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Amada UNIFLOW 4 REMOTE Operation Manual Download Page 146

APPENDIX D:  COMMUNICATION CODES 

 

 

UNIFLOW

®

 4 PULSED HEAT CONTROL 

D-8 

990-908

 

121 AUX_START 
122 AUX_PREHEAT 
123 AUX_REFLOW 

124 SOLDER_COOL_VALVE 

 
 

  

   

 3 

Bytes 

Total 

 
PROFILE 

“DR” Read 

Profile # 

 

 

 

2 Bytes 

 
 

“DS” Set 

ProfileNum (Profile number to be modified: 01 - 63)   

2 Bytes 

 

 , 

   

 1 

Byte 

 

 

PreheatTemp (Preheat temperature: 060 - 300) 

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

ReflowTemp (Reflow temperature: 060 - 600) 

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

Cool1Temp (Cool1 temperature: 025 - 300)   

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

PreheatTime (Preheat time: 000 – 999) 

 

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

Rise2Time (Rise2 time: 00 – 99) 

 

 

2 Bytes 

 

 , 

   

 1 

Byte 

 

 

ReflowTime (Reflow time: 000 – 999) 

 

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

BaseTemp (Base temperature: 025 – 300)   

 

3 Bytes 

 

                            

 

 

 

1 Byte 

 

 

PostheatTemp (Postheat temperature: 025 - 600) 

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

Cool2Temp (Cool2 temperature: 025 - 300)   

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

IdleTemp (Idle temperature: 025 - 100) 

 

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

BaseTime (Preheat time: 000 – 999) 

 

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

PostheatTime (Postheat time: 000 – 999) 

 

 

3 Bytes 

 

 , 

   

 1 

Byte 

 

 

Rise1Time (Rise1 time: 00 – 99) 

 

 

2 Bytes 

 

 , 

   

 1 

Byte 

 

GRAPH Time Span (000-999)  

3 Bytes 

  

1 

Byte 

 

Head Up Delay (000-999)  

3 Bytes 

  

1 

Byte 

 Schedule 

Reference 

(0000000000-ZZZZZZZZZZ)  

10 Bytes 

  

1 

Byte 

 

 

CoarseRate (Coarse heating rate: 0 – 3) 

 

 

1 Byte 

 

 

        0 = Very Slow 

 

 

        1 = Slow 

 

 

        2 = Medium 

 

 

        3 =  Fast 

 

                           , 

 

 

 

1 Byte 

 

 

FineRate (00 – 99)   

 

 

 

2 Bytes 

 

 , 

   

 1 

Byte 

 

 

Preheat Reflow Control (0=TIME, 1=TEMP) 

 

1 Byte 

 

 , 

   

 1 

Byte 

 

 

Preheat Delta Temperature (00 – 99) 

 

 

2 Bytes 

Summary of Contents for UNIFLOW 4 REMOTE

Page 1: ...990 908 REV K PULSED HEAT CONTROL UNIFLOW 4 UNIFLOW 4 REMOTE OPERATION MANUAL ...

Page 2: ...y slow PART NUMBER PART NUMBER PART NUMBER PART NUMBER PART NUMBER 1 298 02 1 298 02 01 1 298 02 02 1 298 02 03 1 298 02 05 1 298 02 06 1 298 02 07 1 298 02 09 1 298 02 10 1 298 02 11 1 298 02 13 1 298 02 14 1 298 02 15 REMOTE Versions Separate Control and Transformer units Controller PART NUMBER 1 299 02 01 1 299 02 02 1 299 02 03 Remote Transformers 4 kVA transformer 180 264 VAC single phase inp...

Page 3: ...ures in Chapter 2 updated programming instructions and correct Schedule Setup Screen 3 of 5 in Chapter 3 added notes and message information in Chapter 5 updated schematics and Remote Profile Inputs table in Appendix B H 42861 11 13 Update to Miyachi America name and logo J 43482 11 14 Updated to Amada Miyachi America name and logo K 43878 9 15 Updated to Amada Miyachi America format Shipment Cont...

