a coworker for

assistance and use proper lifting techniques.
1. Power down both monitors.

2. Unplug all wires from both monitors.
3. Cut all cable ties at the base in the back of the unit.
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4. Remove HDMI cable from spiral wrap.
5. With one hand securing the monitor assembly in place at the bottom of the monitor arm mount,
remove the bottom M5 socket head cap screw from the monitor arm mount.
5.1. Warning: The monitor arm mount may swing, depending on the weight distribution.
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6. Loosen the thumb screw of the touch screen monitor and carefully slide the arm toward the
bottom of the monitor arm mount.
7. Repeat this process for the CCD Witness Camera Display.

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8. With both monitor arms removed, remove the remaining M5 socket head cap screw from the
assembly and place the monitor arm mount to the side.
9. Unbox the AC-RSS-1KSC.

9.1. When choosing an install location, it is best to choose a location in which there is limited to no
access to the rear of the unit, such as against a wall. This is a safety precaution to prevent
operators from bypassing the safety cover and accessing the robot.
10. Install the USB Extension Cable (Item 3) using the two 4-40 x 3/16” long screws provided.
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11. Unplug the Controller Box Power Cable from the back of the unit.
12. Plug the Splice Box in its place.

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13. Plug the Power Cable that was removed in Step 8 into one of the two DIN connectors on the
Splice Box.
14. Remove screws and cable clamps from the rear of the left gantry arm when facing the rear.
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15. With the assistance of a coworker and/or a crane, lift the cover over the unit, with the opening
towards the front of the unit
15.1. The opening is designated by the side with the two light curtains mounted to the left and
right.
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15.2. If necessary, use an M4 hex key to loosen the frame locking bar and slide rail forward. This
crossbar is used as a method from preventing operators from sliding the cover forward to
access the unit. For this reason, limit the amount of adjustment in the crossbar as much as
possible.
16. Plug in Safety Cover cable to the remaining DIN connector of the Splice Box
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17. Route Cables from Step 11 through mouse hole on the right side of the safety cover.
18. Connect the RCA and DC Power extensions to their respective cables.
19. Adjust Monitor Mounting Hardware to the desired height with a distance between fasteners to be
about 245mm (9.65”) apart.
245mm
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20. Remove fasteners and mount the aluminum extrusion to the top spring nut.
21. With one hand securing the extrusion, slide the CCD Monitor Arm into the extrusion, twisting the
thumbscrew clockwise once in place.
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22. Use the same process in the previous step for the touch screen monitor arm.
23. Replace fastener for the bottom spring nut and torque once in place.
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24. Route the cables through the monitor cable clips.
25. Reconnect all cables.
26. Plug in USB extension.
Safety Cover Installation Complete!

Note: Safety Cover Activation MUST be completed for Safety Cover to become functional.
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SAFETY COVER ACTIVATION
Now that the Safety Cover has been installed, please use the following steps to activate the safety
cover within the software.
1. Once the Safety Cover has been installed, turn on system.

2. Log-In Under Either Admin or Engineer
2.1. Operators do not have access to the Safety Cover activation for safety purposes.
3. Tap to enter.
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4. Tap the Global Settings menu
5. Tap the System Settings menu

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6. Tap next to Enable Safety Light Curtain
6.1. Please note that if this function is activated with no Safety Cover connected, the following
message will appear. Administrators and Engineers will be able to navigate to the menu to
turn off the message, but Operators will not have access. If an operator is logged in, they
must reboot the system and an Administrator or Engineer must then log-in and disable the
Safety Cover.
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7. Tap Close
8. The Safety Curtain has now been activated. If the Light Curtain’s infrared beam is ever broken,
the system will cease movement and a pop-up message will appear as shown below. Once the
beam is cleared, the message may then be cleared by tapping OK and the system will can now
resume.
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CHANGING PASSWORD
Note: This procedure will apply to all permissions levels.
1. After logging in, tap the Permissions Identifier Icon in the bottom right corner.
1.1. In this example, a user with Admin permission will be used.
2. Tap on the white space to the right of Enter Current Password

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3. A keyboard will pop up at the bottom of the screen. Type in the current password.
4. Tap on the white space to the right of Enter New Password and enter a new password
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4.1. Passwords must be 4-10 characters in length.
4.2. Passwords are case sensitive.
4.3. It is recommended to include numbers, lowercase and uppercase letters.
5. Tap on the white space to the right of Confirm New Password and re-type the password entered in
step 4
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6. Tap the button to save the password change.
7. A confirmation message will appear if the password change was successful.

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ADDING NEW USER
Note: This function can only be completed at the Admin permission level.
1. After logging in under admin, tap on the admin icon in the bottom right corner.
2. Tap on the Add User menu

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3. Tap on the white space to the right of User ID
4. Enter User ID
4.1. User ID must be between 3-7 characters including spaces.
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5. Tap on the white space to the right of Password to create the user’s password
5.1. User’s password must be between 4-10 characters in length.
5.2. Passwords are case sensitive.
6. Retype password in the white space to the right of Confirm Password to confirm password.
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7. Tap on the yellow box to the right of Class Type to open the dropdown menu
7.1. The two choices for Class Type are:
7.1.1. Engineer
7.1.2. Operator
7.1.3. Permissions for each class type are described in the Software Navigation section of this
manual.
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8. After the Class Type is selected, tap on the button to complete the addition of the New
User
8.1. If the rules for user password is violated, the following message will appear:
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8.2. For passwords that do not match, the following screen will appear:
8.3. A successful addition of a new user will yield the following message:
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DELETING USER
Note: This can only be done at the admin permission level.
2. Tap on the Delete User menu

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3. Tap on the white box next to User ID
4. Type in the User ID that is to be deleted

4.1. The User ID must be typed in EXACTLY as it is listed within the software, otherwise the
following message will appear:
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4.1.1. To verify a User ID’s exact characters, tap on the List Users Menu
4.1.2. Tap on the yellow box to the right of the type of User Permission level to open the drop-
down menu listing all users under the desired permission level.
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5. Return to the Delete User menu and tap the to confirm deletion of user.
5.1. A confirmation message will appear when the User is successfully deleted
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VIEWING USER LOGIN HISTORY

2. Tap on the Login History menu

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3. Login History will display the User ID, Login Time, and Logout Time for the last 5 users.
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CHANGING TIME ZONE
Notes:
 This can only be done at the admin permission level.
 This will affect the unit’s clocks on both the home screen and operating screen.
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Time is adjusted via Coordinated Universal Time (UTC.)
2. Tap on the Time Zone menu

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3. Tap on the Yellow Box to the right of Select Time Zone to expand the dropdown menu.
4. Select the time zone that corresponds to the unit’s location

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4.1. Consult a UTC chart for the appropriate UTC setting.
5. Tap the button to register the time zone change.
6. Tap Close to complete.

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CLEAR PATTERN PARAMETERS
2. Tap on the Factory Settings menu

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3. Tap on the button next to Reset Pattern Parameters
4. Tap Yes to Proceed with resetting unit back to factory default parameters.
4.1. Tap No to cancel.
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5. Tap on the Logout button
6. Tap the Power button

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8. Once the system has rebooted, it will have cleared all parameters created by the user, leaving
only the default pattern parameters.
Parameter Reset Complete!

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RESET TO FACTORY SETTINGS
2. Tap on the Factory Settings menu

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3. Tap on the button next to “Reset Pattern Parameters”
4. Tap “Yes” to Proceed with resetting unit back to factory default settings.
4.1. Tap “No” to cancel.
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5. Tap on the Logout button
6. Tap the Power button

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8. Once the system has rebooted, the settings will have reverted to their original factory state.
IOT SETTINGS
IOT or better known as Internet of Things is the network of physical devices embedded with
electronics, software, sensors, actuators, and connectivity which allows for these devices to connect
and exchange data. Metcal™ is excited to announce that it will be rolling out more and more
products integrated with IOT to allow for better Process Control & Traceability, Training Purposes,
and Troubleshooting. Unfortunately, this is still under development at this time but please check back
for the next software update to include IOT!
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PROFILE MANAGEMENT
PROFILE CREATION
To create a profile, simply tap the Create New Profile button on the Main Menu Bar
Main
Menu Bar
The system will automatically clear the workspace of any previously programmed points and
drive to the Home Position (head driven to the left of the gantry, top plate driven closest to the user,
end effector retracted into the head and with the iron facing left.)
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SAVING A PROFILE
The system is not equipped with an auto-save function and therefore it is a good idea to save
one’s work periodically throughout the programming process. Complete the following steps to save a
profile.
1. Tap the Save icon to open the file management system.
2. Type out the desired File Name

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3. Tap the Save Profile icon.
Profile Saved!
1. In cases in which the user is saving progression, use the following steps:
1.1. Tap the name of the active profile to highlight the profile
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1.2. Tap the Save Profile icon.
1.3. Tap Yes to Proceed with the Changes

1.3.1. Tap No to cancel
Progression Saved!
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SAVING PROFILE TO EXTERNAL USB DEVICE
The RSS-1000-CVSI offers over 9.5 GB of data storage with all systems to store profiles,
images, etc. However, for some users, this may not be enough space. For this reason, the system is
equipped with several extra USB ports that can be used for expandable memory, among other
devices. Complete the following steps to save the profile to an external device.
1. Plug in the external USB device into an available USB port on the rear of the controller box at the
rear of the unit.
2. Wait around 5 seconds for the system to recognize the device.
3. Tap the Save icon to open the file management system

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4. Enter the desired File Name
5. Tap the USB icon to indicate to the system that the file is to be saved to the external USB device.
6. If the profile is to be saved to a particular directory within the external device, tap the directory in
which the profile is to be saved, otherwise proceed to the next step.
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7. Tap the Save icon.
Profile Saved to an External Device!

PROFILE REMOVAL

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1.1. The one of the two following Pop-up Menus will appear
Available
Main
Folders
Directory
(Internal)
Save
Image
Delete
Folder/
Image
Cancel
Profiles
Create
Folder
Without External Memory

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File
Available Main Available Main
Transfer
Folders Directory Files Directory
Button To
(Internal) of Robot (External) of USB
USB
Save
Image
Delete
Folder/
Image
File
Transfer
Button
From USB Cancel
Create
Folder
With External Memory

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2. Tap on the name of the profile that is to be removed
2.1. The name will become highlighted with a blue ribbon once selected
3. Tap the Delete Icon to permanently remove the profile.

3.1. WARNING: This action CANNOT BE UNDONE. Please take careful consideration before
removing a profile.
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4. Tap the Exit icon to leave the file management screen.
Profile Successfully Removed!
FOLDER CREATION
The Smart Interface System allows for the creation of folders to better assist user in organizing
their profiles per the job, customer, operator, type, etc.
Pro Tip: Although not required, Metcal™ recommends adding the following folders for
frequently used file types:
Solder Profiles
Templates
Layouts
TCP
o TCP stands for Tip Cleaning Profiles
Complete the steps on the next page to create a new folder.

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2. Enter the name of the folder that is to be created

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3. Tap the Create Folder icon.
3.1. Note: Folders cannot have the same name as any previously created folder at the same level
within the directory. If this occurs, the following message will appear:
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4. Repeat Steps 2 & 3 until all desired folders have been created.
4.1. To create a subdirectory, tap the arrow to the left of the folder icon to expand its contents
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4.1.1. Note: If the directory is empty the arrow will face down and the folder will appear in an
opened state, but no file names will appear beneath it.
4.2. Tap the folder to ensure it has been selected

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4.3. Enter the name of the subdirectory and tap the Create New Folder icon
5. Once all files have been created. Tap the Exit icon
Folder Creation Complete!

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FOLDER REMOVAL

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2. Tap the name of the folder that is to be removed
2.1. The name will become highlighted with a blue ribbon once selected
3. Clear all contents within the folder.

3.1. Note: This action CANNOT BE UNDONE. Please take careful consideration before removing
any profile or subdirectories.
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4. Once all contents have been removed, tap the Delete Icon to permanently remove the icon
4.1. If any profiles or subdirectories remain, the following error message will appear. This is done
as a safeguard of accidentally an entire folder’s contents
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5. Tap the Exit icon to leave the file management screen.
Profile Successfully Removed!

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CONNECTION VALIDATION VS STANDARD SOLDERING
WHY USE CONNECTION VALIDATION?
A Revolution in Soldering Starts with a Single Joint. Metcal’s exciting newest technology,
Connection Validation (CV) is integrated into the Robotic Soldering System. CV reduces solder joint
defects by validating the intermetallic compound (IMC) formation in a soldered joint and reduces
unnecessary dwell time by signaling to the system to move to the next solder joint in the automatically
after a good joint is formed. CV Soldering Cartridges work in conjunction with SmartHeat® and
patented Chip in Cartridge technology. The time on each solder joint is calculated dynamically
based on the CV algorithm rather than a preset dwell time. This in turn will reduce solder joint defects
and lead to an improvement in quality while also mitigating risk. In addition, the Chip in Cartridge
technology precisely calculates and displays tip temperature on a large color display, improving audit
compliance.
FLOW CHARTS OF SOLDERING PROCESSES
When determining which process, CV or Standard Soldering, is best for a given application, it
is best to understand the process flow for each process during a soldering event. Below are two
diagrams which breakdown when each of the settings within each process are used.
Typical CV Application
Tip at Joint Head Retracts

Pre-Feed Post-Feed
from Joint
Start Delay Feed Delay Time Based on

(From Dot Parameter (From Solder Feeder Connection
Settings) Settings) Validation*
Time
Typical Non-CV Application
Tip at Joint Head Retracts

Pre-Feed Post-Feed
from Joint
Start Delay Feed Delay Dwell Time

(From Dot Parameter (From Solder Feeder (From Dot Parameter
Settings) Settings) Settings)
Time
*Max Time is set by CV Timeout Within the Global Settings Menu

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CV TIP SELECTION
Choose a tip that maximizes contact area between the solder joint and tip. Maximizing
contact area gives the most efficient heat transfer, producing high quality solder joints quickly
and efficiently.
Choose a tip that allows good access to the solder joint. Shorter tip lengths allow for quicker
response. Longer or angled tips may be needed for soldering densely populated boards.
Pick the lowest temperature cartridge that will accomplish the task. Doing so will minimize the
potential for thermal damage.
CV STATE CODES
To better assist users in understanding what is occurring during each solder joint, process
codes are provided in the top right corner of the CV display, as indicated by the arrow.
Please note that when CV is deactivated, the code displayed is OFF.
Below are the definitions for each process code:

RD – Ready
 RD indicates that CV is ready to process information on the next joint.
ST – Start
 ST indicates that the system has detected the start of a solder event
PS – Pass
 PS indicates a successful validation of the IMC at the given joint.
AB – CV Abort
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 AB indicates that the CV calculation has been aborted, or in other words, the IMC
could not be properly formed and thus a failed joint. This can occur for the
following reasons:
1. Insufficient solder
2. Solder tip is not in contact with the pad and/or lead
3. Incorrect soldering cartridge for the application.
TE – CV Thermal Efficiency Failure

 TE indicates that the CV calculation could not be performed due to an issue with
thermal efficiency. In other words, the tip chosen for the job cannot provide
enough of a thermal load to provide a sufficient IMC.
TO – CV Timeout Failure
 TO indicates that the iron has remained on the joint for at the programmed CV
timeout setting and will result in an abort.
ER – Unexpected Error
 ER indicates a catastrophic error with the CV Power Supply.
 The possibility of seeing this error is a very rare occurrence. However, in the
event this error is seen, contact the Metcal Technical Services department
(information found in the back of this manual.)
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SOLDER PARAMETERS AND SETTINGS
SOLDER POINT
1. Tap on the Waypoint button once to toggle to Solder Point.

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2. Select desired Solder Point parameter by scrolling through the parameter list. This can be done
by swiping up or down within the gray parameter box until the desired Solder Point parameter is
highlighted by the yellow band. Once highlighted, the parameter will register as the selected
parameter for programming and any subsequent points programmed will follow the settings within
the highlighted Solder Point parameter.
3. Select desired Transition Movement that is to be exectuted from point to point. For more details
on the differences between Transition Move and Space Move, please refer to the Profile Options
section of the manual. Once selected, the setting will be used for programming and any
subsequent points programmed will follow suit, until the setting is changed. The system allows for
profiles to have a mixture of Interpolation and Space moves. Use of one or another is application
dependent.
3.1. Pro Tip: Programming with Space Move runs the unit at very high speeds. Mistakes made
during programming at this speed can lead to longer downtimes for machines. For this
reason, good practice is to initially program using Interpolation Move. Once the profile has
been tested and deemed satisfactory, the profile can then be optimized for speed by switching
points to the Space Move within the Edit Menu.
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4. To create a new Solder Point parameter, tap the Parameter Table Button , otherwise skip
to Step 5
4.1. To add a new parameter, tap the “Add” button.

