Dover Vitronics Soltec DeltaWave 6622cc User manual

Installation Guide DeltaWave
Version 22.5.0.000
EUROPE
VITRONICS SOLTEC BV
Karolusstraat 20
4903 RJ Oosterhout
the Netherlands
Tel. [phone]
Fax [phone]
VITRONICS SOLTEC GmbH
An der Köhlerei 7
97828 Marktheidenfeld
Germany
Tel. [phone]
Fax [phone]
AMERICAS
VITRONICS SOLTEC Inc.
2 Marin Way
Stratham, New Hamphire 03885
USA
Tel. [phone]
Fax [phone]
ASIA PACIFIC
VITRONICS SOLTEC PTE LTD.
135 Joo Seng Road
#02-01 PM Industrial Building
Singapore 368363
Tel. [phone]
Fax [phone]
VITRONICS SOLTEC MID ASIA
Room 1616, Hansuh Bldg.
11-11, Yeouido-Dong, Youngdeungpo-Ku
Seoul, Korea 150010
Tel. [phone]
Fax [phone]
VITRONICS SOLTEC SH REPR. OFFICE
Room G, 14th Floor, Huadu Mansion
828-838 ZhangYang Road
Shanghai, China 200122
Tel. [phone]
Fax [phone]

ii
Rights
COPYRIGHT 2003 VITRONICS SOLTEC BV
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Vitronics Soltec BV.
This publication remains the property of Vitronics Soltec BV and may not be passed, loaned or given to any third party.
Vitronics Soltec BV reserves the right to make changes in design and specifications without notice.

Installation Guide DeltaWave iii
Preface
During the composition of this manual much attention is given to avoid errors
and mistakes. Also we aimed to give the contents a clear structure.
If during the use of this manual errors or incomplete descriptions are found, or
the reader considers that improvements are necessary to overcome any in-
accuracies, please inform us. We appreciate any comments which will help us to
improve this documentation.
For corrections or clarifications please contact:
1. By mail:
VITRONICS SOLTEC BV
HEAD OFFICE
TECHNICAL PUBLICATIONS
P.O. BOX 143
4900 AC OOSTERHOUT
THE NETHERLANDS
TEL NR. (31) - 162483000
FAX.NR. (31) - 162483285
OR
2. By e-mail:
[email protected]onics-soltec.com

iv

Installation Guide DeltaWave v
Ta b l e o f C o n t e n t s
Preface iii
Table of Contents v
1 Installation 1-1
1.1 General . . . . . . . . . . . . . . . . . . . 1-1
1.2 Transport . . . . . . . . . . . . . . . . . . 1-1
1.2.1 Symbols used . . . . . . . . . . . . . . . 1-1
1.2.2 Dimensions & weight . . . . . . . . . . . . . 1-2
1.2.3 Centre of gravity . . . . . . . . . . . . . . 1-2
1.2.4 Unpacking . . . . . . . . . . . . . . . . 1-3
1.2.5 Lifting with forklift . . . . . . . . . . . . . 1-4
1.2.6 Adjust leveling pads . . . . . . . . . . . . . 1-4
1.3 Installation info . . . . . . . . . . . . . . . . 1-5
1.3.1 Carrying capacity floor per leveling pad . . . . . . . 1-5
1.3.2 Clearance for operate & maintenance . . . . . . . . 1-5
1.3.3 Installation requirement . . . . . . . . . . . . 1-6
1.3.4 Putting in position . . . . . . . . . . . . . . 1-6
1.3.5 Mechanical adjustments . . . . . . . . . . . . 1-6
1.3.6 Electrical connection . . . . . . . . . . . . . 1-8
1.3.7 Air connection. . . . . . . . . . . . . . . 1-8
1.3.8 Nitrogen connection . . . . . . . . . . . . . 1-8
1.3.9 Exhaust system . . . . . . . . . . . . . . 1-9
1.3.10 Personal computer . . . . . . . . . . . . . 1-9
1.3.11 Filling the solderpot . . . . . . . . . . . . . 1-9
1.4 Starting up . . . . . . . . . . . . . . . . . . 1-12
1.4.1 Instructions. . . . . . . . . . . . . . . . 1-12
1.4.2 Functions . . . . . . . . . . . . . . . . 1-12
1.5 Start process . . . . . . . . . . . . . . . . . 1-13
1.5.1 Preparations to start . . . . . . . . . . . . . 1-13
1.5.2 Switch on . . . . . . . . . . . . . . . . 1-13
1.5.3 Re-start after stopping . . . . . . . . . . . . 1-13
1.6 End process . . . . . . . . . . . . . . . . . . 1-14
1.6.1 Preparations to stop . . . . . . . . . . . . . 1-14
1.6.2 Stop procedures . . . . . . . . . . . . . . 1-14
1.6.3 Switch off . . . . . . . . . . . . . . . . 1-14
1.6.4 Re-start after E-stop . . . . . . . . . . . . . 1-14