Page 4: ... Ship Kit Part Number 4 81204 01 PART NUMBER DESCRIPTION QUANTITY 160 116 Bolt Cap Hex Head M6 25 4l 2 160 117 Bolt Cap Hex Head M8 25mml 2 4 39005 01 Cord 3x 14 8ft 1conn End 1 4 38703 01 Plug Set Uniflow 4 1 4 38758 01 Thermocouple Cable Assembly K Type 1 4 38771 01 CD ROM Manual Uniflow 4 1 4 38927 01 FAN 24VDC Power Cable Assy 1 465 206 Nut M8 Hex Machine 2 465 214 Machine Nut Hex M6x1 0p 2 75...

Page 5: ...e Assy 1 Ship Kit Part Number 4 81207 01 PART NUMBER DESCRIPTION QUANTITY 160 116 Bolt Cap Hex Head M6 25 4l 2 160 117 Bolt Cap Hex Head M8 25mml 2 205 2524 39004 01 Cord 3x 14 8ft 2conn End 1 4 38703 01 Plug Set Uniflow 4 1 4 38758 01 Thermocouple Cable Assembly K Type 1 4 38771 01 CD ROM Manual Uniflow 4 1 465 206 Nut M8 Hex Machine 2 465 214 Machine Nut Hex M6x1 0p 2 755 063 Washer 3 8 Brass Sm...

Page 6: ... Keys 1 6 Graph Key 1 6 Data Key 1 7 Profile Number Keys 1 7 Counters Key 1 7 Schedule Edit Keys 1 8 Heating Rate Key 1 8 Setup Key 1 9 Heat No Heat Switch 1 9 Chapter 2 Installation and Setup Section I Planning for Installation 2 1 Space Requirements 2 1 Utilities 2 2 Section II Connections To External Equipment 2 3 Overview 2 3 Uniflow 4 Rear Panel With Initiate Connector 2 3 Uniflow 4 Rear Pane...

Page 7: ...ocess Cycles 3 3 Base 3 4 Rise1 3 4 Preheat 3 4 Rise2 3 4 Reflow 3 4 Cool1 3 5 Postheat 3 5 Cool2 3 5 Profile Description and Programming 3 5 Temperature and Time Parameters 3 5 Schedule Setup Parameters 3 6 Setting the PID Control Number 3 11 Data Key 3 14 Profile Number Keys 3 15 Counters Key 3 15 Total Usage Counter 3 15 Good Reflow Counter 3 16 Clean Counter 3 16 Replace Counter 3 16 Schedule ...

Page 8: ...mits 3 24 Clean Thermode 3 25 Replace Thermode 3 25 Idle Heat 3 25 Communications 3 25 Communication Role 3 25 RS232 485 Select 3 26 Baud Rate 3 26 I D Number 3 26 Reflow Setup 3 27 Set Idle Temperature On Off 3 27 Set Safety Timer 3 27 Set Release Timer 3 28 Max Temperature Limit 3 28 Max Aux Temperature Limit 3 28 Max Idle Temperature Limit 3 29 Display Aux Temp Number 3 29 Display Aux Temp Line...

Page 9: ...ion 4 6 Data Screen Abbreviations and Time Calculations 4 6 Preheat and Reflow Control 4 7 Section IV Process Cycle Parameters 4 10 Temperature Setting Ranges 4 10 Time Setting Ranges 4 10 Section V Operating Instructions 4 11 Pre Defined Reflow Profiles 4 11 Direct Input 4 11 Display Backlight ON AUTO 4 13 Chapter 5 Maintenance Section I Before You Start 5 1 Precautions 5 1 Status Messages 5 1 Se...

Page 10: ...UNIFLOW 4 PULSED HEAT CONTROL x 990 908 CONTENTS Continued Page Appendix C System Timing C 1 Appendix D Communications D 1 Appendix E Guide to Reflow Soldering E 1 ...

Page 11: ...YACHI AMERICA Amada Miyachi America 1820 South Myrtle Avenue P O Box 5039 Monrovia California 91016 Phone 626 256 4128 FAX 626 303 5396 E mail info amadamiyachi com MIYACHI EUROPE Lindberghstraße 1 D 82178 Puchheim Germany Telephone 49 89 839403 0 FAX 49 89 839403 10 The contents of this manual are subject to change without notice If you have any questions or find any errors or omissions in this m...