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4.2. To change the values of any parameter, tap on the black input fields to the right of each
setting within the parameter.
4.3. The system will have a default Dot Parameter with the following values:
3.4.1 3.4.2 3.4.4 3.4.3
4.4. Below is a description of each of the variables within the Parameter Edit screen:
4.4.1. Name
4.4.1.1. Identifies each parameter added.
4.4.1.2. Alpha-numeric keyboard available for an extremely wide range for profile names.
4.4.2. Style
4.4.2.1. Defines whether the parameter under editing is a Dot (Solder Point) or Line
(Solder Line.)
4.4.3. Start Delay
4.4.3.1. Defines how long the soldering iron is to remain on a joint before a pre-feed of
solder takes place. This is done to warm up the lead or object to be soldered.
4.4.3.2. Used when Connection Validation is turned off.
4.4.3.3. Unit of measurement is in milliseconds
4.4.4. Stop Delay
4.4.4.1. Defines how long the iron is to remain on a joint after the post feed of solder has
occurred.
4.4.4.2. Used when Connection Validation is turned OFF.
4.4.4.3. Unit of measurement is in milliseconds.
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3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10
4.4.5. Max Speed

4.4.5.1. Defines the velocity at which the retract height is reached.
4.4.5.2. Unit of measurement is millimeters per second ( )
4.4.6. Acceleration
4.4.6.1. Defines the acceleration at which the retract height is reached.
4.4.6.2. Max Acceleration of 500 is permitted.
4.4.6.3. Unit of measurement is millimeter per second squared ( )
4.4.7. Retract Height
4.4.7.1. Defines the distance from the solder joint the soldering iron will retract in the Z-
Axis before moving in the X, Y, or Θ axes.
4.4.7.2. Used to clear any obstacles of nearby components or other features that may
lead to crashing of the soldering iron/ end effector.
4.4.7.3. Unit of measurement is in millimeters.
4.4.8. Save
4.4.8.1. Saves all values within the Parameter Edit screen.
4.4.9. Copy
4.4.9.1. Function creates a new parameter duplicating all the values within the parameter
being copied.
4.4.9.2. To speed up on time, a good practice when creating a new parameter is to copy
the Dot Default parameter (or other parameter with ideal settings for application) and
customize from there.
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4.4.10. Cancel
4.4.10.1. Aborts the parameter edit and prevents any changes from being made.
5. Once the desired values have been entered, tap the Save Button to save all changes.
6. Tap to enter the desired Solder Wire Feeder settings

6.1. Details on the setting covered in Feeding Solder Section
7. Jog to the location of the point in the desired orientation.
8. Tap the Record button .

8.1. A pink dot will appear on the screen to signify that a point has been recorded.
Programming a Point Complete!
SOLDER LINE
Note: When programming a solder line, the settings for the solder wire feeder will slightly change.
The solder feeder feed rate will dictate the amount of solder that is dispensed for the programmed
line instead of a fixed length. The higher the speed, the greater the volume of solder that is
dispensed. When programming a speed, one should consider the tip geometry, size, and tip
temperature series. For example, a 2.5mm, 700 series, chisel tip should not be programmed faster
than 3 mm/s.
1. Tap on the Waypoint button twice to toggle to Solder Line.
x2
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2. Select desired Solder Line parameter by scrolling through the parameter list. This can be done by
swiping up or down within the gray parameter box until the desired Solder Line parameter is
highlighted. Once highlighted, the parameter will register as the selected parameter for
programming and any subsequent points programmed will follow the settings within the
highlighted solder line parameter.
3. Select desired Transition Movement that is to be exectuted from point to point. For more details
on the differences between Transition Move and Space Move, please refer to the Profile Options
section of the manual. Once selected, the setting will be used for programming and any
subsequent points programmed will follow suit, until the setting is changed. The system allows for
profiles to have a mixture of Interpolation and Space moves. Use of one or another is application
dependent.
3.1. Pro Tip: Programming with Space Move runs the unit at very high speeds. Mistakes made
during programming at this speed can lead to longer downtimes for machines. For this
reason, good practice is to initially program using Interpolation Move. Once the profile has
been tested and deemed satisfactory, the profile can then be optimized for speed by switching
points to the Space Move within the Edit Menu.
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4. To create a new Solder Line Parameter, tap the Parameter Table Button and complete the
following steps, otherwise skip to step 5
4.1. To add a new parameter, tap the “Add” button.

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4.2. To change the values of any parameter, tap on the black input fields to the right of each
setting within the parameter.
4.3. The system will have a default Dot Parameter with the following values:
3.4.1 3.4.2 3.4.4 3.4.3
4.4. Below is a description of each of the variables within the Parameter Edit screen:
4.4.1. Name
4.4.1.1. Identifies each parameter added.
4.4.1.2. Alpha-numeric keyboard available for an extremely wide range for profile names.
4.4.2. Style
4.4.2.1. Defines whether the parameter under editing is a Dot (Solder Point) or Line
(Solder Line.)
4.4.3. Start Delay
4.4.3.1. Defines how long the soldering iron is to remain on a joint before a pre-feed of
solder takes place. This is done to warm up the lead or object to be soldered.
4.4.3.3. Unit of measurement is in milliseconds
4.4.4. Stop Delay
4.4.4.1. Defines how long the iron is to remain on a joint after the post feed of solder has
occurred.
4.4.4.3. Unit of measurement is in milliseconds.
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3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10
4.4.5. Max Speed

4.4.5.1. Defines the velocity at which the retract height is reached.
4.4.5.2. Unit of measurement is millimeters per second ( )
4.4.6. Acceleration
4.4.6.1. Defines the acceleration at which the retract height is reached.
4.4.6.2. Max Acceleration of 500 is permitted.
4.4.6.3. Unit of measurement is millimeter per second squared ( )
4.4.7. Retract Height
4.4.7.1. Defines the distance from the solder joint the soldering iron will retract in the Z-
Axis before moving in the X, Y, or Theta axes.
4.4.7.2. Used to clear any obstacles of nearby components or other features that may
lead to crashing of the soldering iron/ end effector.
4.4.7.3. Unit of measurement is in millimeters.
4.4.8. Save
4.4.8.1. Saves all values within the Parameter Edit screen.
4.4.9. Copy
4.4.9.1. Function creates a new parameter duplicating all the values within the parameter
being copied.
4.4.9.2. To speed up on time, a good practice when creating a new parameter is to copy
the Dot Default parameter (or other parameter with ideal settings for application) and
customize from there.
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4.4.10. Cancel
4.4.10.1. Aborts the parameter edit and prevents any changes from being made.
5. Once the desired values have been entered, tap the Save Button to save all changes.
6. Tap to enter the desired Solder Wire Feeder settings

6.1. Details on the setting covered in Feeding Solder Section
7. Jog to the location of the first point of the Solder Line
8. Tap the Record button

8.1. A pink dot will appear on the screen to signify that a point has been recorded
9. Jog to the location of where the Solder line is to end.
9.1. Warning: Please note that the robot uses vector movements (i.e. will move in all three
directional Axes and rotation about the Z-Axis simultaneously.) Therefore, this factor should
be considered when programming the second point to create the line. For this reason, the
directional jog controls should be used rather than touching on the work space to jog to
prevent a change in height when producing a solder line.
10. Tap the Record button to establish the 2nd point.

10.1. As soon as the button is tapped, the software will create a line (in pink) from the first
point that was programmed in step 6 to the 2nd point that was programmed in step 8.
FEEDING SOLDER
Solder can be fed one of two ways: Manual Feed and Programmable Feed. A description of each of
the Solder Feeder functions can be found here.
Solder Feeder
Options
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SOLDER FEEDER SETTINGS
The software allows you to control how much solder is to be dispensed either by length or by
volume. Upon tapping of the Solder Feeder Parameter button , the following menu will be
displayed:
Feed
by
Length
Solder
Feed
Pre-Tin
Length
Feed
Delay
Feed Fine Speed

Rate Adjust (mm/s)
By toggling the Feed by Length button, the following Feed by Volume converter menu appears:
Solder Desired
Diameter Solder
(mm) Volume
Feed by
Volume
Pre-Tin Solder
Length Feed
Feed Solder
Delay Feed
Length
Feed Fine
Fine Speed
Rate Adjust
Adjust (mm/s)
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Function Description
When active, allows operator to program solder feeder by specified

length.
When active, allows operator to automatically calculate equivalent the

solder feed length based off solder diameter and specified volume. The
calculated length can then be entered manually within the feed by
length window.
Feed Delay establishes time (in milliseconds) between the pre-tinning

of the Iron and the Solder Feed action.
Feed Rate establishes the velocity (in mm/s) the solder is fed to the
iron.
Values in yellow boxes can be changed by tapping on the box. This will bring up a keypad at
the bottom of the work area.
The slide bar in blue allows the operator to establish how much of the total feed length of
solder will be Pre-Tin vs Remaining Solder Feed. This is done by simply sliding the circular
icon left and right until the desired lengths appear in the respective blue boxes. Fine
adjustment can be performed by tapping the + sign to increase the value or the – sign to
decrease the value
The green slide bar allows the operator to select the velocity at which the solder is dispensed.
This is done by simply sliding the circular icon left and right until the desired speed appears in
the green box.
WAY POINTS
Waypoints are programmed locations within a solder program that allow operators to send the
end effector to a desired location before and/or after a solder joint. This is typically used to navigate
around obstacles among other reasons. Please note that the robot uses vector movements (i.e. will
move in all three directional Axes and rotation about the Z-Axis simultaneously.) Therefore, this factor
should be considered when programming waypoints. Use the following steps to program a way point:
1. Verify the Waypoint icon is active

1.1. If not, toggle from Solder Point or Solder Line until icon is visible.
2. Jog to the desired location in the desired orientation.
3. Once the robot has completed the movement, tap the record button
3.1. A blue dot will appear on the workspace, signifying that a waypoint has been recorded.
3.2. When in the program edit screen, waypoints can be moved as needed.
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SOLDER WIRE FEEDER ADJUSTMENT
The RSS-1000-CVSI provides users with a solder wire feeding system with several
adjustments to allow solder feeding for a plethora of applications. Below is a diagram showing the
Solder Wire Feeder assembly mounted to the unit along with the direction of each adjustment. Once
the adjustment has been dialed in to the user’s preferred location, the user can use the locking nuts
to hold the position of the adjustment.
Up/Down
Adjustment
Assembly
Left/Right
Adjustment
Assembly
Rotational
Adjustment
Assembly
Locking Nuts
Rotational
Adjustment 1
Toward/Away
SWF Tube
Adjustment
SWF Tube
Front View
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Rotational
Adjustment
Assembly
Rotational
Adjustment 2
SWF Tube
Rear View
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ADVANCED PROFILE FUNCTIONS
EDIT PROFILE
The Edit Profile function is a very powerful tool that will likely be the most frequently utilized
function when creating and perfecting a profile. Every aspect from of the profile is editable, from the
parameters used, order in which points are soldered, solder wire feeder settings, among many other
settings. This allows the user to adapt any profile in a fraction of the time than it would with the
traditional teach pendant. The display will update with new positions, so the user can see how their
changes will look before they are implemented within the profile. Users even have the option to
quickly identify and remove any point within a profile. Please note that only Admins and
Engineers will have access to this menu. The following three sections will describe each of the
editing options that reside within the edit profile function.
EDIT PROFILE OVERVIEW
The Edit Profile icon is found in the main menu bar.

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Once the edit profile function has been activated, the following screen will appear:
Position of
End
Effector
Solder
Parameters
w/in Profile
Current
Position of Solder
End Parameter
Effector Options
Current
Profile
Solder
Parameters
Settings
Opens the Solder Parameter Edit Screen
Opens the Profile Edit Screen
Reverts profile back to its original state, removing any modifications

made to the existing profile within the editing screen.
Proceed with changes made to the profile. These changes can then be
test run to ensure they were programmed as intended. If satisfied, the
user will still need to save the overall profile to complete the changes.
Cancels all changes made to the profile.
Stops all motors and prompts user that the E-Stop has been engaged.
Upon clearing of the message, the unit will home itself.
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SOLDER PARAMETER EDIT
The Solder Parameter edit screen is the first screen that appears when editing the Profile Edit mode.
The icon will illuminate green to indicate that it is the active screen within the Profile Edit
mode. If the user is unhappy with the settings of any given parameter, they may create and/or
remove Solder Parameters from within this screen. The Solder Parameter settings mirror those that
are detailed in the Solder Parameters & Settings Section
Solder Parameter Options
Copy
Parameter Parameter Remove
Parameter
Type Name Parameter
Settings
Confirm
Parameter
Rename
DOT Lists the parameter type (Dot, Line or Waypoint)
Name of Parameter. In the event the user needs to alter the

Dot Default settings within the Parameter and a new name is desired, the
name can be changed by tapping on the box.
If a name change is desired, the confirms the name change

has taken place. If this button is not tapped, the name
change will not take place.
Creates an exact copy of a Parameter and all its settings.

Copy The copy automatically adds a designator of _C to the
Parameter name to signify it is a copy.
Removes parameter from profile. There can be no instances
of the Parameter within the profile for the Parameter to be
deleted. Reassignment of Parameters is detailed in the next
section.
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To Edit a Solder Parameter, use the following steps:
1. Swipe Up/Down until the parameter that is to be edited is highlighted with a yellow band.
Copy
2. Tap the Copy button
2.1. Although not required, it’s always best to make a copy as to not affect other programmed
points within the profile of which the original parameter is used and works well.
3. If a new name for the parameter is desired, tap the name of the parameter
3.1. A keyboard will automatically pop up at the bottom of the work space.
3.2. Tap the Confirm Parameter Rename button once the name has been entered.
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4. Tap the numeric box to the right of the parameter that is to be changed.
4.1. Both the Solder Parameter setting, and the numeric box will illuminate green to signify the
setting and value that is under edit.
5. Tap the Delete key on the numeric keypad to clear the value
6. Use the keypad to enter the new value.
7. Tap on the next numeric box to the right of the parameter setting that is to be changed.
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8. Once all edits have been made, tap the Profile Edit icon to enter the Profile Edit screen.
8.1. The icon will illuminate green to signify the Profile Edit screen is active.
9. Swipe up/down on the parameters listed to scroll until the desired feature with the parameter that
is to be edited is highlighted by the yellow band.
9.1. Note: Parameters are listed in the following format
Program Parameter
Order Name
Selected Parameter
Parameter Type
10. Tap on the Parameter Name to open the List of Parameters

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11. Use the arrows to navigate to the newly created parameter
12. Tap to proceed with the parameter change.

13. Repeat steps 9 – 11 until all desired features have been changed.
14. Tap to proceed with the changes made to the profile.

15. In the left half of the header bar, the profile name will appear with a message as follows:
15.1. This is to indicate that the profile has been changed but has not been permanently stored to
the system. This allows for the user to test the parameters and make any changes (if needed)
before committing to saving the profile. If satisfied, tap the Save icon to store all changes.
Parameter Edit Complete!

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PROFILE EDIT
The following is an overview of the Profile Edit Screen:
Position of
End Effector Features
w/in Profile
Programmed
Transition
Speed
Parameter
Coordinates
Details
of Feature
Feature Solder
Manipulation Feeder
Options Settings
Features Within Profile Diagram
Program
Parameter
Order
Name
Selected Parameter
Parameter Type
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Transition Speed Section
Programmed Programmed
Speed Transition
(mm/s) Move
Transition speed of a point/line is established when the point is first programmed. When a
point is originally programmed, the transition speed at the time of programming be
automatically set for the joint.
The transition speed and type of transition movement displayed strictly pertain to the
highlighted joint only. The points can be edited individually, or mass edited using the Apply to
All function.
Programmed transition speed can be changed by tapping on the numerical box and entering
the desired value.
o 1-150 mm/s for Interpolation Move.
o 1-300 mm/s for Space Move.
The type of transition movement (Interpolation or Space move) can be changed by tapping on
the displayed movement to toggle from one to the other. For details on Interpolation and
Space Moves, refer to the Profile Options section.
o The speed will automatically update when toggling from Space Move to Interpolation
Move if set for a value greater than 150 mm/s.
Parameter Details
Programmed
Solder Feature Type
Parameter
The Parameter Details section displays the information regarding the highlighted feature
The parameter for any given point can be changed by tapping on the parameter name and
cycling through the parameters within a profile until the desired parameter is highlighted.
Note: A dot cannot be converted into a line and vice versa. If such an action is desired, use
the Snap to function to automatically jog to the desired location and record a new point/line in
its place.
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Coordinates of Feature
Solder Point
Solder Line
Any coordinate can be changed simply by tapping the numerical box next to the desired axis,
under the desired point designator and using the keypad to change to the desired value.
An alternative method for changing the coordinates would be to utilize the axis’ corresponding
record button or utilizing the Offset All and Apply to All Functions
Feeder Settings
Feeder settings displayed in the edit menu mirror the solder feeder settings on the main
screen.
Whether the point was programmed using length or volume, the edit menu will only display the
equivalent length (when programming by volume.)
Any setting can be changed simply by tapping the numerical box next to the desired setting
and using the keypad to change to the desired value.
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Remaining Functions
The Apply to All function will change the coordinates of every
Apply to All
point within the profile, based on the edits of the highlighted
feature. This function is particularly useful for mass editing of
points.
The Snap-To function automatically jogs the head to the
coordinates of the highlighted point. For safety purposes, the
speed is set to 50 mm/s and cannot be changed by user.
The Offset All function offsets all points of a program, based

Offset All off the current coordinates of the end effector. This function is
particularly useful when fixtures are relocated.
The Record X function auto-populates the X-Value based of

Record X
the current coordinates of the end effector.
The Record Y function auto-populates the Y-Value based of

Record Y
The Record Z function auto-populates the Z-Value based of

Record Z
The Record R function auto-populates the R-Value based of

Record R
Reorders a programmed feature toward the start of the

profile. This may be done as many times as is necessary
until the feature has been ordered to the number 1 position of
the profile.
Reorders a programmed feature toward the end of the profile.
This may be done as many times as is necessary until the
feature has been ordered to the number final position of the
profile.
Toggles between motion controls within the edit screen to the

scroll wheel list of programmed points in chronological order.
Refreshes the screen to display a change in coordinates.

Note: This will not remove the old feature position until the
check mark has been tapped to proceed with the changes
within a profile.
Deletes the highlighted point feature. Note: Feature will turn
black but will not be removed until the check mark has been
tapped to proceed with the changes within a profile.
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To edit the points within a profile, use the steps below to navigate to the Profile Edit screen.
1. Tap the Profile Edit button
2. Tap Profile Edit Screen

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Most edits of a given feature are completed by tapping the numerical box to the right of the
yellow box with the description of the setting, with a few exceptions. Specific instructions pertaining
to each parameter are detailed in the following sections.
Edit Transition Speed
1. Swipe up/down on the features listed to scroll until the desired feature that is to be edited is
highlighted by the yellow band.
2. Tap the blue box labeled Space to toggle between Space Move and Interpolation Move
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2.1. The box will change to green and receive a red border to indicate that the setting is under
edit.
3. Tap the numerical box to the right of the yellow box labeled Transition Speed.
3.1. Both the Transition Speed box and the numerical box will illuminate green to signify that the
setting is under edit.
4. Tap the Delete key on the keypad to clear the existing value.
5. Using the keypad, enter the new value for the desired speed.
o 1-150 mm/s for Interpolation Move.
o 1-300 mm/s for Space Move.
6. Repeat steps 1-4 for all values that are to be edited.
6.1. If a desired speed is to be set for all features, the Apply to All function can be used to quickly
set the speed to all features within the profile.
7. Tap to confirm changes and return to the profile for testing.

