epm CIG 300 compact TMS User manual

September 2006 Edition
Operating Manual
Computer-controlled
Double-wave Automatic Soldering Machine
epm CIG (DELTA-N) 300/400/500 compact TMS

September 2006 Edition Preliminary header epm
Page II Operating Manual CIG compact Automatic Soldering Machine
First edition of this operating manual: June 2003
Current status of this operating manual
We reserve the right to make technical changes without previous notice.
©Reprinting or copying of this operating manual, even in extract form, is prohibited. Without the written consent of M/s EPM
Handels AG CH-8954 Geroldswil/Zürich, reproduction of any parts of it in any form whatever, or processing, replication, or
distribution using electronic systems, especially in the form of photocopies, photographs, magnetic processes or other recording
processes is prohibited. All rights reserved, in particular, the right to reproduce and translate this document, as well as patent and
registration rights.
Chapter Title Pages Edition Date
0 Preliminary header,
contents
sixth September 2006
1 Technical Data First September 2007
2 Safety Second December 2004
3 Construction and
Working
First September 2007
4 Installation Third September 2007
5 Operation Third Decemberr 2004
6 Spare parts Catalogue Fourth Mai 2007
7 Diagrams, Lists First September 2007
8 Maintenance, Service, Third Decemberr 2004
9 Storage, Transport Second July 2004
10 Disposal Second July 2004

epm Preliminary header September 2006 Edition
Operating Manual CIG compact Automatic Soldering Machine Page III
Using this Operating Manual
This operating manual is an integral part of the computer-controlled inert-gas double-wave automatic
soldering machine type CIG-compact and contains important instructions for safety and operation.
For all persons who work on and with the automatic soldering machine, it is mandatory to read and
understand the chapters that are relevant to their activity.
There are requirements specified for the operating personnel for all work on and with the automatic
soldering machine. These are described in Chapter 2 “Safety”. Please read this chapter first.
The automatic soldering machine may only be operated for the purpose intended by the manufacturer.
This is defined in Chapter 2 “Safety”. Please read this chapter first.
First read Chapter 2 «Safety».

September 2006 Edition Preliminary header epm
Page IV Operating Manual CIG compact Automatic Soldering Machine
Quality Features of the Automatic Soldering Machine
Ensuring the maximal soldering quality is the logical continuation of our efforts to provide the
owner/operator with a production machine that corresponds to today's requirements and the trend
towards “Zero-Defect” to a significant extent.
In the development of the epm automatic soldering machines type CIG compact, the following were the
objectives that were followed purposefully:
• high operational safety
• no washing of the soldered printed circuit boards
• no using of harmful materials, such as acids
• maximum soldering quality
• maximum degree of utilization
• maximum flexibility
• minimal maintenance effort and cost
• high availability
• minimal space requirement
Design Features:
• a rigid housing for the process modules:
- transport module
- fluxer module
- preheater module
- soldering module
- inert gas module
• same inlet and outlet height of the transportation modules
• ascending and descending transportation track with a facility for adjusting the soldering angle (only
frame transport); completely independent of the housing
• the solder pot is located completely in the inert gas atmosphere, including the wave-soldering pumps
• no additional aprons and gaskets between the process modules
• no tunneling into the production material
• maximum repeatability of the production process
• maximum accessibility of the entire plant for servicing with the minimal time spent
• add-on modules for continuous run available
• compatibility with all other epm soldering machines and epm- transportation modules