Page 12: ...e Control Operation Procedures other than those described in this manual or not performed as prescribed in this manual may expose personnel to electrical shock or DEATH When operating any Reflow unit always wear appropriate personal protective gear Maintenance Service Before performing any maintenance on the Control unit read Chapter 5 Maintenance thoroughly Use the appropriate tools for terminati...

Page 13: ...operation The meanings of the words and symbols are as follows DANGER DO NOT TOUCH THE INSIDE OF THE CONTROL UNNECESSARILY High Voltages are present inside the Control Cabinet Do not touch the inside of the Control unnecessarily with the power turned ON You may receive an electric shock When inspecting the inside of the Power Supply be sure to turn the power source OFF NEVER DISASSEMBLE REPAIR OR ...

Page 14: ...wist or tense any cable The power cable and connecting cables may be damaged which can cause electric shock short circuit or fire If any part needs to be repaired or replaced consult Amada Miyachi America or your distributor Stop operation if any trouble occurs If you detect a burning smell abnormal sounds abnormal heat smoke etc turn power OFF immediately to prevent fire or electric shock Contact...

Page 15: ...firm level surface Injury may result if the Control falls over or drops from an uneven surface Keep combustible matter away from the Control Spatter can ignite combustible materials If you cannot remove all combustible materials cover them with a non combustible material Do NOT cover the Control with a blanket cloth etc Heat generated by the operating Control may ignite a blanket or cover Keep a f...

Page 16: ...niker sowie ein Benutzerhandbuch erfordert ATTENZIONE Questo simbolo indica un operazione che richiede un tecnico qualificato ed il manuale dell utente CUIDADO Este símbolo indica uma operação que requer um técnico qualificado e o Manual do Usuário PRECAUCIÓN Este símbolo designa una operación que requiere un técnico competente y el Manual del usuario 1 Install power supply system Installeer het v...

Page 17: ...courant de soudure Der Schweißstromfluß wird mit dem Schalter WELD NO WELD angehalten Usare l interruttore WELD NO WELD per interrompere il flusso della corrente di saldatura Use a chave WELD NO WELD para interromper o fluxo da corrente de soldagem Utilice el interruptor de WELD NO WELD para cortar el flujo de la corriente e soldar EMERGENCY STOP Open electrical circuit to retract weld head NOODST...

Page 18: ...UNIFLOW 4 PULSED HEAT CONTROL xviii 990 908 ...

Page 19: ...UNIFLOW 4 PULSED HEAT CONTROL 990 908 xix ...

Page 20: ...UNIFLOW 4 PULSED HEAT CONTROL xx 990 908 ...

Page 21: ...UNIFLOW 4 PULSED HEAT CONTROL 990 908 xxi ...

Page 22: ...Y RIGHTS OF A THIRD PARTY WHETHER EXPRESS OR IMPLIED BY LAW COURSE OF DEALING COURSE OF PERFORMANCE USAGE OF TRADE OR OTHERWISE Notwithstanding the foregoing in the event of the failure of any Third Party Product Seller will assist within reason Buyer at Buyer s sole expense in obtaining from the respective third party any if any adjustment that is available under such third party s warranty e Sel...

Page 23: ...replace such Goods or the defective part or ii credit or refund the price of such Goods at the pro rata contract rate provided that if Seller so requests Buyer shall at Buyer s expense return such Goods to Seller i THE REMEDIES SET FORTH IN SECTION 1 H SHALL BE BUYER S SOLE AND EXCLUSIVE REMEDY AND SELLER S ENTIRE LIABILITY FOR ANY BREACH OF THE LIMITED WARRANTY SET FORTH IN SECTION 1 A Representa...

Page 24: ...tions for Additional Acceptance Tests either at Seller s or Buyer s facility shall be mutually agreed in writing prior to issuance or acceptance of the Acknowledgement Performance Warranty The system is warranted to pass the identical performance criteria at Buyer s site as demonstrated during final Acceptance Testing at the Testing Site during the Warranty Period as provided in the Acknowledgemen...