vi
1.7 Mechanical adjustments. . . . . . . . . . . . . . 1-15
1.7.1 Solderwave setting: Smartwave and Mainwave . . . . . 1-15
1.7.2 Backplate setting . . . . . . . . . . . . . . 1-16
1.7.3 Chipwave setting . . . . . . . . . . . . . . 1-17
1.7.4 Setting the solderlevel sensor . . . . . . . . . . 1-18
1.7.5 Foamfluxer . . . . . . . . . . . . . . . . 1-18
1.7.6 Spray drumfluxer . . . . . . . . . . . . . . 1-19
1.7.7 Nozzlefluxer . . . . . . . . . . . . . . . 1-20
1.7.8 Density control unit . . . . . . . . . . . . . 1-21
1.8 Installation sheet . . . . . . . . . . . . . . . . 1-22
Index vii

ICON DESCRIPTION ICON DESCRIPTION
Only Qualified personnel is allowed to work on the
equipment.
Never eat, drink or smoke while working on the
machine.
Wash thoroughly before eating, drinking or smoking.
High voltages are present on various parts of the sys-
tem.
Before working on the electrical circuit, turn main
power off and block the mainswitch with a padlock.
Always wear heat resistant gloves and protective
clothing when working on the machine.
If possible allow the machine to cool down before
starting working on the machine.
When burned, immerse in cold water immediately.
When the burn is severe, consult a physician as soon
as possible.
Always wear heat resistant gloves and protective
clothing when working on the machine.
If possible allow the machine to cool down before
starting working on the machine
When burned, immerse in cold water immediately.
When the burn is severe, consult a physician as soon
as possible.
No smoking or open fire near the machine.
Be sure a fire-extinguisher is in the surroundings of
the machine.
No smoking or open fire near the machine.
Be sure a fire-extinguisher is in the surroundings of
the machine.
All moving parts of the system, including pulleys,
belts, chains, coolingfans, sprocketwheels, vacuum-
doors and cylinders presents a potential danger.
Be careful with covers and doors. Always pay atten-
tion to opening and closing.
The vapours in the board preparation module are
chemical.
Also the dust on the surface of the solderpot is dan-
gerous when inhaled.
Avoid inhaling this vapours / dust by using mouth
protection.
When working on the machine, always protect your
eyes with safety glasses.
Nitrogen
N2
Follow the safety precautions and procedures
described in the Material Safety Data Sheet of
the Nitrogen supplier.
UPS
Uninterruptible
Power Source
When mainswitch is switched OFF, always switch
the UPS to OFF.
Signal light RED
- E-stop Active
Signal light GREEN
- Steady = Machine Run,
- Flashing slow = Machine not at setpoint, machine
stop
Signal light ORANGE
- Steady = Overload (outfeed full), Machine will
block,
- Flashing slow = Alarm
- Flashing fast = Critical alarm. Machine will block
If these rules are not observed it can cause personal injury and/or damage to the machine
 
SAFETY RULES
GENERAL INFORMATION

.

Installation Guide DeltaWave CHAPTER 1 1
Installation 1
1.1 GENERAL
Installing only by trained Vitronics Soltec / Agent personnel.
At the end of this chapter an installation sheet is located.
1.2 T
RANSPORT
1.2.1 SYMBOLS USED
FIGURE 1.1 SYMBOLS ON PACKAGING
1. Position pallet/box for transport
2. Breakable
3. Keep dry
4. Lift here (labels are placed on
position where forklift should lift)
12 4
3