epm Preliminary header September 2006 Edition
Operating Manual CIG compact Automatic Soldering Machine Page V
Table of Contents Chapter 1-12
This table of contents provides a rough overview of the ten chapters in this operating
manual. There is a detailed Table of Contents at the beginning of each chapter.
1Chapter 1: Technical Data
Type specification, type designation, rating data, weights, mains supply requirements etc.
2Chapter 2: Safety
Important safety instructions - mandatory instruction for all users
3Chapter 3: Construction and Working
Description and method of working of the soldering machine (transport system, flux
system etc.)
4Chapter 4: Installation
Instructions for installation work (installation, connections etc.), acceptance log
5Chapter 5: Operation
Operating elements, operation and programming, ongoing work (solder coil etc.)
6Chapter 6: Spare Parts Catalogue
Exploded drawings of assemblies with the relevant material lists
7Chapter 7: Diagrams, Lists
Function schematic diagram, wiring lists, terminal layout plans, boards
8Chapter 8: Maintenance, Service
Troubleshooting list, test diagrams, description of maintenance work, etc.
9Chapter 9: Storage, Transport
Instructions to be followed during the storage and transport
10 Chapter 10: Disposal
Instructions and specifications to be followed for the disposal
11
12

September 2006 Edition Preliminary header epm
Page VI Operating Manual CIG compact Automatic Soldering Machine

epm Technical Data September 2007 Edition
Operating Manual CIG compact TMS Duplex Automatic Soldering Machine Page 1-1
1 Technical Data
Table of Contents Chapter 1
Page
1.1 Type Specification........................................................................................................1-3
1.2 Type Designation..........................................................................................................1-4
1.2.1 Name Plate......................................................................................................1-4
1.3 Rating Data....................................................................................................................1-5
1.3.1 Supply Requirements......................................................................................1-6

September 2007 Edition Technical Data epm
Page 1-2 Operating Manual CIG compact TMS Duplex Automatic Soldering Machine

epm Technical Data September 2007 Edition
Operating Manual CIG compact TMS Duplex Automatic Soldering Machine Page 1-3
1.1 Type Specification
CIG
300
compact
CIG
400
compact
CIG
500
compact
TRANSPORT MODULE
Soldering carrier transport, rail distance 355 mm S
Soldering carrier transport, rail distance 455 mm S
Soldering carrier transport, rail distance 555 mm S
Angle 7°, fix S S S
FLUXER MODULE
Atomizer fluxer S S S
Flow indication S S S
Flow monitoring S S S
Level monitoring S S S
PREHEATER MODULE
Underside preheater 9 x IR-beams S S S
Hybrid / Carbon, underside preheater O O O
Pre-heater regulation via infrared measurement O O O
Inner temperature regulation via temperature
sensor S S S
Passage-process-measurement / control device O O O
SOLDERING MODULE
Double wave (fixed and full wave) S S S
Wörthmann wave instead of full wave O O O
Manual solder pot extension device S S S
Solder pot -extension lengthening for service S S S
Automatic soldering tin replenishment S S S
Soldering tin roll monitoring S S S
INERT GAS MODULE
Gas chamber with valve system S S S
Permanent residual oxygen monitoring S S S
Condensate trap O O O
CONTROLLER
PC controller via "MIS" Management Information
System S S S
"UPTIME" Maintenance Management Software O O O
Printer S S S
Manual coding with 60 codes S S S
Bar coding with 999 codes O O O
Binary coding with 60 codes O O O
Carrier / PCB isolation O O O
S= Standard, A= Selection, O= Option

September 2007 Edition Technical Data epm
Page 1-4 Operating Manual CIG compact TMS Duplex Automatic Soldering Machine
1.2 Type Designation
The type designation of the CIG compact automatic soldering machine comprises the
following designations:
CIG Type designation Computer- controlled Inert Gas
300 Carrier transport type (nominal size)
400 Carrier transport type (nominal size)
500 Carrier transport type (nominal size)
1.2.1 Name Plate
The name plate is located on the rear side of the inlet tunnel.
EPM Handels AG epm
CH-8954 Geroldswil/Zürich
Type: epm CIG ……compact Duplex
Serial No:
Year of manufacture: 2007
U: 3x400/230 VAC F: 50/60 Hz
N: 24.7 kVA
Luft/air P: 6 bar
Fig. 1-1. Name plate