Page 25: ...fect in material and workmanship which are apparent upon receipt by Buyer The foregoing warranty is negated after the initial use No warranty made hereunder shall extend to any product whose serial number is altered defaced or removed Remedies With respect to any such Goods during the Warranty Period Seller shall in its sole discretion either repair such Goods or the defective part THE REMEDIES SE...

Page 26: ......

Page 27: ...f at eye level Consult Amada Miyachi America if custom lengths of connecting cables are required For the rest of this manual both models of Uniflow will simply be referred to as the Control except in specific instances where unique descriptions are required such as specifications connections etc In those cases reference will be made specifically to Uniflow 4 or Uniflow 4R Uniflow 4 Uniflow 4R If y...

Page 28: ... items These items are typically flexible and rigid circuit boards glass panel displays and flex foils With an applied force two parts are brought together with an adhesive foil flex or paste in between them The temperature then may be raised to a preheat temperature as a step toward the final sealing temperature The temperature is then raised to the sealing temperature A plastic deformation of th...

Page 29: ...rols and display for local operator programming 24 VAC or 24 VDC valve outputs 240 2 KVA For thermodes up to 2 3 60 mm long 1 299 02 01 1 299 02 02 1 299 02 03 Front panel Has front panel controls and display for local operator programming 24 VDC valve outputs 240 For use with 2 and 4 kVA transformers 9 040 01 Model X4 240UNF 9 041 01 Model X4 240UNFHV 9 042 01 Model X2 240UNF 9 043 01 Model X2 24...

Page 30: ...908 Heads Thermodes and Accessories For details of solder reflow and heat seal heads thermodes and accessories available from Amada Miyachi America please contact Amada Miyachi America using the phone e mail or mailing information in the Foreword of this manual ...

Page 31: ... and Indicators Front Panel Display LCD The LCD on the front panel displays both graphic and alphanumeric data depending on the function chosen by the Operator NOTE These screens their functions and displays are described in Chapter 3 Using Programming Functions and Chapter 4 Operation ...

Page 32: ...een You use the Left and Right keys to decrease or increase a numeric field value After changing the temperature or time parameters using the keypad the Up key will save your change The Up key will also clear alarm messages and the ALARM and OUT OF LIMITS of relay state Graph Key This key displays the graphic screen for editing the heat profile parameters with the keypad or cursor keys After editi...

Page 33: ...le number on the graphics screen With the data screen on the display pressing either PROFILE NUMBER key returns the graphics screen to the display the keys will then increment decrement the profile number on the screen The PROFILE NUMBER up down keys are disabled when any screen other than the graphic screen or data screen is on the display The number of possible heat profiles than can be stored r...

Page 34: ...active when the graphic screen is displayed HEATING RATE Key The HEATING RATE key brings up the MANUAL TUNING screen This screen allows you to go to the SET COARSE HEATING RATE and SET FINE HEATING RATE heating rate capability to match the heat generating capability of the thermode to minimize the temperature overshoot and undershoot See Chapter 3 Using Programming Functions for details MANUAL TUN...

Page 35: ...OMMUNICATIONS 3 REFLOW SETUP 4 SYSTEM SECURITY 5 COPY PROFILE 6 SET TO DEFAULTS 7 LANGUAGE 8 I O STATUS Number Select an item Graph Data HEAT NO HEAT Switch When this switch is in the HEAT position the programmed profile can initiate heating energy When you set the switch to the NO HEAT position no heating current can flow This function is required to adjust a new thermode to the work pieces prior...

Page 36: ......

Page 37: ...0 908 2 1 CHAPTER 2 INSTALLATION AND SETUP Section I Planning for Installation Space Requirements Dimensions including all projections from the housing but excluding cabling Uniflow 4 Uniflow 4R 2KV Transformer 4KV Transformer Weight ...

Page 38: ...d the Control so that it will not be jostled or struck while in use The work surface must be level stable free from vibration and capable of supporting the combined weight of the total joining system Make sure there are no sources of high frequency energy close by There can be strong magnetic fields around the cables connected between the thermode and the Control To avoid movement secure the cable...