INSTALLATION
2CHAPTER 1
1.2.2 DIMENSIONS & WEIGHT
T
ABLE 1.1 PACKING ON PALLET
T
ABLE 1.2 PACKING IN CRATE
1.2.3 CENTRE OF GRAVITY
FIGURE 1.2 CENTRE OF GRAVITY ON PALLET
A = Centre with empty solderpot.
B = Centre with filled solderpot.
Use forklift with minimum distance between forks of 800 - 1000mm. The length of the forks
under the pallet must be minimum 2/3 of X.
LXWXH
(CM)
WEIGHT TOTAL
WITH SOLDERPOT
EMPTY
(KG)
WEIGHT TOTAL
WITH SOLDERPOT
FILLED
(KG)
420 x 150 x 188 1800 2550
LXWXH(CM)
WEIGHT TOTAL
WITH SOLDERPOT
EMPTY
(KG)
WEIGHT TOTAL
WITH SOLDERPOT
FILLED
(KG)
430 x 160 x 191 2000 2750
TOPVIEW
AB
BACKSIDE
X

1.2 - TRANSPORT
Installation Guide DeltaWave CHAPTER 1 3
1.2.4 UNPACKING
The Vitronics Soltec DeltaWave is packed on a wooden pallet.
When necessary, the machine is packed in crates (e.g. when shipped). If packed in crates the fol-
lowing procedure should followed.
FIGURE 1.3 CRATE
Use the above figure order A,B,C to uncrate. Other order can result in damaging the machine or
personal injury.
Uncrating order:
1. Take off top cover A.
2. Remove side panels B.
3. Remove front and backcover C.
FIGURE 1.4 REMOVING MACHINE FROM PALLET
The machine is bolted to a wooden pallet with 2 tightening straps (A). Remove these straps.
CB
A
                    
AA

INSTALLATION
4CHAPTER 1
1.2.5 LIFTING WITH FORKLIFT
When the transporting straps are removed, the DeltaWave can be placed on the place the cus-
tomer has planned it.
To lift and transport the DeltaWave use the figure below. The points where the forks from the
forklift can be placed are shown.
FIGURE 1.5 LIFTING
This machine can only be lifted (at the vertical beam) as shown on the figure above.
1.2.6 ADJUST LEVELING PADS
FIGURE 1.6 LEVELING PAD
When the DeltaWave is lifted from the pallet, the following has to be done:
1. Adjust the leveling pad with a maximum of X=15 cm. See Figure 1.6.
Be sure that all leveling pads are inserted with the same length.
DISTANCE BETWEEN
FORKS MINIMUM
800 - 1000 mm
LAYERS
FORK
X
FRAME
M20 NUT
M20 LEVELING PAD

1.3 - INSTALLATION INFO
Installation Guide DeltaWave CHAPTER 1 5
1.3 INSTALLATION INFO
1.3.1 CARRYING CAPACITY FLOOR PER LEVELING PAD
FIGURE 1.7 CARRYING CAPACITY
Weight per leveling pad maximum 450 kg.
1.3.2 CLEARANCE FOR OPERATE & MAINTENANCE
FIGURE 1.8 CLEARANCE
T
ABLE 1.3 CLEARANCE
POSITION CLEARANCE FOR
OPERATE (CM)
CLEARANCE FOR
MAINTENANCE (CM)
A100 100
B100 150
C75 75
D75 75

INSTALLATION
6CHAPTER 1
1.3.3 INSTALLATION REQUIREMENT
See 1.8 "Installation sheet", on page 1–22.
1.3.4 PUTTING IN POSITION
FIGURE 1.9 DELTAWAVE
1.3.5 MECHANICAL ADJUSTMENTS
After carefully positioning the machine and allowing for sufficient working space, follow the list
below in setting the machine into its correct attitude.
1. Place the machine on its intended working location.
When the solderpot is filled, be sure that when leveling the machine, the weight on all leveling-
pads stays roughly the same. To achieve this, do not turn a leveling pad for more than a 360°.
2. Adjust the leveling pads of the machine until it stands perfectly level in both longitude and
latitude direction. A spirit level should be placed on the underframe for checking the
longitude direction. For the latitude direction the spirit level should be placed on the
solderpot and/or the both conveyorbars.
LEVELING THE MACHINE ONLY WITH THE LEVELING PADS

1.3 - INSTALLATION INFO
Installation Guide DeltaWave CHAPTER 1 7
3. The solderpot and fluxer units are levelled in relation to the underframe prior to the machine
leaving the factory. The solderpot is set in the basic work position (wave height 7 mm).
FIGURE 1.10 LEVELING SOLDERPOT
4. Although the solderpot can be considered as set, it can be levelled by turning the nuts of the
threaded rods. First remove the safety nut. Remove bolt. Turn the trapezium nut to the right
position. Replace bolt and safety nut. Distance between trapezium nut and safety nut 2 mm.
5. The foam and drumfluxer can be set level by turning the threaded rods with a screwdriver.
6. Close the fluxer valve.
7. Check if the solderpot drain is closed by turning it clockwise.
FIGURE 1.11 CONNECTIONS
AAir & Electrical connection
BNitrogen connection
CExhaust connection
safety nut
bolt
trapezium nut
2 mm
AB
CC