epm Technical Data September 2007 Edition
Operating Manual CIG compact TMS Duplex Automatic Soldering Machine Page 1-5
1.3 Rating Data
Connected
loads Electrical connection 230/400V +10%/–15%, 50/60 Hz, 3PNE
Total connected load ≥31.7 kVA
Pre-fuse (on-site) 3 X 35 A slow-blow
Compressed air • Connection: 1/4“
• Rating: 5 - 6 bar constant
• Quality: filtered 5µ
• Consumption: about 0.16 m3/h production-dependent
Exhaust air at the fluxer • Connection 2 x ∅120 mm
• Rating about 800 m3/h
Inert gas • Connection: 1/2" inner thread
• Rating: 7 bar constant
• Consumption: 15-20 m3/h production-dependent
Transport Transport speed • Carrier transport: 0.5 - 2.5 m/min
Transport angle above waves • Carrier transport: 7° fixed
Fluxer Atomizer fluxer control Width in 9 stages / quantity continuous
Preheater IR-pre-heater rating • CIG 300 compact = 9 X 1.2 = 10.8 kVA
• CIG 400/500 compact = 12 x 1.35 = 12.15 kVA
Carbon/Hybrid-pre-heater rating • CIG 400/500 compact = 6 x 0.9 + 6 x 0.8 = 10.2 kVA
Length • 1150 mm
Temp. measurement PCB • Infrared temperature measurement on the underside
of the PCB
• Passage temperature measuring instrument
Inner temperature continuously regulated
Solder bath Solder bath heating 12 x 1.0 = 6.0 kVA
Solder bath auxiliary heating 4 x 0.5 = 1.0 kVA
Solder bath temperature 230° - 280° C
Solder pot content • CIG 300/400 compact = 380 – 450 kg *) x2
• CIG 500 compact = 550 -650 kg *) x2
*) it depends on the alloy
Heating time of the solder 450 kg bath about 180 min. / 650 kg bath about 200 min
Automatic solder replenishment Solder wire ∅6 mm, coil ∅305 x 110 mm
Solder wave height hollow wave 30 mm
Solder wave height full wave 4 – 9 mm
Solder wave width 300 = 320mm / 400 = 420mm / 500=520mm
Distance between the peaks 70 mm / 100 mm
Stability of solder bath temp. ± 1 °C
Inert gas Permanent measurement 0-100 ppm, 0-1000 ppm, autom. regulation
Gas used Nitrogen
Cleaning Condensate trap (Option)
Controller Robotronix controller PC / MIS
Other Continuous noise level < 65 dB(A)
Residual power consumers 1.3 kVA
Dimensions of the machine
• CIG 300/400 compact = 4,44 x 2,98 x 1,10 m
• CIG 500 compact = 4,44 x 3.28 x 1,10 m
Weight of the machine about 1100 kg (without solder filling)
Color Gray white RAL 9002
Right to make technical changes without prior notice is reserved.

September 2007 Edition Technical Data epm
Page 1-6 Operating Manual CIG compact TMS Duplex Automatic Soldering Machine
NOTE
For dimensional sketches, connections, accesses etc. see Illustrations in chapter 4
1.3.1 Supply Requirements
STOP
The neutral wire (star point) must be connected without fail, since all the three
phases may not be uniformly loaded in every operation case.
In all cases, a proper grounding of the machine must be ensured.
For other mains voltages, an external transformer should be connected upstream; this
should be according to the specific information for the relevant country and the
specifications of the manufacturer.