7.1. Note: If satisfied with the changes, don’t forget to save!
Transition Speed Edit Complete!

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Edit Parameter
highlighted by the yellow band
2. Tap on the Parameter Name to open the List of Parameters

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3. Use the arrows to navigate to the newly created parameter
4. Tap to proceed with the parameter change.

Editing a Point Coordinate
2. Tap the numerical box to the right of the coordinate that is be changed
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2.1. In this example, the X – Value coordinate will be adjusted first
2.2. Once selected, the coordinate and Point 1 boxes will illuminate green
3. Tap the Delete key on the keypad to clear the existing value
4. Use the keypad to enter the new coordinate value
5. Tap the numerical box to the right of the next coordinate that is to be changed
6. Repeat this process until all desired values have been changed.
6.1. The refresh button may be used in order to view the changes made.
6.2. A new green dot will appear at the location of the programmed coordinates.
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6.3. Note: The old point location will remain displayed until the user taps to proceed with
the changes.

7.1. Upon the return to the profile, the old solder point location will have been removed from the
profile.
Editing Line Coordinates
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2. Tap the numerical box to the right of the coordinate that is be changed
2.1. In this example, the Y – Value coordinate will be adjusted first
2.2. Once selected, the coordinate and “Point 1” boxes will illuminate green
5. To ensure the horizontal line is retained, the Y - Value of Point 2 will need to be adjusted to the
same value that was set in Step 4.
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5.1. Note: To change to a vertical line, the X – Values between Points 1 & 2 should remain the
same and the Y – Values will change.
6. Repeat this process for each line until all desired lines have been changed
6.1. The refresh button may be used in order to view the changes made
6.2. A new green line will appear at the location of the programmed coordinates
6.3. Note: The line location will remain displayed until the user taps to proceed with the
changes.

7.1. Upon the return to the profile, the old solder line location will have been removed from the
profile.
Editing a Solder Line Complete!

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Editing Coordinates Using Record Coordinate Function
1. Install appropriate PCBA and fixture associated with the profile under edit.
3. Tap the Snap-To button to automatically send the end effector to the solder point
selected.
4. Once the end effector arrives at the programmed solder point, tap the Motion Control button to
toggle to the motion controls.
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4.1. The features within profile scroll wheel toggles to the motion controls.
5. Tap the box underneath Snap
6. Once the box is selected, use the keypad to enter the desired increment for controlled movement.
6.1. This increment is highly application dependent. Use good judgement when selecting this
value.
6.1.1. For densely populated boards, 0.1 mm is highly recommended as the Snap increment.
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6.2. Note: The Snap value is shared between the X, Y, Z, and Θ axes
6.2.1. Use extreme caution when switching from rotational increments to planar increments
and vice versa.
6.3. For continuous jogging or jogging over long distances, tap the Snap button to toggle to Jog
6.3.1. The jog controls function identically to the coarse movement controls on the main
screen.
6.3.2. Please note that the jog speed will be that of which is selected within the global
parameters. Use with caution!
7. Using the motion controls, jog the end effector to the desired location.
8. Once in the desired location, begin tapping the Record Coordinates of all axes that changed in
order to get to the new location.
8.1. In this example, the X & Y Axes were changed. Therefore, Record X and Record Y are used.
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8.2. Upon tapping any of the Record Coordinate functions, the axis being recorded will illuminate
green and the box will automatically be populated to match the global coordinate.
9. Repeat this process for any other points within the profile
Editing a Coordinate Using the Record Coordinate Function Complete!

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Editing Coordinates Using Offset All Function
The Offset All function is a very useful tool for mass editing. This feature will offset all points
within a previously created profile with respect to any point within a profile. This is similar to the offset
feature within the main screen of the software, with the exception that this offset can be saved as a
new profile for use later. The Offset All function can be used for changes in fixture locations, changes
in fixture heights, among other applications.
Please note that when using the Offset All function, ALL coordinates that have changed from the
original program will be relatively adjusted to every point within the program. This can especially be
problematic when there are multiple orientations or heights within a program. For example, say a
given program included half of the programmed points at an orientation of 0° and the other half at
180°. If a 45° rotation was used during the offset, the values of the new coordinates would then be
changed to 45° and 225° respectively. Please take careful consideration when using the Offset All
function and choosing which values to offset.
Complete the following steps to successfully edit coordinates using the Offset All function.
1. Install the appropriate PCBA and fixture associated with the profile under edit.
2. Choose a feature within the profile as the point of reference.
2.1. In this example, the fixture was moved to the bottom right of the working envelope. Therefore,
the solder line will be chosen as the reference feature as it is the furthest most feature in the Y
and in the X Axes.
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3. Tap the Snap-To button to automatically send the end effector to the starting point of the
solder line.
4. Once the end effector arrives at the starting point of the soldering line, tap the Motion Control
button to toggle to the motion controls.
5. Use the motion controls to jog to the new location of the feature and/or components that are to be
line soldered.
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5.1. Alternatively, one may wish to jog to the new location of a feature using any of the movement
commands from the main screen. Use the following steps to jog using the main screen
controls:
5.1.1. Tap the Absolute Move button

5.1.2. Enter new the coordinates of a feature and tap Move to execute the command.
5.1.2.1. Note: In cases in which the coordinates are unknown, the coarse and fine
movement motion controls may be used
5.1.3. Tap the Edit Profile icon to open the editing screen.
5.1.4. Tap the Profile Edit button

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5.1.5. Scroll to the feature that is to be used as the offset reference.
5.1.6. Proceed to Step 6.

6. Once the end effector is in the new location of the desired feature, tap the Offset All button
6.1. The feature highlighted will be repositioned to the new location and the coordinates are
automatically populated.

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7.1. Upon tapping the Edit Profile confirmation button, the remainder of the points will appear in
their new locations.
Pro Tip: The Offset All function can be used as a means of creating templates for various positions of
individual PCBA’s within an array of PCBA’s. This in turn can be used in conjunction with the Merge
Profile function to create one massive program to exponentially decrease programming time.
For more details on how to use the Merge Profile function for Printed Circuit Board Assemblies, refer
to Printed Circuit Board Assembly Based Merge of the Merge Profile section. Don’t forget to save
each template as a separate file!
Editing a Coordinate Using the Offset All Function Complete!

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Editing Feeder Settings
Refer to the comparison diagram below to see the relationship between solder feeder settings within
the Profile Edit Screen and the Main Solder Feeder Settings Menu
Note: Feed ratio is the percentage of the pre-tin vs the overall length fed. 5mm of 25 is 20%.
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2. Tap the numerical box to the right of the solder feeder setting that is to be changed.
2.1. Note: The setting under edit will illuminate green once selected.
5. Repeat this process for all solder feeder settings that are to be edited.
5.1. Don’t forget to use the Apply to All function if the setting is to be used throughout the entire
profile.
6. Tap to confirm the changes and return to the profile for testing.
Editing Solder Parameters Complete!

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Edit Order of Features Within a Profile
2. Tap the or to change the feature’s order.
2.1. Note: In this example, the feature chosen was the final feature of the profile. Therefore, only
the function can be used in such a case.

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profile.
Reordering of Features Within Profile Complete!
Remove a Feature from a Profile
2. Tap the to remove the feature.

2.1. Note the feature will turn black to indicate it is to be deleted (shown on the next page.)
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profile.
MERGE PROFILE
The Merge Profile function allows users to combine previously programmed profiles into a new
profile in locations defined by the user. The user can create a library of solder profiles based off
components dimensions, which in turn can be merged into an overall profile of a printed circuit board
assembly to significantly reduce the amount of time to program. They can also use this function to
create multiple instances of a pattern that is not practical, or possible with an evenly distributed array.
The following procedures will provide instructions on how to merge profiles for different scenarios.
COMPONENT BASED MERGE

This is typically used in applications in which the component pattern to be merged is used
quite frequently, as multiple random instances within the PCBA, in cases that are not conducive to
using the array function (shown later). Components such as integrated circuit chips, transistors, etc.
can all be stored within the system to be inserted in any profile, when needed. One must have the
dimensions of the component readily available to use this feature to its fullest extent. Although
tedious to set-up, once a library of components is saved, future printed circuit boards can be
programmed with the greatest of ease.
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1. Tap New Profile to ensure that the workspace is clear of all programmed points.
2. Navigate to Profile Options and tap the waypoint icon once to toggle to solder point.
3. Swipe Up or Down to scroll to the desired dot parameter that is to be used.
4. When programming the following points, one must consider the geometry of the component, its
orientation, and critical dimensions. For this example, the following Operational Amplifier will be
used in the orientation shown below.
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5. To position the end effector at pin 1, jog 6.40mm in the +Y direction, and 270° in the
counterclockwise direction.
5.1. Note: Given the mechanical tolerances, the dimensions may need to be slightly edited once
inserted within a program. Please see the Edit Profile section for more details.
6. Tap the record button

7. Jog the end effector in the +X direction in 2.54mm increments for the next three pins, recording a
point at each pin.
8. To navigate to pin 5 in the correct orientation (for the ideal application with no obstacles or
prohibiting geometry,) the following values would be used.
8.1. From the global coordinate perspective, the displayed coordinates should read close to the
following:
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10. Jog the end effector in the -X direction in 2.54mm increments for the next three pins, recording a
point at each pin.
10.1. Dependent on the geometry of the component programmed, this may be sufficient for the
program. If this is true to the application skip to step 11. However, Metcal follows the IPC-J-
STD-001 and IPC-A-610 standards when soldering. Therefore, in this example, the
component will be soldered with alternating pins on alternating sides to be compliant.
10.2. Tap to enter the Edit Profile Screen
10.3. Tap to reach the Edit Segment Screen

10.4. Swipe up/down on the program order until DOT# 7 is highlighted
10.5. Tap to reorder the point to position 2.

10.6. Swipe up on the Program Order until DOT #4 is highlighted.
10.7. Tap to reorder point to position 3.

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10.8. Repeat this process until the points are programmed in the order shown below
10.9. Tap to save the changes
11. Tap to save the template.

11.1. Pro Tip: Save the Template with the name of Component Solder Parameter Template to aid
with identification
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12. Once the file name has been entered, tap to complete the save.
13. Tap to open profile the component is to be merged with.
14. Tap the name of the profile and tap to open the profile
15. Jog end effector to the location in which the component is to be inserted with reference to pin 8.
16. Tap on the Merge button.

16.1. The following menu will appear.
17. Tap Select File
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18. Tap the name of the component template that was created in the previous steps and tap
to continue.
19. Tap Insert to merge the template with the profile.
19.1. The component will then be merged into the profile.

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19.2. Steps 16-19 can be repeated for as many components are required for an assembly.
20. Test the profile and make the necessary tweaks with the Edit function.
21. Tap the Save button to save the profile.
Component Based Merge Complete!
PRINTED CIRCUIT BOARD ASSEMBLY BASED MERGE
This function is typically used when multiple instances of the same printed circuit board
assembly are to be soldered within the same profile. A user will program and perfect a single
instance of the printed circuit board assembly profile. Upon completion, the user can then create
multiple instances of this profile to correspond with a multi-PCBA fixture for use in production. This
procedure will describe how to produce multiple instances of a profile, after it has been perfected.
The fixture in this example will house four PCBA’s at 200mm apart in both directions.
2. Tap the Merge button

2.1. Note: If the profile that is to be used was programmed in a different location than the multi-
PCBA fixture has the first board positioned, one must jog the corresponding offset.
2.1.1. EX: If the board was programmed at 25mm in the X – Axis and 25mm in the Y – Axis
and the fixture now holds the board at 75mm in the X & Y – Axes, then an offset of 50
must be used by jogging the head 50mm in the X – Axis and 50mm in the Y – Axis
2.2. In this example, the first PCBA was programmed using the multi-PCBA fixture
3. Tap Select File
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4. Tap the name of the profile template that is to be used and tap to continue.
5.1. The profile for the single board should now appear in the workspace.
6. Tap to toggle to the fine adjustment jog controls.

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6.1. Alternatively, the absolute position function can be used as well.

7. Enter the X – Axis Coordinate ONLY for the location of the next board.
7.1. In this example, the location of the next board is 200mm to the right of the first programmed
board.
8. Tap the Merge button.

9. Tap Select File
10. Tap the name of the profile template that was selected in Step 1 and tap to continue.
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11.1. The 2nd profile will appear in the work space.
11.2. The location of the next board is 200mm in the Y – Axis. To save travel time from board to
board, the PCBA directly the one programmed in step 10 will be programmed next.
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12. Enter the Y – Axis Coordinate ONLY for the location of the next board.
12.1. In this example, the location of the next board is 200mm below the second programmed
board.

14. Tap Select File
15. Tap the name of the profile that was selected in the previous steps and tap to continue.
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16.1. The template will now appear in the bottom right section of the fixture
17. Enter the Y – Axis Coordinate ONLY for the location of the next board.
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17.1. In this example, the location of the next board is 200mm to the left of the first programmed
board.

19. Tap Select File
20. Tap the name of the profile that was selected in the previous steps and tap to continue.
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21.1. The template will now appear in the bottom right section of the fixture
22. Test the profile and make the necessary tweaks with the Edit function.
23. If satisfied, tap to save the profile

Printed Circuit Board Assembly Based Merge Complete!
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GENERATE ARRAY
The Generate Array function greatly reduces programming time when programming repetitive points
at fixed distances. It gives the user a variety of options to customize the array to meet almost any
application. When activated, the following screen will appear:
1.1
1 1.2
7
6.1
6.2 8
1. Number of Rows and Columns Within Array

1.1. Rows
1.2. Columns
1.3. Any number that is entered as a decimal will automatically be rounded to the nearest whole
number
2. Row Offset
2.1. In millimeters (mm)
3. Column Offset
3.1. In millimeters (mm)
4. Skip Instance(s)
4.1. Tap the to activate
4.1.1. A will appear along with a text box

4.2. Instances which are to be skipped are entered with a space in between each value.
4.2.1. Ex: An entry of “3 5” will skip the 3rd and 5th instance within the array.
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1.1
1 1.2
7
6.1
6.2 8
5. Array Path Pattern

5.1. Establishes the order and direction in which the features within the array are executed.
6. Direction of Array
6.1. Toggle +/- X (Left/Right)
6.2. Toggle +/- Y (Up/Down)
6.3. Settings determine which direction the array will be programmed
7. Run Generate Array
7.1. Proceed with Creation of Array
8. Cancel Generate Array
8.1. Cancel the Creation of Array
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Examples of Generate Array Settings
1. Number of Rows and Columns Within Array
2. Row Offset
3. Column Offset
Columns
Offset
50mm
Rows
Offset
50mm
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4. Skip Instance(s)
Note: Order in which skipped instances are entered does not matter
Pattern Type & Direction of Array will determine which value an instance is assigned.
1 2 3 4
8 7 6 5
9 10 11 12
16 15 14 13
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5. Array Path Pattern
5.1. Vertical Zig Zag
1 4 7
2 5 8
3 6 9
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5.2. Horizontal Zig Zag
1 2 3
4 5 6
7 8 9
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5.3. Vertical Square Zig Zag
1 6 7
2 5 8
3 4 9
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5.4. Horizontal Square Zig Zag
1 2 3
6 5 4
7 8 9
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5.5. Spiral
1 2 3
8 9 4
7 6 5
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6. Direction of Array
6.1. Right Down

The first point programmed will be at the top left of the array.
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6.2. Right Up
The first point programmed will be at the bottom left of the array.
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6.3. Left Down
The first point programmed will be at the top right of the array.
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6.4. Left Up
The first point programmed will be at the bottom right of the array.
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Single Point Array
2. Navigate to Profile Options and tap the waypoint icon once to toggle to solder point
3. Swipe Up or Down to scroll through the dot parameters until the desired dot parameter that is to
be used is highlighted by the yellow band.
4. Position the end effector at the location of the top left corner of where the array is to be
programmed.
5. Tap the Generate Array button
5.1. The button will illuminate gold to signify the array function is active
6. Tap the Record button to designate the first point of the array.
7. Tap the Generate Array button once again to signal the end of all patterns that are to be included
within the array
7.1. The button will return to grey in color

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8. Enter the desired values in the respective fields
9. After all the values have been filled, tap Run

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

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Multiple Pattern Array
Some applications require waypoints to be inserted or have certain multiple features that are
repeated. The Generate Array function allows for an array of multiple patterns to be created just as
easily as a single point. The following procedure will use the PCB below as an example with the five
transistors programmed at the dimensions shown
15mm
10mm
2. In this example, a waypoint will be programmed before each solder point to ensure that iron
approaches the lead of the transistor in a desired path.
3. Jog to the location of the first waypoint.
4. Tap the Generate Array button
4.1. The button will illuminate gold to signify the array function is active
5. Navigate to Profile Options and verify that the Waypoint icon is active.
6. Tap the Record Button

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7. Tap the Waypoint icon once to toggle to Solder Point

8. Swipe Up or Down to scroll through the dot parameters until the desired dot parameter that is to
be used is highlighted by the yellow band.
9. Jog to the first pad of the transistor.
10. Tap the Record Button

11. Repeat this process for the next two points of the transistor.
11.1. Note: If in any case an error is made, use the Undo / Redo buttons
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12. Once All points have been programmed, tap the Generate Array to signal the end of all patterns
that are to be included within the array
12.1. The button will return to grey in color
13. From the design of the printed circuit board, there are five transistors total in two rows that are
offset from one another. To program all transistors in one sweep, the values within the Generate
Array function must be programmed using logic and reasoning. The following sub-steps will
describe which values were chosen and why they were chosen.
13.1. Rows and Columns
13.1.1. The array can be visualized as 2 rows and 5 columns of components

C1 C2 C3 C4 C5
R1
R2
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13.2. Row Offset
13.2.1. The dimensions provided show that between rows, there is a 10mm distance between
two common pins
13.3. Column Offset
13.3.1. Note: If dimensions are known/given, always go with those before making any
inferences.
13.3.2. The measurements provided show that between the 1st and 3rd column, there is a
15mm distance between two common pins. It is assumed that the stagger is not unevenly
positioned and therefore it can be inferred that transistor R2C2 lies at the midpoint of
transistor R1C1 and R1C3.
13.4. Array Path Pattern
13.4.1. The Vertical Square Zig Zag was chosen as this would have the least amount of travel
time from transistor to transistor. The Vertical Zig Zag could also apply as the next two
instances would be skipped. However, the Vertical Square Zig Zag makes for a simpler
Instance Skip programming (see 13.6). The reason behind this is that in all other
patterns, they result in jogging to transistor R1C3 which is located 15mm in the X –
direction (given.) The distance to transistor two can be calculated using the Pythagorean
Theorem ( ) which results in a travel distance of 12.5mm
7.5mm
12.5mm 10mm
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13.5. Direction of Array
13.5.1. The Right Down Direction was chosen as the points programmed were on the first
transistor in the top left corner of the board in the orientation in the fixture
13.6. Instances Skipped
13.6.1. With the chosen Array Path Pattern and Direction of Array, the following order is
programmed. The numbers in gold designate the points in which will programmed in the
array and the numbers in black designate the instances that will be skipped
1 4 5 8 9
2 3 6 7 10
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14. Tap the Run Button
15. The programmed points will now appear in the workspace in the correct spacing.
Pro Tip: This program can be saved and used as a template for multi-board soldering!
Multiple Pattern Array Complete!