Page 39: ... equipment are made through the rear panel The transformer cable connections from the reflow soldering or heat seal head are made at the transformer cable terminals on the front panel NOTE If you require compressed air cover gas and cooling water service for the reflow soldering or heat seal head please refer to the head manufacturer s user s manual for service specifications UNIFLOW 4 Rear Panel ...

Page 40: ...CHAPTER 2 INSTALLATION AND SETUP UNIFLOW 4 PULSED HEAT CONTROL 2 4 990 908 UNIFLOW 4 Rear Panel Without INITIATE Connector ...

Page 41: ...CHAPTER 2 INSTALLATION AND SETUP UNIFLOW 4 PULSED HEAT CONTROL 990 908 2 5 UNIFLOW 4R Rear Panel With INITIATE Connector UNIFLOW 4R Rear Panel Without INITIATE Connector ...

Page 42: ...inal voltage range for each model is set at the factory either 100 to 120 VAC or 200 to 240 VAC Connect the Transformer Uniflow 4R Version Only Before you start be aware that electrical noise may cause error messages such as the MAX TEMP alarm and the temperature control will not be as good To prevent electrical noise follow the instructions for proper cable placement in the following instructions...

Page 43: ... CONNECTOR 3 Once the RED dots are aligned push the cable into the transformer connector until it stops then twist slightly counterclockwise until the connectors are secured together 4 To prevent electrical noise on the thermocouple place the thermocouple cable along side of the transformer cable that goes between the Transformer and Control NOTE To disconnect twist the TRANSFORMER CABLE CONNECTOR...

Page 44: ... correct If the thermocouple polarity is reversed the control may display the error message OVER POWER ALARM Check TC thermocouple Cycle Power See Appendix B Main Thermocouple Input Connector J9 for the correct connection The Control will not respond to an initiation signal until the thermocouple is properly connected The LCD will display an error message if the thermocouple is not connected 3 Plu...

Page 45: ...ROL 990 908 2 9 6 Connect the two transformer cables from the head to the transformer terminals on the Control front panel for the standard version or to the transformer terminals on the remote transformer for the remote version Transformer Terminal Dimensions ...

Page 46: ... Fired Air Actuated Head instructions 1 Adjust the reflow soldering head force adjustment knob to produce 5 units of force as displayed on the force indicator index 2 Connect the reflow soldering head firing switch cable connector to the Control firing switch INITIATE cable connector 3 Set the HEAT NO HEAT switch on the Control front panel to the NO HEAT position In this position the Control canno...

Page 47: ...isplay You will use this screen to enter heating parameters Force Fired Air Actuated Head 1 Adjust the head force adjustment knob to produce 5 units of force as displayed on the force indicator index 2 Connect the head firing switch cable connector to the Control firing switch INITIATE cable connector 3 Connect the Foot Switch Cable to the Foot Switch connector on the Control rear panel ...

Page 48: ...breaker on the rear panel of the Control to the ON position The default graphic screen will display You will use this screen to enter heating parameters 9 Turn the air regulator clockwise to produce 10 psi on the air regulator pressure gauge 10 Press the foot switch down to close the first level and hold the foot switch at the first level The thermode should descend to the parts 11 If the parts ar...

Page 49: ... actuate the first level and set the thermode on the parts Release the foot switch and verify that thermode does not impact during retraction If it does impact during retraction go to Step 17 16 Repeat Step 16 adjusting the Head Up Speed Control Knob until the thermode does not impact at the UP position ...

Page 50: ......

Page 51: ... For the rest of this manual screens containing both graphic and alpha numeric data will be shown in color like the screen on the right Screen Navigation and Menu Selection Refer to the bottom line of the display The contents are prompts instructions for editing and exiting the screen You will find operation specific instructions like these on every menu screen The highlighted word or symbol indic...

Page 52: ...sequence The instruction on the right is an escape function returning the Control to its Ready mode in the graphics or data display screens For example pressing the GRAPH key to returns you to the graphic display Run Mode Press the GRAPH or DATA key to enter the RUN mode With the GRAPH screen on the display The Control can run processes when either the GRAPH or DATA screens are displayed These scr...