epm Safety December 2004 Edition
Operating Manual CIG compact Automatic Soldering Machine Page 2-1
2 Safety
Table of Contents Chapter 2
Page
2.1 Introduction...................................................................................................................2-3
2.1.1 Who may Work on and with the Automatic Soldering Machine?....................2-3
2.1.2 Usage Conformant with Intended Purpose.....................................................2-4
2.1.3 Improper Use ..................................................................................................2-4
2.2 Warning Notices and Symbols....................................................................................2-5
2.2.1 Instructions and Symbols in the Operating Manual ........................................2-5
2.2.2 Cautionary Symbols on the Automatic Soldering Machine.............................2-6
2.2.3 Warning Notices in the Vicinity of the Automatic Soldering Machine .............2-7
2.3 Principles of Safety......................................................................................................2-8
2.3.1 Influence on Other Safety Concepts ...............................................................2-8
2.3.2 Danger Zones .................................................................................................2-8
2.3.3 Safety-relevant Instructions.............................................................................2-8
2.3.3.1 For all life phases..................................................................................2-8
2.3.3.2 For the majority of the life phases.........................................................2-8
2.3.3.3 Further safety-relevant instructions ......................................................2-8
2.3.4 Safety Measures, Organizational....................................................................2-9
2.3.5 Safety Elements and Functions, Emergency Stop etc....................................2-9
2.3.6 Removing Protective Devices .........................................................................2-9
2.4 General Safety Rules..................................................................................................2-10
2.4.1 Legal Specifications ......................................................................................2-10
2.4.2 Checking the Working of Protective Devices................................................2-10
2.4.3 Energy Connections......................................................................................2-10
2.4.4 Spare Parts ...................................................................................................2-10
2.4.5 Modifications .................................................................................................2-10
2.5 Responsibilities..........................................................................................................2-11
2.5.1 Responsibilities of the Manufacturer.............................................................2-11
2.5.2 Responsibilities of the Operator....................................................................2-11
2.5.2.1 Training, Instruction ............................................................................2-11
2.5.2.2 Competences......................................................................................2-11
2.5.2.3 Instructions in Case of Dangers..........................................................2-11
2.5.2.4 Duty of Care and Maintenance ...........................................................2-11
2.5.2.5 Duty of Observation and Reporting ....................................................2-11
2.5.2.6 Location of the Operating Manual.......................................................2-11
2.5.2.7 Foreign Language-Speaking Personnel.............................................2-11

December 2004 Edition Safety epm
Page 2-2 Operating Manual CIG compact Automatic Soldering Machine
Definition of Terms
Manufacturer
The company EPM Handels AG is designated as the “Manufacturer” in this operating manual.
Operator
As the super-ordinate person, the operator is responsible for the proper use of the automatic soldering
machine. The operator must fulfill the responsibilities described in chapter 2.5.2 in a proper manner.
Life phases of the plant, product life phases
This should be understood to mean all the states and usage phases of the automatic soldering ma-
chine, from the time of leaving the production site until the time of disposal.
In this operating manual, the product life phases are addressed by the following chapters: Installation
(erection, mounting), Operation, Maintenance/Servicing, Storage/Transport and Disposal.

epm Safety December 2004 Edition
Operating Manual CIG compact Automatic Soldering Machine Page 2-3
2.1 Introduction
This chapter presents the safety requirements that must be complied with without fail when
using the computer-controlled inert gas double wave automatic soldering machine (called
the “Automatic soldering machine” in the following).
For all persons work on and with the automatic soldering machine, it is mandatory to read
and understand the chapters that are relevant for their activity. This particularly applies to
this chapter, which is mandatory for all persons and all activities. This also applies to per-
sonnel who only work occasionally on the automatic soldering machine, e.g. during tooling
up and maintenance.
Please read this chapter carefully.
• Have you understood everything?
• Is there anything that is not clear?
If you have any questions please contact your supervisor.
The purpose of this safety specification is to ensure the safety of the user when using and
handling the automatic soldering machine.
2.1.1 Who may Work on and with the Automatic Soldering Machine?
There are different qualifications prescribed for personnel working on and with the auto-
matic soldering machine. You can find these at the beginning of each respective chapter of
this operating manual. For example: the requirements for operating personnel can be found
at the beginning of chapter 5 “Operation”; those for servicing personnel in chapter 8 “Ser-
vice” etc.
STOP
The personnel qualifications describe the minimum requirements that must be
specified for safe working on and with the automatic soldering machine. The opera-
tor ensures compliance with them.
CAUTION
Persons who are allergic to flux or solder must avoid coming in direct contact with
these substances.