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SET GO‐TO LOCATION
A Go-To Location is a user-defined position in the workspace that the system automatically
jogs the end effector to at the end of a profile. Each subsequent profile would then start from this
location, effectively replacing the home position (default) until a new location is established or the
home is reset as the Go-To Location. When establishing the Go-To location, one should consider
obstacles between the last solder point and the desired Go-To Location as the Smart Interface
System will complete a vector move to reach the Go-To Location. In addition, one should also
consider other aspects such as accessibility to the PCBA fixture and tip cartridge as these are
frequently replaced items. The Go-To Location is a global setting and therefore will affect all profiles
used. The following will describe how to establish a Go-To Location.
1. Jog to desired Go-To location
2. Navigate to the Go-To Location button in the Advance Profile Options Section
Advance
Profile Options
2.1. The following menu will appear.

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3. Tap Record to establish the current position
3.1. The coordinates will automatically populate the fields.
4. Tap Save to proceed with the changes

4.1. Tap Cancel to revert to the original location.
4.2. To reset the home location, tap the Home Icon
Set Go-To Location Complete!

OFFSET PROFILE
The Offset Profile function allows for the user move every feature within a profile in the X, Y,
and Z – Axes, as programmed by the user. This can be useful when a fixture has been removed from
the unit, replaced at a later time and the programmed points appear to have shifted. This can also be
used to compensate for the mechanical tolerances when changing solder cartridges. The offset will
continue to take effect until the user removes them or programs a new offset.
WARNING: The Offset Profile function is a Global Setting, or in other words, will affect ALL profiles.
Please be mindful of this when programming any offset.
Use the following steps to successfully program an offset.
1. Tap the Open Profile button to open the desired profile

2. Jog to the desired Offset location of the first point of the program.
2.1. If the Offset location is unknown, jog to the first point within the program and use the fine
adjustment jog controls to dial in the offset location.
3. Tap the Offset button

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3.1. The following menu will appear
4. Tap the Record button to automatically record the position of the end effector in the X, Y, and Z
axes.
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5. Tap the Save button to proceed with the offset
5.1. Tap cancel to cancel the changes.
Programming an Offset Complete!
To Remove the Offset:
1. Tap the Offset button

2. Tap the green box on the left
2.1. The green box represents the offset in the X-Axis
2.2. Upon tapping the green box, the numeric keyboard pops up.
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3. Tap the Delete button to clear the value
4. Tap on the next green box, representing the Y-Axis, and repeat step 3
5. Tap on the yellow box, representing the Z-Axis, and repeat step 3
6. Tap the Save button to proceed with restoring the original profile without an offset.
Removing an Offset Complete!

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DRY RUN
The Dry Run feature, located in the Solder Feeder section of the display, is a very useful tool
to aid users in validating their program. The purpose of this feature is to allow the user to validate all
positions of programmed points within a profile, validate transition paths across the board, transition
paths to the cleaning zone, among many others. This allows users to resolve a majority of issues,
well before ever putting solder to the iron. The function is toggled on and off:
Dry Run Activated Dry Run Deactivated
When activated, the following actions will take place:

The Connection Validation Settings will be disabled
RF will automatically shut off without the ability to turn it on until the Dry Run is either
completed or toggled off
o In other words, the iron will remain cool, preventing any damage to the PCBA under
testing.
No solder will dispense on any joint
All time delays (start delay, feed delay, and dwell) are disabled for the duration of the run
o The system defaults to a one second pause at each joint
Along with the actions mentioned above, the system will execute the program in the order that
was programmed, executing cleaning zone commands in the intervals defined by the user.
To further aid in perfecting a given profile, the Dry Run can be used in combination with the
Profile Step Run Feature, located within the Global Settings Directory, within the System Settings
Menu.
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Step Run Enabled
Dry Run Disabled
When enabled, the system will run the program in steps, or in other words, by individual
movement commands, for all points within a program. After the Smart Interface System executes a
single movement command, the system will pause and wait for the user to tap the Run Profile
Continue button to execute the next command. For example, with Profile Step Run and Dry
Run activated, the system will execute the X, Y, & Θ movement commands to position the end
effector above the first cleaning zone point, as the cleaning zone is the first point for all profiles. The
end effector will remain in this position until the user taps the Run Profile Continue button, after which
the end effector drives down to the programmed height of the cleaning zone’s starting point. This
allows users to pin-point precisely where a problematic point or movement will occur.
Pro Tip: Set the Solder Station Link to 0 when using step run to reduce the amount of waiting
time between executing movement commands.
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TIP ALIGNMENT
Metcal™ recommends inspecting each cartridge before use. If the plating has been
compromised or there is a change in performance, replace immediately to ensure the highest quality
soldering. Due to mechanical tolerances that occur when producing the soldering cartridges, some
slight adjustments may need to be made to a solder profile. To minimize the amount of adjustment
necessary when changing out cartridges, Metcal™ provides a Tip Alignment Fixture with every unit to
ensure that the cartridge is placed within the End Effector Cartridge Lock in the exact same position
every time. The Fixture Tip Alignment Fixture comes preassembled with the 2.5mm chisel insert but
inserts for other geometries will be made available (sold separately.)
For further ease of alignment, Metcal™ offers the Center Point Tool (sold separately) to ensure
that the axis of rotation of tip is aligned with the axis of rotation of the end effector. It will also simplify
the process of adding an offset from a given point (if desired.)
TIP ALIGNMENT
1. Insert M2.5 set screw (2800-0836) into End Effector Cartridge Lock (7059-0650) and hand tighten
with the M1.3 Allen Key
1.1. Do NOT tighten beyond the ID of the End Effector Cartridge Lock
Good Bad
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2. Slide End Effector Cartridge Lock over the CV cartridge from the connector side down as shown.
3. Insert End Effector Cartridge Lock into Tip Alignment Fixture Assembly (7059-9160) with the set
screw facing the rear of the unit.
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4. Rotate the CV cartridge as necessary until the tip fits within the groove of the fixture.
5. Torque the set screw in the End Effector Cartridge Lock 1.5 in-lbs, once in the correct orientation.
Tip Alignment Complete
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CENTER POINT ALIGNMENT
1. If not already, Log-In to Robotic Soldering System using 1000 for the password and tapping
once entered.
2. Tap the button to toggle to the fine adjustment jog controls.

3. Drive end effector down in the Z-Axis by 20mm using the highlighted icon.
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4. Using the M2.5 Allen key, loosen the M3 screw of the accessory bracket and rotate accessories
(Solder Wire Feeder Tube Assembly and CCD Camera) out of the way.
Before After
5. Remove the CV Cartridge assembly from the Tip Alignment Fixture.
6. Loosen set screw of Soldering Robot CV-H8-AV*.
*Note: Loosening of set screw

is only required if a different
tip geometry is inserted.
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7. Insert cartridge assembly into the End Effector Cartridge Holder in the orientation shown.
8. Rotate assembly 90° clockwise to lock into place.
9. Slide the End Effector Spring Retainer down toward the cartridge until there is a reasonable
amount of spring force applied to the cartridge assembly. Once in place, hand tighten the set
screw into place.
9.1. To test if there is a reasonable amount of spring force applied to the cartridge assembly,
rotate the cartridge assembly counter clockwise and remove it from the End Effector. Then try
reinserting the cartridge assembly back into the End Effector.
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9.1.1. If the spring force is too great, loosen the set screw and adjust the End Effector Spring
Retainer up and away from the cartridge.
9.1.2. If the spring force is too weak, loosen the set screw and adjust the End Effector Spring
Retainer down and toward the cartridge.
9.2. Once in the correct location, torque the set screw into place.
10. Attach the Center Point Tool Assembly (7059-9150) to the End Effector with the thumb screw
facing the rear of the unit.
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11. Adjust the Center Point Tool Assembly up or down to get the dowel pin as close to the tip
cartridge as possible.
Rear View
12. Loosen the locking nut by rotating it counter-clockwise.
Thumb
Screw
Locking
Nut
13. Use the thumb screw to the right of the end effector to adjust the cartridge closer or further away
from the alignment pin. The objective is to position the solder tip such that the reaches the
alignment pin
13.1. Rotate the thumbscrew clockwise to raise the cartridge assembly up and the tip away from
the alignment pin.
13.2. Rotate the thumbscrew counter-clockwise to lower the cartridge assembly down and the tip
toward the alignment pin.
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13.3. The images below are examples showing the ideal position and alignment that is out of
position.
Out of alignment, use step 13.1 Perfectly Aligned Out of alignment, use step 13.2
13.4. Once in position, rotate the locking nut clockwise to lock in position.
13.5. Note: If thumbscrew is adjusted to the maximum limit, readjust to lower limit and loosen the
entire assembly via the M5 SHC screw to move the cartridge into position.
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14. Once tip is aligned, use the jog controls to position the align the Center Point Tool Assembly to the
circular feature on the calibration fixture.
14.1. Carefully jog the end effector down in the Z-Axis in small increments to confirm alignment
has been achieved.
14.1.1. If the alignment tip is out of alignment with the circular feature, use the fine adjustment
jog controls to carefully jog it into place.
Out of Alignment Aligned

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15. Once in position, loosen the thumb screw and remove the Center Point Tool Assembly from the
unit and return to 0° using

15.1. Although not required, it is good practice to record the X & Y position values on a piece of
paper so that in the event the robot needs to be homed, there will be no need to realign the
alignment pin. The X & Y values can be entered in the Absolute Move feature and the robot
will return to the previously aligned location.
16. Carefully jog the end effector down in the Z-Axis until the tip is around 5mm away from the fixture.
Then slide the Calibration Fixture vertically until it contacts the solder tip.
16.1. Once contact has been made, lock in place by rotating the thumb screw clockwise
underneath slide bar.
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17. Use the rotational jog controls to rotate the End Effector a full 300°, watching the solder tip closely.
During the whole rotational movement, the solder tip should remain within the circular feature and
rotate about its axis.
17.1. If the tip remains within the circular feature and rotate about its axis, proceed to step 18
17.2. If the cartridge does not remain within the circular feature and rotate about its axis, confirm
the X & Y position is correct be reinstalling the fixture and verifying the alignment pin is
concentric to the circular feature on the Calibration Fixture.
17.3. If the position is correct per the fixture but the tip is out of alignment, repeat steps 10-17.
Center Point Alignment Complete!
CAMERA CALIBRATION & FUNCTIONS
CALIBRATION
The RSS-1000-CVSI has a Computer Vision Camera used to establish Fiducial Points for
auto-alignment (future feature,) Pattern Recognition on a PCBA, 1:1 movement on an image when
jogging, and General Inspection of the PCBA. Instructions for use of these functions will be covered
in their respective sections.
The unit will be factory calibrated for a board height of 38.1mm. However, design of any
fixture that deviates from this height will require re-calibration of the camera at the new height.
Correct calibration of the Computer Vision Camera is essential to the several functions of the RSS-
1000-CVSI. It is imperative that this procedure be followed step by step, line by line. Failure to do so
could result in undesired results during operation or increase the possibility of damage to the
workpiece or unit. To minimize the need for constant camera calibration, Metcal™ recommends
designing all fixtures to be of uniform height, when possible.
Note: Fixtures shall be designed to position the working surface of the PCBA within the range of
29.5mm [1.16”] to 76.0mm [2.99”]. Any fixture that positions the top surface of the printed circuit
board outside of this range will not be able to successfully use the Fiducial Point alignment, Pattern
Recognition, 1:1 movement on an image when jogging.
The following steps will provide instruction on how to successfully calibrate the Computer Vision
camera:
1. Install PCBA with designated fixture.
2. Verify the Connection Validation Power Supply RF is in the OFF position.
2.1. The CV display should read that it is in Standby mode, as indicated by the arrow.
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3. Install desired Connection Validation cartridge.
3.1. Verification of cartridge at the correct pivot position can be completed by referring to the Tip
Alignment section
3.2. WARNING: Do NOT turn on the Connection Validation Power Supply after installation of
cartridge.
4. Use the jog controls to position the cartridge point over the PCBA.
5. Slowly jog end effector down in the Z-Axis until the cartridge is 5mm above an open area of
PCBA, free of components.
6. Use the Fine Adjustment jog controls to slowly jog end effector down until cartridge first contacts
PCBA substrate.
6.1. Record the Z-Axis value in the Global Coordinate Display on a piece of paper.
7. Tap the Home button

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8. Loosen the Z-Axis thumb screw (indicated by the arrow) and verify the Calibration Slider Block
assembly is in the lowest position.
9. Tap the Absolute Position button

10. Enter the value recorded in step 6.1 in the yellow box to the right of Z Position
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11. Tap Move to drive end effector down to height of PCBA.
12. Raise Calibration Slider Block assembly until the black raised feature of the Scaling Block
contacts the cartridge tip as shown in Figure 12
12.1. Lock into place by turning clockwise on the thumb screw directly beneath the Height
Adjustment Block, as indicated by the arrow.
Figure 12
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12.2. Loosen the thumb screw of the Calibration Slider Block and adjust assembly left or right until
the tip is in line with the black raised feature of the Scaling Block, shown in Figure 12.2.
Figure 12.1
Figure 12.2
13. Tighten thumb screw once in the correct location.
14. Tap the Home button

15. OPTIONAL: Some find it useful to set Z-Limit safety height to the height recorded in step 6.1 to
reduce programming time. However, doing so may introduce the risk of collisions with
components mounted to the working surface of PCBA. Use with Caution.
16. Tap the Camera button to turn on the camera.

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16.1. Note: The Camera button will illuminate blue and an image will appear in the
workspace area.

18. Tap the Camera Settings Menu
19. Tap Start next to Camera Calibration to start the camera calibration.
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19.1. The diagram below describes the functions used for camera calibration
Camera
Reset
Offset X &
Calibration
Y values
Record
Camera
Offset
Coarse Jog
Coarse Jog
Speed
Speed
Value
Slide Bar
(mm/s)
Fine
Coarse Jog
Adjustment
Direction
Direction
Fine
Fine
Adjustment
Adjustment
Increment
Slide Bar
(mm)
Continue
Cancel
to Next
Calibration
Step
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20. Tap Reset Calibration button. This will clear the existing calibration offset and scale. Origin will
no longer be established, and scale is reset to 1:1.
20.1. Note: This instantaneously resizes the image to fill the complete work space with camera
stream.
20.2. Warning: Resetting calibration without completing the entire calibration will result inaccurate
movement when using the workspace to jog to a location.
21. Using coarse jog controls & fine adjustment, align the origin (top left corner of Scaling block) to the
origin of the work space on the screen (top left corner of displayed camera image, bottom image)
Origin
Origin
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21.1. Hint: When the cursor is located over the workspace area, coordinates will be displayed in
black at the center bottom of the work space. This can be used to navigate to the (0,0) point
of the workspace, which is the origin.
22. Once the two origins have been aligned, tap the Record Camera Offset button
22.1. Note: This action will populate the X & Y fields with the initial offset.
22.2. Note II: The live video is now converted to a still image.
23. Tap next to advance to the scaling page.