Page 53: ...displayed will rotate the screen display through the GRAPH and two Schedule Setup screens Graph Schedule Profile The screen shown to the right displays the default profile settings The profile temperature and time parameters are edited while the GRAPH screen is displayed For a complete description of the information displayed on the GRAPH screen refer to Chapter 4 Operating Instructions Process Cy...

Page 54: ... shown as being set for 1 0 seconds It can be set from 0 to 9 9 seconds When it is set to 0 0 seconds the Rise1 state is omitted Preheat You can use Preheat to activate flux for removing solder oxides between solder plated parts You can also use Preheat to reduce warping on large thermodes by decreasing the temperature difference between Preheat and Reflow periods The temperature for this state is...

Page 55: ...ovides a reduction in contaminant buildup on the thermode The point at which during the Postheat stage when the thermode will be lifted is determined by the user setting for Head Up Delay Postheat is shown as having a time of 2 0 seconds and a set point temperature of 250 C Time can be set for 0 to 99 9 seconds When it is set to 00 0 seconds the Postheat state is omitted Set point temperature can ...

Page 56: ... ON then the Control will monitor temperatures and trigger an Out of Limits if the peak and or average temperature is outside the set limits If set to OFF the Control will not monitor any peak or average temperatures Item 2 on the menu PREHT PEAK TIME DELAY allows the operator to set the Control to ignore the first part of the Preheat process cycle when selecting the peak Preheat temperature This ...

Page 57: ...le Setup Page 2 of 5 You can also press the and keys to step through the Schedule Setup screens This screen contains parameters for the Main thermocouple and the temperature the Control is controlling It also includes some general profile parameters Press the 1 key to toggle PREHEAT ENVELOPE LIMITS to between ON and OFF SCHEDULE SETUP Page 2 of 5 1 PREHEAT ENVELOPE LIMITS OFF 2 REFLOW ENVELOPE LIM...

Page 58: ...e RISE1 Period time there will not be any envelope during Rise1 RISE1 TIME DELAY 0 5 After edit Page to accept new value Number Change Adjust Graph Data Even if the value for RISE1 TIME DELAY is greater than the RISE1 Period time there will be an envelope during the entire PREHEAT time The RISE2 TIME DELAY has the same functionality as the RISE1 TIME DELAY Press the 5 though 8 keys to set the Enve...

Page 59: ...beginning of the Postheat period and sets the point when the head will be lifted from the part The HEAD UP DELAY can be set from 0 to 99 9 seconds The HEAD UP DELAY will only be executed on Profiles with a POSTHEAT time greater than 0 seconds HEAD UP DELAY 01 0 After edit Page to accept new value Number Change Adjust Graph Data Press the key to set the IDLE TEMPERATURE The IDLE TEMPERATURE can be ...

Page 60: ... the ten character Schedule Reference Text is blank and then re enter the new reference text you want Pressing the GRAPH key when the Schedule Setup Page 2 of 5 screen is displayed will change the display to the Schedule Setup Page 3 of 5 This screen contains control parameters Press the 1 key to toggle PREHEAT AND REFLOW CONTROL to between TIME and TEMPERATURE Refer to pages 4 7 and 4 8 in chapte...

Page 61: ...D CONTROL Number The following table provides a guide to selection of a PID CONTROL number It is recommended to start with a PID CONTROL number of 185 With this initial setting you can then optimize the Coarse Heat Rate and Fine Heat Rate settings After that you can return to the PID CONTROL number for additional adjustments For applications that require very fast rise of temperature with minimal ...

Page 62: ... Page Graph Data if the peak and or average temperature is outside the set limits If set to OFF the Control will not monitor any peak or average temperatures Item 2 on the menu PREHT PEAK TIME DELAY allows the operator to set the Control to ignore the first part of the Preheat process cycle when selecting the peak Preheat temperature This parameter can be set from 0 to 99 9 seconds If this paramet...