December 2004 Edition Safety epm
Page 2-4 Operating Manual CIG compact Automatic Soldering Machine
2.1.2 Usage Conformant with Intended Purpose
The automatic soldering machine is intended for the automatic, transport-bound soldering
of electronic printed circuit boards in an inert gas atmosphere.
The type designations CIG 300/400/500 compact relate to different soldering widths and
transporting options for the printed circuit boards with the corresponding dimensions and
weight of the automatic soldering machine (see Chapter 1 Type Designation). As a con-
cept, all automatic soldering machines are built identically.
Typical applications:
• soldering of printed circuit boards with conventional components (THT)
• soldering of printed circuit boards with SMD components (SMT)
Usage conformant with intended purpose also includes:
• adherence to the technical data (see below)
• the use of standard and mandatory original accessories
• compliance with this operating manual and adherence to the instructions and specifica-
tions in it
2.1.3 Improper Use
Any other use or any use in excess of this will be considered to be improper. In case of
damage, the manufacturer will correspondingly claim non-liability for claims.
In particular, the following improper uses are known and strictly prohibited for rea-
sons of safety:
• Manual dip-soldering with the machine is prohibited (danger of burning)
• In particular, the use of easily flammable fluids for cleaning purposes is forbidden. Ow-
ing to the generation of heat, such fluids can catch fire and result in a fire or an explo-
sion.

epm Safety December 2004 Edition
Operating Manual CIG compact Automatic Soldering Machine Page 2-5
2.2 Warning Notices and Symbols
Generally, there are concomitant dangers with the use of technical products. Dangers that
could not be eliminated either by design-related measures or by protective devices are
called residual dangers.
Although the automatic soldering machine distinguishes itself by a high quality and safety
standards, and although it has been built according to the state-of-the-art and the recog-
nized technical rules, injury or damage to property cannot be completely ruled out in case
of operating errors, improper use or misuse, owing to existing residual dangers.
Therefore, in this operating manual and on the plant, various warning notices and symbols
are used to draw attention to these residual dangers during purpose-conformant usage and
to emphasize important technical requirements, as well as to avoid erroneous operation.
2.2.1 Instructions and Symbols in the Operating Manual
a) Danger symbols
STOP
Information about dangers that can lead to
•life-threatening body injuries
WARNING
Information about dangers that can lead to
•medium to serious body injuries
•considerable property damage
CAUTION
Information about dangers that can lead to
•slight body injuries
•minor damage to property
b) Instruction symbol
NOTE
Information that points to technical requirements. Non-compliance can result in
faults, inefficiency and possibly in loss of production.

December 2004 Edition Safety epm
Page 2-6 Operating Manual CIG compact Automatic Soldering Machine
2.2.2 Cautionary Symbols on the Automatic Soldering Machine
The following danger symbols indicate unavoidable residual dangers and therefore re-
quire constantly attentive operation of this plant in accordance with this operating manual.
On the cover of the atomizer fluxer (1x)
On large service doors at the rear (2x)
WARNING
• Fluxer cover:
Danger of the fluxer cover snapping shut while closing. Take care that no body
parts reach into the inner space. Danger of injury!
• Shutter
When the shutters are open, do not reach into the tunnel, they close automati-
cally
• In the inside of the machine:
- Do not touch running conveyor chains on the drive units
- Do not touch the toothed belt pinion on the solder pump drive
Danger of finger crushing
Controller drawer on front side (1x )
On the cover of the Roboflux pump (1x) On terminal box cover of solder bath (1x)
On every interface (4-5x) On every motor (3 - 4x)
On all terminal boxes (6-7x) Near every plug (2x)
Symbol “Warning: dangerous electrical voltage”
Danger of an electrical shock if attempting to touch or manipulate inner components.
Only technical personnel may open the door.
Automatic soldering machine top front near the ribs (3x)
Automatic soldering machine top rear in the middle (1x)
Automatic soldering machine rear, on every service door (3x)
Symbol “Warning: hot parts”
Touching them when the energy supply is on, or has just been turned off, can result in
scalding or burns.
Automatic soldering machine rear, near the atomizer fluxer (1x)
On the measuring cell of the oxygen analyzer (1x)
Symbol “Warning: corrosive substances “
Avoid touching the fluid electrolyte during the filling or replenishment of the oxygen meas-
uring cell. Non-compliance can result in corrosion of the skin.
Near the fluxer housing, rear (1x)
Symbol “Smoking prohibited”
Danger of a fire or explosion when working with easily flammable fluids (flux/cleaning
agents). The instructions of the manufacturer of the substance must also be followed.