24. Adjust the camera scale slide bar to 100mm
24.1. For fine adjustment of the slide bar in the positive direction, tap the + button.
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25. In the working area of the displayed image, tap on the end of the Scaling Block.
25.1. Areas in pink will be off-screen but shown for illustration.
26. Use the fine adjustment directional arrows to place the crosshair directly on the end of the Scaling
Block
26.1. Note: Use the fine adjustment slide bar to increase/decrease movement as needed. The
units are in mm.
27. Once in position, tap the Set Camera Scale button to save this scaling size and tap the next
button to proceed to the next step.
27.1. Note: Upon tapping the next button, the image reverts to live video and the image is now
scaled to size relative to the work area. the robot will automatically return to the home
position and the end effector will rotate 90° to allow for fine adjustments to be made, although
it may not be required.
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27.2. A “scaled image” means that any movement commands issued by tapping on the image will
reflect actual distances on the PCBA. For example, if two components were physically 10mm
apart from one another, the displayed image distance may vary, depending on the
magnification (1X, 2X, or 3X). However, in any of the three magnification cases, the operator
would be able to position the end effector over one component, tap on the other component
and the system would travel 10mm.
28. To determine if fine tuning is required, inspect along the edges of the raised surface of the scaling
block displayed in the workspace. The newly scaled image should not have any gap to the left or
above this raised surface (i.e. no bare aluminum should be visible.) Examples have been
provided below.
Gap
No
Gap
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28.1. Fine tuning allows for operator to readjust the image into the correct location at the scaled
image size one last time before the calibration is complete.
29. Once the image has been repositioned, tap the check mark to complete the calibration.
29.1. It is highly recommended that a Position Verification Test be conducted (detailed in the next
section) in order to verify that calibration was successfully completed.
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POSITION VERIFICATION TEST
A successful calibration is crucial to utilization of the software to accurately program using camera
images as well as the other camera-based functions. Therefore, a position verification test is highly
recommended after any calibration to confirm that the calibration was a success. The following steps
will detail how to confirm that a calibration was successful.
1. Using the jog controls, position the crosshair over the circular feature of the Scaling Block
II
2. Slowly drive end effector down to Scaling Block

2.1. If the calibration was performed successfully, the tip should land at the centroid of the circular
feature, tangent to the circular feature, or somewhere in between, dependent on the offset
calibrated. The location may vary, dependent on angle of manual end effector adjustment,
application location (further from centroid for larger pins of the component to be soldered,
closer to centroid for smaller pins of the component to be soldered,) or an improperly
executed tip alignment.
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2.2. Below is an example of where the solder tip should be positioned once it is near the circular
feature:
3. Rotate the end effector about the point, careful not to jog in any direction.
3.1. If the tip does not appear to rotate about the feature’s axis, refer to the Tip Alignment section.
3.2. If position of solder tip is satisfactory, proceed to next step
3.3. If position of solder tip is unsatisfactory, skip to the Fine Adjustment After Calibration section.
4. Jog end effector over to installed PCBA.
5. Locate a feature on the board, such as a pin to be soldered.
6. Use the fine adjustment to position the crosshair directly on the centroid of feature.
7. Slowly jog end effector down until solder tip has reached location at which soldering would take
place (contacting pin and pad.)
7.1. If position of solder tip is satisfactory, verification complete!
7.2. If position of solder tip is unsatisfactory, record the offset in X & Y and skip to the Fine
Adjustment After Calibration section.
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FINE ADJUSTMENT AFTER CAMERA CALIBRATION
Fine adjustment after calibration is used for operators who would like to adjust the position of the
soldering tip relative to the crosshair (such as compensating for a larger pin or pad,) after an invalid
Camera calibration, or after failure of the position verification test.
WARNING: If the height has changed since the last Camera calibration, a full calibration MUST be
performed. This procedure should not be used as a shortcut to calibrate the camera. Doing so may
have undesired results and/or may cause damage to workpiece or unit.
1. Tap the Home Button to ensure you are at the origin.
2. Tap the Global Settings Button .

3. Tap the Camera Settings menu.
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4. Tap Start button next to Camera Calibration
5. Tap the Next button

5.1. Do NOT touch any of the other controls or buttons
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6. Tap the Next button to proceed the Fine Adjustment section & send the unit to the Home position.
6.1. Do NOT touch any of the other controls or buttons
7. Once in the Fine Adjustment section, input the X & Y offset (if known) by adjusting the fine
adjustment slide bar to the desired value and moving in the correct location
7.1. Use the Diagram below to enter the values with the appropriate sign (positive or negative)
when entering the fine adjustment.
+X -X
+Y +Y
+X -X
-Y -Y
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7.2. Pro Tip: To determine the values to input as the X & Y offset, use the fine adjustment buttons
to jog in defined increments until the desired location is achieved. Record the value of the
total travel in the X & Y directions using the diagram above. Use these values when in the
Fine Adjustment section of the Camera Calibration.
8. Tap the Check Mark to store the new offset values
Fine Adjustment After Camera Calibration Complete!

TAKING A SCREENSHOT
Screenshots are used for multiple functions within the software such as establishing Fiducial
Points (future feature), Pattern Recognition, or simply using an image to create a program.
Please be mindful of the lighting when screenshots are taken. The objective is to maintain consistent
lighting from when screenshots are taken to machine operation. Therefore, it is good practice to keep
the unit in a stationary location in which the lighting is controlled. WARNING: Failure to adhere to this
recommendation can have adverse effects on a program that uses any of the camera functions.
1. Tap the Camera Icon to enable the Computer Vision Camera

1.1. Note: The icon will illuminate blue when active and an image should appear in the workspace.
2. Use the jog controls to move to the desired location for screenshot.
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2.1. If necessary, use the quick theta snaps to rotate the end effector 90° to clear any bracketry of
end effector from obscuring view.
3. Tap the Take Screenshot icon

3.1. The following Pop-up Menu appears
Available
Main
Files
Directory
(Internal)
Save
Image
Delete
Folder/
Image
Cancel
Create
Folder
Without External Memory

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Available File Available

Files/ Main Main
Transfer Files/
Folders Directory Directory
Button To Folders
(Internal) of USB
USB (External)
Save
Image
Delete
Folder/
Image
File
Transfer
Button
From USB Cancel
Create
Folder
With External Memory

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4. Highlight the folder in which the screenshot is to be saved in by tapping on the folder.
5. Enter name for the screenshot.

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6. Tap the Save icon to store the screenshot.
OPENING AN IMAGE/SCREENSHOT/ DXF/ GERBER
The Smart Interface System allows for the importation of DXF as well as ART file types, in
addition to any images captured on the unit. When any of the previously mentioned file types are
imported, the system will automatically place the image at the origin point (0,0) in the X-Y Plane.
Screenshots will appear in the location the image was taken and at the scale the camera was
calibrated at.
Before importing any DXF or ART file types, please make sure they created with a 1:1 scale as
unscaled images will either appear extremely large or possibly not at all.
Please note that .PNG files that are to be imported shall come from another RSS-1000-CVSI
with a fixture of EXACT height and scaling. Failure to do so will lead to programming errors on
the imported image.
Supported ART files must be formatted to RS-274X or Extended Gerber format. Standard
Gerber’s or RS-274-D format is NOT supported as the Standard Gerber is technically obsolete,
revoked, and superseded by RS-274X format.
1. Verify that the camera is turned off
1.1. Icon should be grey in color.

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2. Tap on the Open Image icon.

3. Highlight the desired image by tapping on the file name.
4. Tap the open icon.

4.1. Image will appear in the workspace located where the picture was taken
Opening an Image Complete!

IMAGE ZOOM
1. Verify that the camera is turned off
2. Tap the Open Image icon.

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5. Tap on The Zoom icon

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5.1. The menu has the following functions:
Scrolls Zoom
Image Up Slide Bar
Scrolls
Image Left
Scrolls Scrolls
Image Image Reset to
Down Right 1X Zoom
6. Using the slider, slide the green dot right to the desired magnification
6.1. The current zoom options are 1X, 2X, and 3X Zoom. In the event the zoom is insufficient for
the application at hand, the camera may be adjusted mechanically to lower the camera to the
workspace. Please note that this action WILL REQUIRE RE-CALIBRATION. Please see
Mechanically Lower Camera section for instructions.
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7. Use the directional arrows to reposition the still image into the desired location using the following
motion. See example below.
8. In the example on the previous, page, the operator will need to use the and icons to
center the image.
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ESTABLISHING FIDUCIAL POINTS (Future Feature, Not Present in this Release)
The establishment of fiducial points for a pattern is a very important and powerful feature within
the software. Fiducial points are essentially user defined target registration marks that the system
utilizes to determine the orientation of the printed circuit board and adjust a profile accordingly.
Although Metcal™ recommends fixturing for repeatability, there are some applications in which this is
not practical or when tolerancing within the fixture is loose enough to produce variability between the
mounting of successive boards. For this reason, the fiducial points are used to recognize a shift in
orientation from what was originally programmed, and the software will automatically shift all patterns
by the calculated shift in orientation. For the best results, use of the Fiducial Points function should
occur PRIOR to the programming of any points. This will only need to be done once for each profile
programmed. Please note that the fiducial point function can cover a wide range of translational
adjustments but has a limitation of 1.5° of rotation, relative to the center of the PCBA. However, by
utilizing a fixture for mounting of the board, 1.5° will accommodate most applications.
Please be mindful of the lighting when establishing fiducial points AND when running the profile
associated with fiducial points. The objective is to maintain consistent lighting from when screenshots
are taken to machine operation. Therefore, it is good practice to keep the unit in a stationary location
in which the lighting is controlled. In addition, do not crowd around the unit or stand in front of a light
source when taking a screenshot. The simple act of hovering over the unit while the screenshot is
taken can have negative effects as this will cast a shadow over the unit. Avoid casting shadows that
will not be present during normal operation. WARNING: Failure to adhere to this recommendation
can have adverse effects on a program that uses any of the camera functions. A drastic enough
change in lighting from when the fiducial points were established to when the unit begins running a
profile associated with fiducial points can cause the profile to lockup.
1. Tap the Camera icon to enable the Computer Vision Camera

3. Tap the “Take Screenshot” icon

4. Save the image
4.1. Pro Tip: It is good practice to keep the name of the image consistent with the profile to be
programmed. For example, if an Engineer were to program Metcal’s I/O PCBA, the name
“Metcal I/O PCBA” should be used when taking a screenshot and when saving the
programmed pattern.
5. Do NOT use the jog controls to move in any direction after the image has been taken. When
fiducial points are established, the X and Y locations are stored within the software. Whenever
the profile is run, the robot will automatically jog to this store X and Y location to search for the
images. Any deviation from the stored X & Y location will be perceived as a shift and the pattern
will be shifted a distance equivalent to this deviation.
6. Tap the Camera icon to turn off the Camera
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10. Tap the “Set Fiducial Points” button
10.1. The icon will illuminate blue when active
10.2. Increasing magnification is permitted

10.2.1. See Image Zoom section for magnification instructions.
11. Tap and drag from top left to bottom right of the feature in order to create a box around a location
on the image as the first fiducial point.
11.1. Pro Tip: Select an object or feature that is unique and distinct from any other feature on the
board.
11.1.1. Examples of good objects to select for fiducial points are drilled holes for mounting or
holes drilled specifically for fiducial points of computer vision systems.
11.1.2. Examples of bad objects to select for fiducial points include resistors, capacitors,
sticker labels, and various other components as these can have variations in assembly
from board to board
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12. Tap and drag from top left to bottom right of the feature in order to create a box around a location on
the image as the second fiducial point.
12.1. Pro Tip: Select an object that is located diagonally and at a considerable distance from the first
fiducial point.
12.2. Examples of good and objects provided in the previous step are still applicable to this step as
well.
13. Upon releasing finger from touch screen, a dialogue box will appear as follows:
13.1. The image on the left depicting the first point established, the image on the right depicting
the second point established.
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13.2. If unsatisfied with the either of the two points, tap Cancel. Deselect and reselect the Set
Fiducial Points button and repeat steps 11 & 12.

13.3. If satisfied, tap Ok.
14. Once fiducial points have been established, you can proceed with programming of profile.
15. After saving the profile, reopen the profile in order to register the establishment of fiducial points.
Note: The camera MUST be turned on before running the program in order for fiducial points to work
properly. In addition, the robot must be “homed” in-between each run.
Fiducial Points Establishment Complete!
PATTERN RECOGNITION
Pattern Recognition is another advanced feature within the Smart Interface System’s arsenal.
This feature greatly speeds up programming processes by allowing the user to define a pattern for
the system to search for and letting the Smart Interface System find other instances of the defined
pattern. The user can then apply the desired predefined program to each desired instance.
Please be mindful of the lighting when using pattern recognition. The objective is to maintain even
lighting throughout the working envelope. Therefore, it is good practice to keep the unit in a
stationary location in which the lighting is controlled. In addition, do not crowd around the unit or
stand in front of a light source when taking a screenshot. The simple act of hovering over the unit
while the screenshot is taken can have negative effects as this will cast a shadow over the unit.
Uneven lighting or the casting of shadows will make two of the same features appear as two separate
features to the computer vision camera, thus making one of the two patterns unrecognizable when
the function is used. See examples below:
User
User
Defined
Defined
Pattern
Pattern
Missed
Patterns
Recognized
Patterns
Uneven, Focused Lighting Evenly Distributed Lighting

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Template Creation
Creation of a Template or Layout is required before use of Pattern Recognition. The template
is used to insert specific soldering parameters into a pattern once patterns/features have been
recognized by the Smart Interface System. Please note that due to physical limitations
1. Tap to ensure that the workspace is clear of all programmed points.
2. Tap once to toggle to solder point

3. Swipe Up or Down to scroll to the desired Dot Parameter that is to be inserted on each pattern
identified.
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4. Once the desired Dot Parameter is highlighted yellow, tap the Absolute Move icon.
4.1. Enter the following values
4.2. Tap Move to execute the command

4.3. The end effector will be positioned dead center to the work space.
5. Tap the Record button

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6. Tap to save the template

6.1. Pro Tip: Save the Template with the name of “Solder Parameter Template” to aid in
identification of the parameters used and to separate it from normal solder profiles.
Template Creation Complete!
Pattern Recognition Using Template
1. Install PCBA with designated fixture at the current calibrated height.

2. Verify the Connection Validation Power Supply or RF is in the OFF position.
Alignment section
3.2. WARNING: Do NOT turn on the Connection Validation Power Supply after installation of
cartridge.
4. Use the jog controls to position the cartridge point over the PCBA.
5. Slowly jog end effector down in the Z-Axis until the cartridge is 5mm above an open area of
PCBA, free of components.
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PCBA substrate.
6.1. Record the Z-Axis value in the Global Coordinate Display on a piece of paper.

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10. Tap to save the image

programmed pattern.
11. Turn off the Camera
11.1. Icon will return to grey in color.

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14. Tap the Open icon.

15. Tap the Pattern Recognition button
15.1. The button will illuminate blue when active

15.2. In addition, the Pattern Recognition Window will appear
Filter
Adjust Filter %
Neg
Filter
Insert Adjust
Pattern Pos
Delete Coarse
Pattern Adjust
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16. Select the pattern to be recognized by tapping the top left corner of the object to be recognized
and swipe diagonally until a yellow box is formed around the desired pattern.
16.1. If unsatisfied with the area selected, a new box may be created using the same method
previously mentioned.
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16.2. The system will automatically detect the number of identical patterns per previously
established filter percentage.
16.3. If needed, adjust the Computer Vision increase the filter until all patterns are recognized.
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16.4. In the event the filter is too large and unintended objects are identified, decrease the filter
percentage.
17. Tap the Insert Pattern button

18. With Template highlighted (by default) tap Select File
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19. Select the desired template to be inserted
20. Tap the Open Icon

20.1. The template name will now be displayed.
20.2. Tap Cancel if incorrect template was selected.
20.3. Tap Ok to continue.
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21. The Smart Interface System will automatically insert the template onto all recognized patterns
22. In the event certain patterns are to be omitted, complete the following steps, otherwise continue to
Step 23.
22.1. Tap the Delete Pattern button

22.1.1. The icon will illuminate blue, signaling that the Delete Pattern function has been
activated
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22.2. Once active, tap the patterns that are to be removed.
22.2.1. In the event a pattern was deleted on accident, repeat steps 16-21.
22.2.2. Once all desired patterns have been removed, tap the Pattern Recognition button to
turn the feature off
22.2.3. The Icon will return to its original grey color

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23. Tap to enter the Edit Profile Screen
24. Tap to reach the Profile Edit Screen

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25. Tap the box to the right of Z-Value and below Point 1
25.1. Once selected, the box will illuminate to a neon green.
26. Use the keypad to enter the height of the PCBA

26.1. If the height of the fixture is unknown, use the following steps, otherwise skip to Step 28.
26.2. Tap the Motion Control icon to access the motion controls.
26.2.1. The motion controls will now appear in place of the scroll wheel
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26.3. Tap the numerical box below the Snap button
26.3.1. The box will become highlighted once selected.
26.4. Use the keypad to enter a value of 5mm

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26.5. Tap the Z-Axis down button to begin jogging the end effector down toward the PCBA in 5mm
increments.
26.6. Once the Solder Tip has reached 5mm above the PCBA, change the snap value to 0.2mm
and carefully continue to jog down until the tip contacts the surface of the substrate.
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26.7. Tap the Record Z button
26.7.1. The numerical box to the right of Z-Value will automatically be populated with the
current height of the end effector.
26.8. Proceed to Step 28

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27. Tap Apply to All
27.1. The Smart Interface System will automatically change the Z-Values for ALL programmed
points.
28. Once the Z-Value has been inserted for every point, tap to save changes.
29. Tap to save all changes.
Pattern Recognition Using Template Complete!
Note: Metcal™ highly recommends testing out a profile before going into production. In some
cases, patterns may be recognized close to the corners of the camera viewing area, where the
curvature of the camera combined with parallax error may give the false impression of the actual
distance of objects. In such cases, points on an image may appear in the programmed location but
physically may be in another location altogether. For this reason, it is best to run the unit in Demo
Mode and/or use the Snap-To button for each point to confirm each programmed solder joint is in the
desired location and edit as needed.
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Layout Creation
Creation of a Template or Layout is required before use of Pattern Recognition. The template
is used to insert specific soldering parameters into a pattern once patterns/features have been
recognized by the Smart Interface System. The Layout tool differs from a Template in that it gives
users a much more precise method for not only inserting a Layout but a better defined and controlled
method of programming a Layout. Users can create a Layout for various components live, without
the need for looking up drawings or retrieving dimensions from a manufacturer. Complete the
following steps to create a layout.
1. Install a bare (if possible) PCB with the hole pattern that the Layout is being created for. Make
sure to use the designated fixture at the current calibrated height.