INSTALLATION
8CHAPTER 1
1.3.6 ELECTRICAL CONNECTION
Only qualified electricians should work on the electrical circuits of the machine.
1. Feed the mains-cable for the whole machine trough the top side of the infeed section.
2. Connect the mains leads in accordance with the diagrams.
Check the current rotation of the phases. The current rotation of the phases L1, L2, L3 must be
clockwise.
3. Block the mainswitch with a padlock to prevent dangerous situations.
1.3.7 AIR CONNECTION
1. Connect the air supply hose to the 10 mm hose spigot at the rear infeed side of the machine.
Make sure that the supplied air is free of oil and moisture.
1.3.8 NITROGEN CONNECTION
When nitrowave installed only.
1. Connect the nitrogen supply hose to the 10 mm hose spigot at the rear outfeed side of the
machine.

1.3 - INSTALLATION INFO
Installation Guide DeltaWave CHAPTER 1 9
1.3.9 EXHAUST SYSTEM
Two exhaust gauges of 160 mm (6.3”) are provided. One for the flux unit and one for the solder
fumes. These should be connected with the customer’s exhaust system (not supplied by
Vitronics Soltec).
For specifications see Chapter Appendix in this manual.
• Inflammable and/or explosive gas might develop in the machine because of the evaporation
of the solvent in the flux.
• An exhaust system that functions well, will solve most of this problem.
• It is therefore necessary to have a sufficient exhaust in the machine.
• The exhaust system also has to be checked continuously on its functioning well.
• The machine is prepared to interfere in the E-stop circuit of the machine with a potential
free contact of the exhaust system. This contact has to be normally open, and therefore
closed when the exhaust functions well (fail safe).
NEVER USE THE MACHINE WITHOUT THE EXHAUST SYSTEM
1.3.10 PERSONAL COMPUTER
The complete Personal Computer is packed in boxes for transporting. Unpack all boxes and put
the PC, monitor and keyboard on the PC-arm. Connect all cables.
1.3.11 FILLING THE SOLDERPOT
There are two different ways to fill the solderpot:
1. Filling with granulated solder.
When granulated solder is used: fill solderpot equally.
The level of the solder in the bath shouldn’t be less than 15 mm and not more than 20 mm below
the top off the solderpot (solderpumps not running).

INSTALLATION
10 CHAPTER 1
FIGURE 1.12 SOLDERLEVEL, MIN MAX AND MAX
2. Filling with solderbars.
When filled with bars, its impossible to melt them on the heated sides of the solderpot. There-
fore the sumps must be removed.
When a nitrowave is on the solderpot also the nitrowave covers must be removed.
FIGURE 1.13 CHIPWAVE CYLINDER
FIGURE 1.14 SMARTWAVE BELT
ONLY FOR CHIPWAVE
1. Remove connection cylinder.
A
B
ONLY FOR SMARTWAVE
2. Remove cover smartwave
belt.
3. Remove pulley (on smartwave
ax) and belt.

1.3 - INSTALLATION INFO
Installation Guide DeltaWave CHAPTER 1 11
FIGURE 1.15 REMOVING BOLTS SUMPS
4. Remove sumps.
5. Fill solderpot with bars.
Make sure the bars are placed against the heated sides of the solderpot.
A
B

INSTALLATION
12 CHAPTER 1
1.4 STARTING UP
1.4.1 INSTRUCTIONS
STARTING UP IS ONLY ALLOWED BY QUALIFIED PERSONNEL
BEFORE STARTING UP, START UP THE FOLLOWING PROCEDURE:
1. Open the N2/Air valve. Adjust the pressure on 6 bar maximum for air and 5 bar for N2.
2. Take off the padlock on the mainswitch and switch on the mainpower.
3. Switch on the PC and monitor.
1.4.2 FUNCTIONS
The PC will start up (if already setup) the PC program. If not installed please install the PC pro-
gram as described in the User manual, chapter 3.
1. Reset E-stop. This can be done in the RESET MENU. Check if all E-stops are resetted and
that the wirebridges are made where necessary.
2. Test all sensors on the PLC module. (Only when first installed).
3. Back to STATUS MENU. Test all functions.