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Operating Manual CIG compact Automatic Soldering Machine Page 2-7
Automatic soldering machine top rear in the middle (1x)
On the cover of the fluxer (1x)
Symbol “Wear protective eyewear”
• In case of negligent manipulation on the solder (e.g. ladling out oxide), hot solder
sprays can get into the eye and in the worst case, result in blinding.
• Wearing protective eyewear when changing the flux barrel or opening the fluxer cover
during operation is prescribed.
Automatic soldering machine top rear in the middle (1x)
Symbol “Wear protective gloves/protective clothing”
In case of negligent manipulation on the solder (e.g. ladling out oxide), the hands come
near the hot smelt (danger of scalding or burning and uncontrolled reflexes). In case of
negligent handling, hot solder sprays can fall on clothes (personal property damage).
Touch hot cover sheets (for removing and cleaning) only with protective gloves.
Automatic soldering machine at the rear, on the large service doors (2x)
Controller drawer on front side (1x)
Symbol “Entry to unauthorized persons prohibited” Entry only to qualified service person-
nel, see chapter 8, no access to operating personnel!
2.2.3 Warning Notices in the Vicinity of the Automatic Soldering Machine
(To be put up by the operator on the wall of the room where the automatic soldering ma-
chine is being operated, near the fluxer).
Symbol “Smoking prohibited”
Danger of a fire or explosion when working with easily flammable fluids (flux/cleaning
agents).

December 2004 Edition Safety epm
Page 2-8 Operating Manual CIG compact Automatic Soldering Machine
2.3 Principles of Safety
2.3.1 Influence on Other Safety Concepts
The safety concept of the automatic soldering machine described here is an autonomous
one. Other upstream and downstream machines, auxiliary equipment (mandatory accesso-
ries in the supply schedule like: starting modules, extension modules, motor modules,
height adjustment modules, converters, lifts, etc.) are not affected by it.
STOP
If the automatic soldering machine is integrated in a production line, the op-
erator must work out a plant-specific safety concept.
2.3.2 Danger Zones
These are marked by warning notices (see 2.2.2 and 2.2.3).
2.3.3 Safety-relevant Instructions
2.3.3.1 For all life phases
WARNING
Ensure that when closing the atomizer fluxer cover, no body parts (hand, arm,
head) come in contact with its edges. Danger of injury.
2.3.3.2 For the majority of the life phases
(commissioning, operation, maintenance, repair)
STOP
When changing the flux barrel, when flushing the system, the instruction in
chapter 8 must be followed. Non-compliance can build up pressure in the
system, which can result in loosening of a hose joint, or escaping of corro-
sive fluid (flux) and hence lead to skin corrosion, eye injury and damage to
clothing. Requirement: wear protective eyewear.
CAUTION:
With the fluxer cover open and the shutters open, do not reach into the tunnel. The
automatically closing shutters can result in crushing of the hand and arm.
CAUTION:
The hot zones can continue to be very hot for a certain time after the automatic sol-
dering machine has been switched off. Touch the hot cover plates (for removing
and cleaning) only with protective gloves. They are heavy and if dropped, can cause
injuries to the foot or the leg.
2.3.3.3 Further safety-relevant instructions
These can be found in the introduction or in the context of the respective chapter. For ex-
ample, the operator can find them in chapter “Operation”, the service engineer in chapter
“Service” etc.