Alignment section
3.2. WARNING: Do NOT turn ON the Connection Validation Power Supply/ RF after installation of
cartridge.
4. Tap the Camera icon to turn on the camera.
4.1. The camera icon will illuminate to blue in color when active
5. Tap to ensure that the workspace is clear of all programmed points.
6. Tap once to toggle to solder point

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7. Swipe Up or Down to scroll to the desired Dot Parameter that is to be inserted on each pattern
identified.
8. Use the jog controls to position the camera image centered over the area of the PCB
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10. Save the image
programmed pattern.
11. Tap the camera icon once more to turn off the Camera

13. Highlight the desired image by tapping on the file name and tapping the Open File icon.
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14. Jog the head to the position (X, Y) where the first joint of the layout is to be soldered.
14.1. The zoom function may be utilized to locate the first joint.
15. Slowly jog end effector down in the Z-Axis until the cartridge is 5mm above the Layout area.
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PCBA substrate.
17. Tap the Record Button to establish the first point of the Layout.
18. Repeat this process for the remaining joints of the transistor.
18.1. Include any orientation changes that may be required, as the application dictates.
18.2. Note: If unsure of the orientation when programming, do not panic. The Profile Edit tool
allows for quick and painless edits to several points in a snap, even after the layout is used.
More details on the Profile Edit tool can be found in the Profile Edit section of the manual.
19. Tap the Save button in the Main Menu Bar to bring up the file management menu.
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19.1. Pro Tip: Save the Layout with the name of “Solder Parameter Layout” to aid in identification
of the parameters used and to distinguish from normal solder profiles.
20. Tap the Save Profile button.
Layout Creation Complete!

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Component Layout Creation
The Smart Interface System allows users to create a library of layouts based on component
dimensions. This is typically used in applications in which the component layout is to be used in
several instances within the PCBA. Components such as integrated circuit chips, transistors, etc. can
all be stored within the system to be inserted in any profile, when needed. One must have the
dimensions of the component readily available to use this feature to its fullest extent. Although
tedious to set-up, once a library of components is saved, future printed circuit boards can be
programmed with the greatest of ease.
2. Navigate to Profile Options and tap the waypoint icon once to toggle to solder point.
3. Swipe Up or Down to scroll to the desired dot parameter that is to be used.
4. Tap on an arbitrary location within the workspace so that all points recorded can be seen
4.1. Points programmed along any of the limits may be difficult to see.
5. When programming the following points, one must consider the geometry of the component, its
orientation, and critical dimensions. For this example, the following Operational Amplifier will be
used in the orientation shown on the next page.
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6. Select the transition movement type by toggling between Interpolation Move and Space
Move
7. Tap the record button to establish the coordinate of the first pin.
8. Jog the end effector in the +X direction in 2.54mm increments for the next three pins, recording a
point at each pin.
8.1. Note: Given the mechanical tolerances, the dimensions may need to be slightly edited once
inserted within a program. Please see the Edit Profile section for more details.
9. To navigate to pin 5 in the correct orientation, the following values would be used.

11. Jog the end effector in the -X direction in 2.54mm increments for the next three pins, recording a
point at each pin.
11.1. Dependent on the geometry of the component programmed, this may be sufficient for the
program. If this is true to the application skip to step 11. However, Metcal follows the IPC-J-
STD-001 and IPC-A-610 standards when soldering. Therefore, in this example, the
component will be soldered with alternating pins on alternating sides to be compliant.
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11.2. Tap to enter the Edit Profile Screen.
11.3. Tap to reach the Profile Edit Screen

11.4. Swipe up/down on the program order until DOT# 7 is highlighted.
11.5. Tap to reorder the point to position 2.

11.6. Swipe up on the Program Order until DOT #4 is highlighted.
11.7. Tap to reorder point to position 3.

11.8. Repeat this process until the points are programmed in the order shown on the next page.
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2 6
8 4
1 5
7 3
11.9. Tap to proceed with the changes.
12. Tap to save the template.

12.1. Pro Tip: Save the Layout with the name of “Solder Parameter Layout” to aid in identification
of the parameters used and to distinguish from normal solder profiles.
14. Tap the Save button to save the layout.
Component Based Layout Complete!

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Pattern Recognition Using Layout
30. Install PCBA with designated fixture at the current calibrated height.
30.1. This fixture should be the same one used to program the layout. In the event the fixture is
different, it is imperative to check the Z-Axis heights of each point before running any
program. Failure to do so may produce unfavorable results.
Alignment section
32.2. WARNING: Do NOT turn ON the Connection Validation Power Supply/ RF after installation
of cartridge.
33.1. Note: The icon will illuminate blue (shown below) when active and an image should appear
in the workspace.
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34.1. The ideal location for a screenshot would position the area of the PCBA that is to be
soldered centered within Computer Vision viewing area.
34.2. If necessary, use the quick theta snaps to rotate the end effector 90° to clear any bracketry
of end effector from obscuring view.

36. Save the image
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programmed pattern.
37. Tap the camera icon once more to turn off the Camera

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40. Tap the Open icon.

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

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42.1. The button will illuminate blue when active

42.2. In addition, the Pattern Recognition Window will appear in the CV display area.
Filter
Adjust Filter %
Neg
Filter
Insert
Adjust
Pattern
Pos
Delete Coarse
Pattern Adjust

43. Select the pattern to be recognized by tapping the top left corner of the object to be recognized
and swipe diagonally until a yellow box is formed around the desired pattern.
43.1. Note: Pattern selection MUST occur around component in which the crosshairs are located
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43.2. If unsatisfied with the area selected, a new box may be created using the same method
previously mentioned.
43.3. The system will automatically detect the number of identical patterns per previously
established filter percentage.
44. If needed, adjust the Computer Vision increase the filter until all patterns are recognized.
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44.1. In the event the filter is too large and unintended objects are identified, decrease the filter
percentage.
45. Tap the Insert Pattern button

46. Tap the Layout button
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47. Once the Layout button is highlighted, tap Select File
48. Select the desired template to be inserted

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49. Tap the Open Icon

49.1. The Layout name will now be displayed within the green box below Select File.
49.2. Tap to cancel
49.3. Tap to proceed with Layout insertion.
50. The Smart Interface System will automatically insert the Layout onto all recognized patterns
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51. In the event certain patterns are to be omitted, complete the following steps, otherwise skip to
Step 23.
51.1. Tap the Delete Pattern button

51.1.1. The icon will illuminate blue, signaling that the Delete Pattern function has been
activated
51.2. Once active, tap the patterns that are to be removed.
51.2.1. In the event a pattern was deleted on accident, repeat steps 16-21.
51.3. Once all desired patterns have been removed, tap the Pattern Recognition button to turn the
feature off
51.3.1. The Icon will return to its original grey color
52. Tap to enter the Edit Profile Screen

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53. If any changes are to be made to the Parameter, proceed with any changes, otherwise skip to the
next step.
54. Tap to reach the Profile Edit Screen
55. Tap the box to the right of Z-Value and below Point 1
55.1. Once selected, the box will illuminate to a neon green.
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56. Use the keypad to enter the height of the PCBA
56.1. If the height of the fixture is unknown, use the following steps, otherwise skip to Step 28.
56.2. Tap the Motion Control icon to access the motion controls.
56.2.1. The motion controls will now appear in place of the scroll wheel
56.3. Tap the numerical box below the Snap button

56.3.1. The box will become highlighted once selected.
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56.4. Use the keypad to enter a value of 5mm
56.5. Tap the Z-Axis down button to begin jogging the end effector down toward the PCBA in 5mm
increments.
56.6. Once the Solder Tip has reached 5mm above the PCBA, change the snap value to 0.2mm
and carefully continue to jog down until the tip contacts the surface of the substrate.
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56.7. Tap the Record Z button
56.7.1. The numerical box to the right of Z-Value will automatically be populated with the
current height of the end effector.
56.8. Proceed to Step 28

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57. Tap Apply to All
57.1. The Smart Interface System will automatically change the Z-Values for ALL programmed
points.
58. Once the Z-Value has been inserted for every point, tap to save changes.
59. Tap to save all changes
Pattern Recognition Using Layout Complete!
Note: Metcal™ highly recommends testing out a profile before going into production. In some
cases, patterns may be recognized close to the corners of the camera viewing area, where the
curvature of the camera combined with parallax error may give the false impression of the actual
distance of objects. In such cases, points on an image may appear in the programmed location but
physically may be in another location altogether. For this reason, it is best to run the unit in Demo
Mode and/or use the Snap-To button for each point to confirm each programmed solder joint is in the
desired location and edit as needed.
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MECHANICAL ADJUSTMENT OF COMPUTER VISION CAMERA
In the event digital zoom is insufficient for a given application, the camera may be
mechanically lowered. This in turn will increase the displayed image size. However, please note
that once the Computer Vision Camera has been mechanically adjusted, ALL previously programmed
solder patterns that are associated with Fiducial Points will NO LONGER BE VALID as the camera
will require calibration. In addition, all images previously taken will no longer have the correct scaling
factor, thus making jog commands using images inaccurate. This option should only be used as a
last resort or prior to creation of any profiles.

2. Jog to a position where the fixtured printed circuit board is within view of the camera.
2.1. For optimal results, locate a specific feature on the board
3. With an M2.5 hex key, loosen the 3x socket head cap screws to the left of the computer vision
camera assembly.
Socket
Head Cap
Screws
4. Adjust the assembly as far down as needed, using the reference feature that is displayed.
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4.1. If the image becomes out of focus:
4.1.1. Open the door of the Computer Vision System
4.1.2. Loosen the bottom locking thumb screw to allow for focal adjustment.
4.1.2.1. If needed, remove the thumb screw, focus the lens, and place into an alternative
locking screw hole.
Alt Thumb
Hole Screw
4.1.3. Once in focus, tighten thumb screw.

5. If satisfied with the image and focus, torque the socket head cap screws to 4.5 in-lbs.
Mechanical Adjustment Complete!
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TIP CLEANING
OVERVIEW
The Smart Interface System allows for complete customization of cleaning of the solder tip for
each run. Operators can choose the frequency, location, direction, and orientation of the cleaning
profile to accommodate a myriad of applications.
The Tip Cleaner assembly is located to the right of the work area, as shown below.
The Tip Cleaner assembly consists of two large stainless-steel brushes (1) for maximum tip
cleaning coverage. The properties of the stainless-steel minimize the amount of solder fusion to the
bristles, increasing the life of the brushes. As the solder tip enters the Tip Cleaner assembly, residual
solder on the tip will be brushed onto the Cleaning Tray (2). The tray is held in place with a magnetic
catch, so removal is a snap. As the tip exits the Tip Cleaner, the silicone cover (3) further prevents
residual solder from exiting the assembly.
Complete the steps on the following pages to set up a Tip Cleaning Profile.
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TIP CLEANING PROFILE SET UP
1. Tap the Create New Profile icon in the Main Menu Bar to clear the workspace of any
existing profile/ programmed points and send the unit to the home position.
2. Verify the Waypoint Icon is active in the Profile Options Section.
3. Verify the Interpolation Icon is active in the Profile Options Section

3.1. WARNING: Programming a Tip Cleaning Profile with Space Move may result in a collision,
depending on where the next programmed point of the profile is located. Best practice is to
program the Tip Cleaning Profile with Interpolation move
4. Jog the end effector in the X-Axis to the entrance of the Tip Cleaning assembly.
5. Tap the Record Button to establish the first point of the cleaning zone.
5.1. Pro Tip: Record coordinates of the first position on separate piece of paper to quickly establish
the start location in the Implemenation of Tip Cleaning Profile section.
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6. Jog the end effector until the end of the cleaning zone is reached.
7. Tap the Record Button once at the end of travel.

8. Return to the entrance of the Tip Cleaning assembly.
9. Tap the Record Button to establish the exit point.
10. Tap the Save Icon on the Main Menu Bar to Save the Profile
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10.1. Pro Tip: Give the profile name a designation of TCP at the beginning of the name to
designate the profile as a cleaning profile to easily identify it when the time comes to select a
cleaning profile (covered later in this section.) In the example below, TCP 1 was given as the
name of the profile.
11. Tap the Save icon
Tip Cleaning Profile Setup Complete!

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ADVANCE TIP CLEANING PROFILE
Please note that the instructions provided were to program a very simple cleaning profile, but
many more movements can be added. Commands to move the end effector up/down as well as
rotation can be implemented within a cleaning profile. In addition, commands to move in the X, Z,
and Theta (rotation) can be executed all at once, if desired. Commands in the Y-Axis will be
ineffective as movement in the Y-Axis is controlled by moving the top plate.
1. Tap the Create New Profile icon in the Main Menu Bar to clear the workspace of any
existing profiles and send the unit to the home position.
2. Verify the Waypoint Icon is Active in the Profile Options Section.
3. Verify the Interpolation Icon is active in the Profile Options Section

3.1. WARNING: Programming a Tip Cleaning Profile with Space Move may result in a collision,
depending on where the next programmed point of the profile is located. Best practice is to
program the Tip Cleaning Profile with Interpolation move
4. Jog the end effector in the X-Axis to the entrance of the Tip Cleaning assembly.
5. Tap the Record Button to establish the first point of the cleaning zone.
5.1. Pro Tip: Record coordinates of the first position on separate piece of paper to quickly establish
the start location in the Implemenation of Tip Cleaning Profile section.
6. Jog the end effector to the next desired location.
6.1. In this example, the tip will follow the path shown on the next page within the Cleaning Zone,
for a total of 2 passes.
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90°
8mm
3mm
8mm
16mm
6.2. Please note that this path will NOT provide the optimal cleaning of the solder tip, as
successful cleaning profiles are typically application driven. This path was chosen
merely for instructional purposes.
6.3. To program the path above, use the following steps:
6.3.1. Tap the Motion Control Icon to toggle to the Fine Adjustment motion controls
6.3.1.1. The following menu should be visible:
Visual Representation of
Path
6.3.2. Enter 8mm in the Z-Axis and tap the Up Icon
6.3.3. Tap the Record Button

6.3.4. Enter the following values tap their respective directions
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Path

6.3.6. Enter 8mm in the Y-Axis and 5mm in the Z-Axis fine adjustment.

6.3.8. Enter 8mm in the Z-Axis and tap the Down Button

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6.3.10. Return to the start location by entering 16mm in the X-Axis and tapping the Left Button
Path

6.3.12. Repeat steps 5.3.1-5.3.9
6.3.13. Tap the Save Icon on the Main Menu Bar to Save the Profile
6.3.14. Pro Tip: Give the profile name a designation of TCP at the beginning of the name to
designate the profile as a cleaning profile to easily identify it when the time comes to
select a cleaning profile (covered later in this section.) In the example below, TCP SAE
was given as the name of the profile.
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6.3.15. Tap the Save icon
Advanced Tip Cleaning Profile Complete!

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IMPLEMENTATION OF TIP CLEANING PROFILE
Once a cleaning profile has been created, the next task is to establish where the cleaning zone
is located. The cleaning zone starting point is customizable to accommodate most applications.
Custom cleaning zone locations will be covered in the next section. The Tip Cleaning Profile is a
global setting, or in other words, a setting that will affect all profiles. This profile will remain as the
cleaning profile until a new profile is selected. Therefore, it is imperative that the user be diligent
when programming the cleaning profile and verify that cleaning profile implemented will be compatible
with the solder profile selected. Cleaning will occur at the beginning of every profile as well as the
programmed frequency for solder points and solder lines. In addition, for every transition from a
solder point to a solder line (and vice versa), the system will automatically clean the tip before
performing the other type of soldering action.
1. Navigate to the Toolbar and select the Tip Cleaning Settings Icon
Toolbar
1.1. Note: The icon will illuminate when active

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1.2. Once the Tip Cleaning Settings is activated, the following menu will appear:
Name of
Active
Open Tip TCP
Record
Clean
TCP Start
Profile
Location
(TCP)
Solder
Coord. of
Point
Clean
TCP Start
Frequency Location
Solder
Line Clean
Frequency
Set # of
Solder Set
Solder Confirm Cancel
Retract Length
Points/ Changes Changes
Length (mm)
Lines

This function opens the profile directory to allow user to select desired
Tip Cleaning Profile. WARNING: Do NOT select a Solder Profile for a
TCP as this will lead to undesired results and potential damage to the
unit.
Solder Point Clean Frequency establishes the number of joints the

robot will solder before heading to the cleaning zone to execute the
TCP.
Solder Point Clean Frequency establishes the number of lines the

robot will solder before heading to the cleaning zone to execute the
TCP.
This function allows for the user to establish the start location of the
TCP. The start location can be established at any point within the
working envelope 400mm x 400mm x 100mm x 300° (X, Y, Z, Θ). The
coordinates of the current TCP start location are displayed directly
beneath the icon.
Establishes length of solder that is to be retracted back into feeder tube
during tip cleaning. Depending on the position of the feeder tube
relative to the solder tip, the length of solder exposed can vary.
Exposed solder can be repositioned during the cleaning zone;
therefore, it is ideal to program length of solder to fully retract into
feeder tube during solder cleaning.
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2. Tap the Open Tip Clean Profile button

3. Select the desired Tip Cleaning Profile
3.1. In this example, TCP Mr Clean.rbt is used as the Tip Cleaning Profile
4. Tap the Open Profile Icon to proceed with loading of the Tip Cleaning Profile
4.1. WARNING: Tapping of the Open Profile Icon will immediately send the robot to the home
position. Please clear the working envelope of any obstructions or limbs before sending the
command.
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5. Jog end effector to the front of the Tip Cleaning Assembly
5.1. Pro Tip: Absolute Move can be used to position the end effector at the start of the
cleaning profile by entering the coordinates recorded from either step 4.1 from either the basic
or advanced tip cleaning profile setup procedures in their respective locations in the Absolute
Move menu.
6. Tap the Record Tip Cleaning Profile Start Location button to establish the start location of
the Tip Cleaning Profile.
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7. Tap on the yellow box to the right of the Solder Point Clean Frequency icon to enter the
number of joints the unit will solder before heading to the cleaning zone.
8. Tap on the yellow box to the right of the Solder Point Clean Frequency icon to enter the
number of joints the unit will solder before heading to the cleaning zone.
9. Tap on the yellow box to the left of the Solder Retract Length icon to enter the length (in
millimeters) of solder that is to be retracted into the solder tube assembly during the cleaning zone
9.1. This information will only be known once the solder feeder tube assembly is adjusted in the
desired location.
9.2. With the iron hot, solder should be fed until the solder wire contacts the tip.
9.3. After contact is made, use a pair of calipers to measure the length from the solder feeder tube
to the tip of the un-melted solder wire.
9.4. Enter measured value in the yellow box to the left of the of the Solder Retract Length icon.
10. Tap the Confirmation button to accept all settings and proceed with the implementation of
10.1. Tap the Cancel button to make any further changes or to abort any changes
altogether.
Tip Cleaning Profile Implemented!

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TIP CLEANING TROUBLE SHOOTING
This section will describe what to do when a Tip Cleaning Profile error appears. The Tip
Cleaning Profile error message will only appear when trying to run the profile, not immediately when
an invalid Tip Cleaning Profile/Start Location is programmed. The following message will appear
when an error has occurred:
An error can occur when one of two events happens:

1.) The programmed Tip Cleaning Profile Start Location is incompatible with the selected Tip
Cleaning Profile.
2.) The selected Tip Cleaning Profile is incompatible with the programmed Tip Cleaning Profile
Start Location.
At first glance, it appears that the two events are one in the same, which is partially true. The
main cause is that a point or multiple points from the TCP are falling outside the working envelope, as
a result of the previously two mentioned causes. When this error occurs, the system will identify how
many points are outside the working envelope and their coordinates.
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In the example provided, two points are identified as falling outside the working envelope. One
point identified as out of bounds is located at 400.007, 0, 50, 0 (X, Y, Z, Θ) and the other is located at
405.002, 0, 50, 0. Because the working envelope is 400, 400, 100, 300, the X-Axis points need to be
adjusted. However, one must decide whether to reprogram the two points within the working
envelope or to choose a starting point 5.1mm to the left so that both points of the Tip Cleaning Profile
are brought back within the boundary of the unit. Both approaches are acceptable, but the choice
between one or the other should be based off the application. Use the following table to help decide
whether to change the start location or the TCP.
Reprogramming Decision Guide
Changing the TCP Start Location Changing the Points Within TCP
≥ 3 Points Are Out of Bounds < 3 Points Are Out of Bounds
TCP is very complex Obstructions Prevent New Start Location
TCP Provides Ideal Cleaning TCP Contains Extraneous Points
Process Control Prevents Change of TCP Solder Point Accidentally Programmed in Cleaning Profile
EDITING A CLEANING PROFILE

If after reviewing the reprogramming decision guide, it is determined that the points within a Tip
Cleaning Profile must be reprogrammed, the following steps will instruct on how to do so.
1. Clear the error messages by tapping Ok
2. Tap the Open Profile icon to display all available profiles

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3. Tap the Tip Cleaning Profile in question
4. Tap the File Open Icon to open the TCP

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5. Tap the Edit Profile Icon

5.1. The Edit Screen will appear, as shown below.
6. Tap the Point Edit button

7. Swipe up or down to scroll to first point in question.
7.1. Note: Waypoints will be identified as “MOVE”
7.2. The point under edit will be highlighted with a yellow band.
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8. Tap the green box to the right of X - Value
9. Tap the backspace key on the numeric keypad.

10. Enter a value that will fall into range based off the programmed Tip Cleaning Profile Start
Location.
10.1. In this example, two points were identified as out of bounds, one located at 400.007, 0, 50, 0
(X, Y, Z, Θ) and the other was located at 405.002, 0, 50, 0. Because the value programmed
within the profile was 390.007, this would imply that the Tip Cleaning Profile Start Location
was programmed at 390mm in the X-Axis. (This is because the programmed point is at
390.007 in the X-Axis but identified as out of bounds at 400.007. There is a 10mm shift to the
right in the X-Axis. A shift can only occur if the TCP Start Location is programmed in a
location differing from the start location of the TCP. In this case, it was programmed at
390mm.)
10.2. Using this example, the proper choice would be any value >10mm to the left but not a value
so great that it no longer falls within the cleaning zone. Therefore, a value of 10.5 will be
chosen, which in turn makes the X-Value coordinate 379.5.
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11. Swipe up to scroll to the next point.
12. Using the same logic in step 12, the next X-Value selected would be 384.5.
13. Tap the Confirm Changes icon to proceed with the modifications.
14. Tap the Save Icon to save changes.

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

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19. Select the Tip Cleaning Profile that was edited in the previous steps.
19.1. In this example, TCP Mr Clean.rbt is used as the Tip Cleaning Profile
20. Tap the File Open Icon to open the TCP.
21. Tap the Confirmation button to proceed with the changes made.
22. Tap the Run Icon to test the TCP and verify that all points were re-programmed correctly
and that the tip cleaning is sufficient for the intended application.
22.1. If the profile is not to the operator’s satisfaction, repeat the steps listed within this procedure
until the desired TCP is achieved.
Editing a Cleaning Profile Complete!

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CUSTOM CLEANING LOCATIONS
There may be some applications in which the provided Tip Cleaning Assembly is incompatible,
or the Customer wishes to use their preferred tip cleaning device. For this reason, the Smart
Interface Software allows for the customization of where a cleaning profile can take place to meet a
wide variety of applications. The appropriate method for cleaning the tip is highly dependent on the
tip cleaning device itself. Therefore, this procedure will solely describe how to set a custom cleaning
start location. Please take careful consideration when selecting the new cleaning profile location.
Failure to do so may result in damage to the unit. Below is the setup that will be used in this
example.
165mm 250mm
1. After the desired Tip Cleaning Profile is created and loaded, tap the Absolute Move icon to
position the end effector at the start location of the TCP.
1.1. In this example, the start location was programmed to be at 165mm in the X -Axis, 250mm in
the Y-Axis, and 65mm in the Z-Axis. However, as a safety precaution, only X & Y will be
programmed to ensure any collisions will be prevented in the vector movement.
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2. Tap the yellow box labeled “Move” to execute the command.
3. Within the toolbar, tap the Motion Control icon once to toggle to Fine Adjustment
4. Enter 65mm in the Z-Axis controls and tap the down arrow.
5. Tap on the Tip Cleaning Settings Icon
6. Tap the Record Tip Cleaning Profile Start Location button to establish the start location of
Custom Cleaning Location Programming Complete!

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BRUSH REPLACEMENT
After a fair amount of use, solder will eventually build up within the bristles of the stainless-
steel brushes provided in the Tip Cleaning Assembly. The frequency in which one will need to
replace the brushes is application specific and will depend on frequency of use, amount of solder
dispensed, etc. Therefore, it is best to inspect the brushes after every shift and use good judgement
to determine whether they should be replaced. When the time comes for replacing brushes, use the
following steps.
WARNING: Appropriate Personal Protection Equipment (PPE) is REQUIRED

when performing this procedure. Failure to do so may result in injury.
1. Put on PPE
1.1. Puncture Resistant Safety Gloves
1.2. Safety Glasses
2. Remove Tip Cleaning Assembly cover.
3. Grasping from the back side of the bristles (as indicated by the arrow,) slide the brushes toward
the front of the assembly until the brush is completely removed.
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4. Repeat for the other side.
5. Insert the new stainless-steel brush with the bristles facing inward and brush backing fitting within
the holding feature of the Tip Cleaning Assembly base.
6. Push until each brush contacts the stop.

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7. Repeat for other brush.
8. Reassemble lid.
Brush Replacement complete!

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INSTALLATION & USE OF FUME EXTRACTION & NITROGEN
The RSS-1000-CVSI is plumbed and ready for fume extraction, as well as nitrogen, although
both are sold separately. Metcal™ offers several fume extraction systems, which can be found at the
following web address:
http://www.okinternational.com/metcal/english/globalnavigation/products/fume-extraction
Nitrogen must be purchased from a reputable supplier.
FUME EXTRACTION
For the safety of the operators and working environment, Metcal offers a full line of solder fume
extractors. From volume to bench-top fume extraction, Metcal™ has systems to purify the air by
filtering harmful smoke and particulates from the working area. However, the RSS-1000-CVSI can be
used with any fume extraction device that attaches to the Extraction Hose (included.) The
dimensions of the Extraction Hose are shown below.
56mm
1380mm ± 10
75mm
When a fume extraction device is connected, the tubing is routed at the rear of the gantry as
shown:
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The tubing is then routed with the cable chain at the top of the gantry, and then routed to the
end effector, close to the iron. The fume extraction tube is indicated by the arrow below:
Please note that there is no interaction between the software and fume extraction. All settings
for fume extraction are done independently of the Robotic Soldering System. In addition, to achieve
the highest performance of the soldering iron, please be mindful of the airflow setting on the fume
extraction device. Keep airflow settings at such that they do not impact the idle power of the tip. The
idle power is the power shown in the Connection Validation Display when the RF has been turned on,
power bar has settled, and no load is present on the soldering iron. This idle power will vary based
on tip geometry and temperature series.
NITROGEN
Nitrogen (also referred to as N2) is an inert gas that is used as a means increase soldering
performance when compared to conventional soldering. N2 reduces oxidation during the soldering
process, thus increasing tip life and protecting components being soldered. In addition, it can reduce
the amount of dross that can occur during soldering.
An added benefit is that nitrogen is environmentally neutral, or in other words, will not react
with other elements. Therefore, it will not create any greenhouse gasses or other harmful reactions.
In addition, a nitrogen rich environment will significantly minimize the need to clean impurities off the
iron, therefore reducing the amount of environmentally unfriendly chemicals needed to accomplish
this task.
Nitrogen can be plumbed to the unit, either from a N2 generator or from an N2 tank. However,
because of the wide variety of fittings that can be used, a fitting will not be provided with the RSS-
1000-CVSI. Once the proper fitting for the N2 tank used is acquired, connect it to a high pressure,
6mm OD tubing. The open end of tubing will connect to the N2 entry point, located to the left of the
pressure regulator at the rear of the unit, as shown on the next page.
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Metcal™ recommends dialing the N2 pressure regulator between 0.3-0.45MPa. < 0.3MPa will
clear out the pressure regulator reservoir. The maximum setting for the air pressure regulator should
not exceed 0.45MPa as this not consumes a significant amount of N2 but also decrease fatigue life of
tubing.
Once the input air has been connected to the system, N2 can be toggled ON/OFF via the
Smart Software. Once logged into the software, navigate to the Toolbar at the right-hand side of the
work area.
Toolbar
Tap the N2 icon once to activate the flow. The icon will illuminate to the gold color shown
below.
Tap the N2 icon once more to deactivate the flow. The icon will return to its original gray
color.
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TROUBLESHOOTING
Motion Control
Symptom Cause Solution
The physical emergency stop
Twist the button clockwise to release the button.
button is activated.
Unit is Locked Communications cable is Check connections of Communications Cable on the Robot Side and the
1 Up/ Cannot unplugged. Controller Box side
Move Communications cable is
Contact Metcal Technical support for replacement parts
damaged.
Touch screen USB unplugged. Check USB connection at monitor and controller box.
CCD Witness camera monitor Lower monitor arm or extend out monitor arm to location in which solder
arm is hitting the Solder Feeder. feeder does not contact monitor.
Object is caught underneath the
Grinding Remove object from underneath top plate.
top plate.
Sound Heard
2 Calibration slider assembly is
During
Movement positioned too far left, Reposition calibration slider further right to avoid contact with gantry arm.
contacting left gantry arm.
Solder tip cleaning tray arm is Loosen mounting screws of solder tip cleaning tray arm on the right gantry
contacting fixture. arm and raise arm until tray clears obstacle.
Speed settings are set too low Tap the speed settings icon and adjust the slide bar to the desired speed.
Within the edit program window, select the Parameters button to reach the
edit parameter window. Within this window, scroll through the parameters
within the box to the left of the keypad until the parameter that is behaving
Parameter speed programmed
slowly is highlighted by the yellow ribbon. Increase the speed by entering
too low.
the desired value in the blue-green box to the right of the yellow "Speed"
box. Tap the checkmark to proceed with the changes. Don't forget to save
the profile if satisfied with the changes.
Within the edit program window, select the Parameters button to reach the
edit parameter window. Within this window, scroll through the parameters
Unit is moving within the box to the left of the keypad until the parameter that is behaving
3 extremely slowly is highlighted by the yellow ribbon. Increase the acceleration by
slow Parameter acceleration entering the desired value in the blue-green box to the right of the yellow
programmed too low. "Acceleration" box. Always choose an acceleration value far greater than
the programmed speed. Tap the checkmark to proceed with the changes.
Don't forget to save the profile if satisfied with the changes. Tap the
checkmark to proceed with the changes. Don't forget to save the profile if
satisfied with the changes.
Within the edit program window, select the Patterns button to reach the
edit pattern window. Within this window, increase transition speed by
entering the desired value in the blue-green box to the right of the yellow
Transition speed programmed
"Transition Speed" box. Tap the light blue "Apply to All" box to apply this
too low.
transition speed to every transition within the profile. Tap the checkmark
to proceed with the changes. Don't forget to save the profile if satisfied
with the changes.
Theta rotation
is moving
4 Theta speed set too low. Adjust to desired speed and tap the reset button to clear previous settings.
extremely
slow.
7000-5970 Rev. A
page 363 of 396
Soldering/ Connection Validation
Connection Validation power supply Turn on Connection Validation power supply via the red switch
is powered off. on the upper rear, right side of the unit.
Check connections at the bottom of the Connection Validation
TTL Line is unplugged power supply at the rear of the unit, and at the robot at the
bottom rear of the unit.
"CV Unavailable"
1 TTL Line is damaged Contact Metcal Technical Support for replacement parts.
Displayed
Check connections at the bottom of the Connection Validation
USB Line to Connection Validation
power supply at the rear of the unit, and at the robot at the
power supply is unplugged.
bottom rear of the unit.
USB Line to Connection Validation
Contact Metcal Technical Support for replacement parts.
power supply is damaged
Connection Validation power supply Turn on Connection Validation power supply via the red switch
is powered off. on the upper rear, right side of the unit.
Only Metcal produced Connection Validation cartridges may be
Cartridge Not
2 Non-Conforming Cartridge Inserted used with the system. Competitor cartridges will not work in
Heating Up
system.
CV-H8-AV Cable Worn Replace CV-H8-AV Cable (Instructions can be found here.)
"ESD" Appears Red Verify there is a solid connection between the Connection
3 Ground Fault Detection
on CV Display Validation power supply and the end effector cable.
Cycle power at the top-right of the back side of the unit. If

"Load" Appears on Failure to Load Firmware in Dual
4 cycling power does not clear error code, contact Metcal
CV Display Simultaneous Mode
Customer Support.
Loosen set screw in end effector or cartridge lock to readjust
No Cartridge Detected soldering cartridge so that the connector engages when
"Open" Appears inserted within end effector.
5
On CV Display
"Temp" Appears Remove any objects blocking the ventilation of the power
6 Power Supply is Overheating.
On CV Display supply.
Only Metcal produced Connection Validation cartridges may be

Non-Conforming Cartridge Inserted used with the system. Competitor cartridges will not work in
system.
"NCC" Appears on Remove cartridge with silicone removal pad and reinsert back
7 Cartridge Inserted Incorrectly
CV Display into end effector, If
Loosen the M4 set screw of the CV-H8-AV of end effector and

Intermittent Cartridge Not Inserted All the Way release the spring tension to allow for full travel into the internal
8 “Error” Message connector.
on CV Display
Constant “Error”
9 Message on CV CV-H8-AV Cable Worn Replace CV-H8-AV Cable (Instructions can be found here.)
Display
Camera
Loosen locking screws (if needed) and adjust the lens until the
Lens has become out of focus.
camera is visible in focus. Once in focus, recalibrate the camera.
Ensure the lens locking screws are tightened al Using a micro-
Dirt/debris stuck on lens.
1 Image Not Clear fiber cloth, carefully clean dirt debris away.
Thread lens back into lens adapter by rotating clockwise, being
Lens has loosened from adapter. mindful not to adjust the focus on the lens. A change in focus will
require full camera calibration.
7000-5970 Rev. A
page 364 of 396
No Image When
2 Camera is USB was unplugged upon boot up. Save any changes. Plug in USB cable and cycle power.
Activated
Live Image No
3 USB has become unplugged. Save any changes. Plug in USB cable and cycle power.
Longer Live
Solder Feeder
Cut the solder wire 3mm (≈1/8") from deformation area of
solder. Remove solder at feeding mechanism with a pair of
needle nose pliers. Use a pick to remove any solder stuck in
Jam at feeding mechanism
the grooves of the feeder wheel. Remove length of solder
that remains in the tube. Manually feed solder once all
obstructions have been cleared.
Visually inspect solder feeder tube for any obstructions.
Remove solder feeder tube tip and inspect for obstructions.
Jam within tube
If neither has an obstruction, inspect the solder alignment
tube for obstructions.
Feeder tube too close to iron, causing solder
Contact Metcal Technical Support for replacement part.
Solder Not to collect within tube.
1
Dispensing Insert Solder Feeder Communication Cable into its
Solder Feeder Communication Cable designated location. Fasten locking ring to the connector on
unplugged or not plugged in all the way. the robot to ensure that the connector is completely inserted
into the robot.
Only use the diameter solder specified on the front door of
Non-compatible diameter solder used in the solder feeder. The solder feeder is designed to only
solder feeder. work with the designated solder diameter. Use of any other
solder diameter will result in jamming.
The Solder Feeder is equipped with a switch to detect the
No solder is in the feeder. presence of solder. In the event no solder is detected, an
indicator will appear in the CV menu.
Solder Feeder has become unplugged at Plug in connector. Tap the "Feed Solder" icon to confirm
head. functionality.
No Solder
2 Feeder Motor Insert Solder Feeder Communication Cable into its
Movement Solder Feeder Communication Cable designated location. Fasten locking ring to the connector on
unplugged or not plugged in all the way. the robot to ensure that the connector is completely inserted
into the robot.
Software
Controller box power cable is not Check connections of Power Cable on the Robot Side and the
plugged in. Controller Box side
Check to make sure monitor is plugged in both at the monitor
and at the external power supply. Check to see if the green
No power to the monitor.
LED indicator is illuminated, indicating that the monitor is
powered on.
Robot Powers On, Monitor on incorrect input. See monitor manual for instructions on switching inputs.
1 Software Does Check connections of HDMI cable both at the monitor and at
Not the controller box. If both are plugged in completely and
HDMI cable not plugged in
correctly, contact Metcal Technical Services for a
replacement cable.
Check connections of HDMI cable both at the monitor and at
the controller box. If both are plugged in completely and
HDMI cable damaged
correctly, contact Metcal Technical Services for a
replacement cable.
7000-5970 Rev. A
page 365 of 396
Move the Pattern Recognition Filter slide bar further left until
Computer Vision Pattern Recognition
the desired patterns are the only ones identified by the
Filter set too loosely (too far to the right.)
Pattern yellow circles.
Recognition
Recognizing
2 When drawing the rectangle around the desired pattern, it is
Additional
good practice to keep the rectangle as close to the featured
Patterns Not
User defined Pattern Recognition pattern as possible. When there are large open areas around
Specified
Selection Box includes additional space the feature, the Vision System may become confused as to
outside the pattern. what exactly is the pattern to be identified. Only select what
is necessary to identify a pattern (refer to pattern recognition
section of manual for more detail.)
Uneven lighting will cast shadows or produced localized
bright spots on a work piece. This will have adverse effects
on the pattern recognition software. Although to the human
Unevenly distributed lighting on eye objects may be known to be the correct pattern, shaded
workpiece. features will be treated separately from well lit features.
Therefore, keep lighting evenly distributed and diffuse
across the entire workpiece. Choose an installation location
in which lighting is controlled.
The software will identify features with dirt/debris/ or
Pattern markings as completely separate features than those that are
Recognition Not perfectly clean. Therefore, keep all workpieces visually
3
Recognizing Dirt/Debris/Markings on workpiece clean by cleaning with isopropyl alcohol or appropriate
Patterns cleaning solution. Do NOT mark workpieces with tape or
permanent marker unless the they are identical from board
to board.
When drawing the rectangle around the desired pattern, it is
good practice to keep the rectangle as close to the featured
User defined Pattern Recognition pattern as possible. When there are large open areas around
Selection Box includes additional features, the feature, the Vision System may become confused as to
not relevant to pattern. what exactly is the pattern to be identified. Only select what
is necessary to identify a pattern (refer to pattern recognition
section of manual for more detail.)
If the solution cannot be found in the table above, please contact us at:
http://info.okinternational.com/metcal-request-application-support
Or one of the following locations below:
Americas
Metcal, a division of OK International Inc.
10800 Valley View Street
Cypress, CA 90630
U.S.A.
Tel: 1-714-799-9910
Fax: 1-714-828-2001
Email: NA-CustCare@okinternational.com
Europe
Sales Support
Europe & UK
Metcal, a division of OK International Ltd.
Eagle Close, Chandlers Ford
Hampshire, SO53 4NF
U.K.
Tel: +44 (0) 23 8048 9100
Fax: +44 (0) 23 8048 9109
7000-5970 Rev. A
page 366 of 396
Email: europe-orders@okinternational.com
Sales Support
Germany
Tel: 00 49 (0) 3222 109 1900
Fax: 00 49 (0) 3222 109 1901
France
Tel: +33 (0)1 76 71 04 03
Fax: +33 (0)1 70 71 21 50

Asia
China
Metcal, a division of OK International
4th floor East, The Electronic Building, Yanxiang Industrial Zone
High Tech Road, Guangming New District
Shenzhen, P.R.C.
Tel: +86-755-2726 6366
Fax: +86-755-2329 5492
Email: china@okinternational.com
Sales Support
Japan
Sales: +81-198-22-7928
Service: +81-03-4520-9629
Fax: +81-03-6745-1439
Email:
India
Division of Dover India Pvt. Ltd.
India
Tel: +91 9762452474
Email: drane@metcal.com
Singapore
OK International (Sales Support Office)
Singapore
Tel: +65 9798 4443
Email: ryip@metcal.com
7000-5970 Rev. A
page 367 of 396
MAINTENANCE & INSPECTION
Tasks Performed with Power Off
Task Location Daily Monthly Quarterly Biannual Annual
Covers X X X X X
Mounting Brackets X X X X X
Inspection of Fasteners
Monitors X X X X
End Effector
X X X X X
Components
Cleaning of Dirt &

X-Axis Linear Guide X X X X X
Debris

Y-Axis Linear Guide X X X X X
All Vents X X X X
Solder Feeder X X X X X
Cleaning of Dirt & Cable Chain X X X
Debris
Tip Cleaner Tray X X X X
Tip Cleaner
X X X X X
Brushes*
Top Plate* X X X
X X X
Lubrication Linear
Y X X
Guides*
Z & ** X X
Unit Power X X X X X
Inspection of Cables CV Power X X X X X

All Connections
X X X X X
(Pages 15-17)
* As Needed, Dependent on Usage.
** WARNING - Lubrication of Z & θ Axes require disassembly of Computer Vision System. Disassembly of Computer Vision System
may require recalibration of Camera, which will affect programs with Fiducial Points assigned.
Tasks Performed with Power On

All Axes X X X X X
Tip Cleaner Arm X X X X X

Clearing of Obstructions
Inspection of Fasteners
Emergency Stop X X X X X
Power Button X X X X X
7000-5970 Rev. A
page 368 of 396
Working Area X X X X X
Fans X X X X
Emergency Stop X X X X X
Lighting Controls X X X X X
Fans X X X X X
Functionality of Key
Components
(Contact Technical Soldering Iron X X X X X
Support for
Malfunctions)
Touch Screen X X X X X
CCD Camera X X X X X
Computer Vision
X X X X X
Camera
7000-5970 Rev. A
page 369 of 396
REPLACING CV-H8-AV
With the constant flexing of the cable during operation of the unit, the CV-H8-AV Cable will
need to be replaced every so often. The time between replacements will depend on usage. To keep
the RSS-1000-CVSI operating at highest levels off efficiency, it is imperative to keep up with the
maintenance schedule listed on the previous page. Typically, damage due to wear over time will
likely occur at the strain relief, as indicated by the arrow.
In the rare event a failure occurs within the CV-H8-AV itself, the software will display both the
Error and Open error codes within the CV Display as shown below. These error codes in addition to
the NCC may flash on/off, indicating an intermittent signal.
A lack of performance with a brand-new CV soldering cartridge is another good indicator that it
is time to change the CV-H8-AV. If the system experiences any of the previously mentioned issues,
please use the following steps to successfully replace the CV-H8-AV.
7000-5970 Rev. A
page 370 of 396
1. Remove CV Cartridge (if any) from the assembly by rotating the cartridge lock 90°
counterclockwise
1.1. Pull out from the assembly once in the correct orientation.
2. Use an M2 hex key to loosen the set screw of the Spring Retainer on the CV-H8-AV
7000-5970 Rev. A
page 371 of 396
2.1. Allow the Spring Retainer to hang freely.
3. Loosen the Locking Nut of the Solder Wire Feeder to remove the Solder Wire Feeder tubing.
4. Carefully cut all cable ties along the path of the CV-H8-AV cable.
4.1. Take careful note where cable ties are placed as the locations have been chosen for optimal
flexibility while minimizing the risk of binding and decreasing fatigue life of strain relief.
7000-5970 Rev. A
page 372 of 396
5. Remove the cable from the assembly and place CV-H8-AV on gantry until it is fully disassembled
from unit.
7000-5970 Rev. A
page 373 of 396
6. Unfasten the four M3 pan head machine screws and remove the washers of the CV Power Supply
enclosure at the rear of the unit.
7. Lift off the lid of the enclosure to gain access to the connectors of the CV-H8-AV.
8. Disconnect the CV-H8-AV from the two ports of the CV Power Supply.
7000-5970 Rev. A
page 374 of 396
8.1. The 6 Pin Mini DIN Plug (top port) can be disconnected by grasping each side and lifting in
the direction coaxially to the connector.
8.2. The RF Connector (bottom port) can be disconnected by unthreading the connector and lifting
in the direction coaxially to the connector.
9. Discard the old CV-H8-AV responsibly

9.1. Do NOT trash, send out for proper electronics recycling
7000-5970 Rev. A
page 375 of 396
10. Feed the new CV-H8-AV cables through their respective cutouts on the cover.
11. Connect the 6 Pin Mini DIN Plug to the top port and the RF connector to the bottom port.
7000-5970 Rev. A
page 376 of 396
12. Seat the CV Power Supply enclosure lid and fasten the four M3 pan head machine screws and
washers.
13. Route the CV-H8-AV cable along the path shown in Step 6, replacing all cable ties along the way.
7000-5970 Rev. A
page 377 of 396
14. Insert CV Cartridge and Cartridge Lock into the End Effector Cartridge Holder. Rotate clockwise
to secure in place.
15. Tap the Home Button to ensure the End Effector is positioned at 0,0,0,0 (X, Y, Z, Θ)
16. Slowly and carefully jog the End Effector down in the Z-Direction towards the calibration
fixture, stopping at roughly 5mm above the fixture.
17. Tap the Motion Control button to toggle to the fine adjustment menu.
7000-5970 Rev. A
page 378 of 396
18. Enter 0.2mm in the Z-Axis fine adjustment and carefully position the end effector to the calibration
fixture height, adjusting the values as needed until the cartridge gently contacts the fixture.
18.1. Please note that the orientation of the cartridge will likely no longer be aligned at this point
and/or out of position in the X-Axis. DO NOT loosen set screw of the Cartridge Lock to
account for orientation or position issues (see next step.)
19. Slide the Spring Retainer of the CV-H8-AV down until a sufficient amount of pressure has been
applied to the End Effector Cartridge Holder.
7000-5970 Rev. A
page 379 of 396
19.1. Use an M2 hex key to torque the set screw of the Spring Retainer once in place.
19.1.1. Torque to 1.4 N·m (19.0 in-lbs.)
20. Remove cartridge lock and reinsert.

20.1. If the required force is too great for comfort, unfasten set screw and repeat Step 27,
otherwise proceed.
7000-5970 Rev. A
page 380 of 396
21. Power ON the RF to verify a good connection has been made
21.1. If an NCC error signal is received, loosen the set screw and repeat steps 27 & 28 with
greater spring force than previously applied.
21.1.1. Restart the system via the power switch on the front of the unit.
21.2. If no errors appear, proceed to next step.
22. Reconnect the Solder Wire Feeder tubing and hold in place with locking nut.
CV-H8-AV Replacement Complete!

7000-5970 Rev. A
page 381 of 396
CHANGING SOLDER WIRE FEEDER
Metcal™ offers a variety of Solder Wire Feeder Kits to aid in tackling a wide range of
applications. All kits include two feed gears, two solder alignment funnels, and guide tubing for the
specified diameter. Below is a list of what is currently offered.
Solder Wire Feeder Kits
Part Number Description
AC-RSS-05-SWFKIT Solder Wire Feeder Kit, Ø 0.5 MM
All kits can be adapted to any unit with a few simple steps. Use the following procedure to
change out the Solder Wire Feeder to meet
1. Cut solder above the top solder alignment funnel.
2. Remove remaining solder from tubing by pressing and holding the Pulse Solder Feeder Backward
button.
7000-5970 Rev. A
page 382 of 396
3. Use an M1.5 Ball-End L-Key to loosen the set screw and remove top alignment funnel.
4. Using an M1.5 hex key, ¼ turn the mounting screws of Solder Wire Detection switch counter-
clockwise.
4.1. Do NOT remove screws completely, as this will require disassembly of Solder Wire Feeder to
gain access to nut plate, to which the screws are fastened to.
7000-5970 Rev. A
page 383 of 396
5. Use an M1.5 Ball-End L-Key to loosen the set screw and remove bottom solder alignment funnel.
6. Loosen locking nut of the solder wire feeder assembly and pull down to remove from assembly.
7000-5970 Rev. A
page 384 of 396
7. Loosen lucking nut of the solder wire feeder tubing adjustment assembly.
8. Pull tubing from back side

7000-5970 Rev. A
page 385 of 396
9. Pull the front half of the guide tube from front side
10. Use a M1.5 hex key to loosen the 2x set screws of retaining ring until set screws begin to protrude
from the driving gear
10.1. Pro Tip: Reduce speed of solder wire feeder to 2 mm/s and tap the Pulse Solder Feeder
Forward button until the other set screw is accessible.
7000-5970 Rev. A
page 386 of 396
11. Remove retaining ring.
12. Remove feed gears.

12.1. Note: Gears will both come out at the same time.
13. Fit the new feed gears together, as shown below.

7000-5970 Rev. A
page 387 of 396
14. Install feed gears with the larger diameter wheel on the left and with the gear teeth facing down.
15. Place retaining ring onto post of the left feed gear and torque set screws to 0.4 N-m (3.5 in-lbs.)
16. Insert new solder alignment funnel on the bottom and torque set screw.
7000-5970 Rev. A
page 388 of 396
17. Insert new alignment funnel on the top and torque set screw.
18. Adjust Solder Wire Detection switch such that the arm of the switch lies in the solder path.
18.1. Test location by inserting solder through the top funnel to confirm solder activates switch
18.2. There will be an audible click when the switch has been properly engaged.
7000-5970 Rev. A
page 389 of 396
19. Torque mounting screws of Solder Wire Detection switch.
20. Slide locking nut of solder wire feeder over the new tubing with the raised feature of the locking
nut facing away from the tubing.
21. Insert tubing until there is about 1mm of clearance between the tubing and the Solder Wire Feeder
gears.
7000-5970 Rev. A
page 390 of 396
22. Insert bottom portion of guide tubing through the locking nut of the Solder Wire Feeder Tubing
Alignment assembly.
23. Insert the nozzle tubing through the underside of the assembly.
23.1. Tighten locking nut once in place.
7000-5970 Rev. A
page 391 of 396
24. Insert solder through the funnels until contact is made with the feed gears.
25. Tap the Pulse Solder Feeder Forward button within the solder feeder options menu to feed
solder through tubing, until it comes out through the nozzle.
25.1. The solder may need to be pushed further into feed gears by hand in order for the gears to
bite into the solder to feed it forward.
7000-5970 Rev. A
page 392 of 396
26. Cut excess solder.
Solder Wire Feeder Change Complete!

REPLACING A FUSE
The RSS-1000-CVSI comes with one spare fuse. Replacement fuses can be purchased from any
electronic components distributor as long as they meet the following specifications required for the
robot.
Fuse Specifications
Attribute Value
Fuse Type Fast Blow
Fuse Dimensions Ø 5 mm x 20 mm LG
Voltage Rating 250 VAC
Current Rating 2A
Mounting Style Holder/ Clip
Termination Style Clip
1. Toggle the main power switch to the “OFF” position.
OFF
7000-5970 Rev. A
page 393 of 396
2. Unplug the main power cord.
3. Using a flat-head screwdriver, pop open fuse box clip.
4. The unit comes equipped with one spare fuse, shown by the arrow.
7000-5970 Rev. A
page 394 of 396
5. Remove blown fuse.
6. Push out the spare fuse using a flat headed tool
7. Place the new fuse in the clip as shown

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

7000-5970 Rev. A
page 396 of 396
WHEN TO CHANGE SOLDERING CARTRIDGE
Metcal™ recommends inspecting each cartridge before use. If the plating has been
compromised or there is a change in performance, replace immediately to ensure the highest quality
soldering. Use the following pictures to identify a good cartridge from one that may be in need to be
replaced.
Good for Use Time for Replacement
Thank you for reading our manual! Don’t forget to visit our website for the latest in soldering
as well as keeping up to date on the latest software and manual for the RSS-1000-CVSI Robotic
Soldering System!
http://www.okinternational.com/metcal

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USER MANUAL, RSS-1000-CVSI

Robotic Soldering System

Visit us on the web at www.okinternational.com/metcal

OTHER SAFETY TIPS

Operating System Linux O/S

Power Supply & Soldering Iron

Touch Screen Monitor

Computer Vision Camera

Solder Wire Feeder

Motor driver Integrated

In addition to Connection Validation, the RSS-1000-CVSI includes Smart Interface System.

1 Computer Vision Camera 10 Emergency Stop Button

18 CV Power Supply Power Switch 25 Nitrogen Inlet

3. Remove accessory box

6. Loosen nuts of unit’s feet to remove shipping brackets.

7. Remove shipping foam from the following locations:

7.1. Top Plate

7.3. End Effector

8. Replace Connection Validation Housing Cover once foam is removed

ROBOT HEAD CONNECTION

*Plug into an external outlet, see next page for instructions

Power Off Restart

Admin Engineer Operator

Header Solder Feeder

Eject USB Emergency Stop

Function Permissions Description

The Save Profile function saves all programmed parameters. This

The Global Settings function gives users access to system settings,

The Eject USB function must be activated to safely remove any

The E-Stop function is a virtual option of an emergency stop to halt the

Name of Profile CV Cartridge of

Appears when the Create New Profile function is utilized.

Appears after any points are programmed into a profile.

Appears when an existing profile is opened.

Undo Waypoint/ Redo Waypoint/

Function Permissions Description

Waypoints are user defined locations that can be programmed before

Interpolation Move is the first of two types of transition movements that

Undo removes the last programmed point or line. There is no limitation

Function Permissions Description

Solder Feeder Dry Run Toggled Dry Run Toggled

Function Permissions Description

Pulses solder forward for the duration of the button press.

Pulses solder backward for the duration of the button press.

Solder Feeder Parameters allow users to toggle between feeding

Open Image/ Pattern

Function Permissions Description

Takes screenshot of the active work area. This function is only

With the camera enabled, Pattern Recognition allows users to select a

Active Temperature Connection

Proper Grounding Connection Connection

Function Permissions Description

Connection Validation Graph button toggles between Net Power Meter

Toggle On/Off radio frequency (RF) current for Connection Validation.

Connection Validation Graph

Cartridge Serial Cartridge Production

Connection Validation Settings

Celsius Toggled Fahrenheit

CV Audio CV Audio Solder Station Solder Station

Function Permissions Description

Displays the tip temperature in degrees Celsius.

Displays the tip temperature in degrees Fahrenheit.

Exits the screen