Page 63: ... is outside the user set Reflow Envelope Limits If set to OFF the Control will not monitor or display any temperature envelopes for Reflow Press the 3 though 6 keys to set the Envelope Limits These parameters allow you to set the upper and lower envelope limits for the auxiliary thermocouple temperature The numbers entered will be the difference between the expected temperature of the Auxiliary th...

Page 64: ... HIGH TEMP LIMIT 25 C schedule setup page 5 of 5 PREHEAT LOW TEMP LIMIT 25 C schedule setup page 5 of 5 REFLOW HIGH TEMP LIMIT 25 C schedule setup page 5 of 5 REFLOW LOW TEMP LIMIT 25 C schedule setup page 5 of 5 RISE1 TIME DELAY 0 5 SEC schedule setup page 2 of 5 RISE2 TIME DELAY 0 0 SEC schedule setup page 2 of 5 The results of these sample settings are shown below DATA Key The DATA key brings u...

Page 65: ...NTERS Key This key brings up the REFLOW COUNTERS screen Based on your settings for the Reflow Counters the Control will display messages when the thermode needs cleaning or replacement This screen provides a menu of selections for setting the thermode cleaning and thermode replacement counters and choosing responses to the counter settings NOTE With this and all other menu screens on the display y...

Page 66: ...an counter value is reached STOP will require the Operator to reset CLEAN COUNTER SETUP 1 CLEAN COUNTER OFF 2 CLEAN COUNTER ACTION STOP 3 EDIT CLEAN COUNTER 000010 Number Select an item Graph Data the clean counter before the Control will run another process and the System Ready relay state will be inactive CONTINUE will allow the Control to perform additional processes even if the clean counter i...

Page 67: ...replace counter is not reset If CONTINUE is selected the Control will continue to display the Replace Counter message after each process and the System Ready relay state will be active Press 3 to edit the remaining counts before the Replace Counter must be reset With the numeric keys you may select a number up to 999999 Schedule Edit Keys The Schedule Edit Keys allow you to edit the time and tempe...

Page 68: ...ES HEATING RATE Key The HEATING RATE key brings up the MANUAL TUNING screen This screen allows you to go to the SET COARSE HEATING RATE and SET FINE HEATING RATE capabilities to match the heat generating capability of the thermode to minimize the temperature overshoot and undershoot For example given a very small peg tip thermode with a heat generating tip diameter of 0 020 inch 0 5mm the COARSE h...

Page 69: ... 3 4 17FW 30 to 60 mm 1 2 to 2 4 in 3 4 17FW 60 to 100 mm 2 4 to 4 0 in 3 4 NOTE 17BW and 17FW thermodes 60 to 100 mm long can only be heated using 4kVA Models Selecting 2 on the MANUAL TUNING screen will bring up the SET FINE HEATING RATE screen The default value is 85 A value from 85 to 95 is appropriate for 80 of thermodes The effective range of the SET FINE HEATING RATE is usually in the 50 to...

Page 70: ...ween OFF and ON Selecting ON continuously activates the head cool valve which supplies drive power for a user supplied air solenoid valve The drive power is connector selectable at either 24 VAC or 24 VDC NOTE If Idle Heat is turned ON the head cool valve is automatically turned on This valve controls air to cool a hot thermode holder on a reflow solder or heat seal head See Appendix B Electrical ...

Page 71: ...he parts Use LATCH with automated or fixtured applications Once the second level of a 2 level foot switch is activated the heating cycle will continue to completion unless the EMERGENCY STOP switch is actuated LIST OF HARDWARE Press the 4 key to bring up the AUTO RECOGNIZED HARDWARE screen This screen lists the system software recognized hardware complement See Appendix B Electrical and Data Conne...

Page 72: ...stheat stage the buzzer will sound at the Cool 2 temperature setting SET OUTPUT RELAYS Press the 8 key to bring up the RELAY screen The RELAY screen allows you to select the Alarm for Status actuation states or each relay RELAY 1 RELAY 1 OPEN WHEN NOT ACTIVE 2 RELAY 2 OPEN WHEN NOT ACTIVE 3 RELAY 3 OPEN WHEN NOT ACTIVE 4 RELAY 4 OPEN WHEN NOT ACTIVE 5 RELAY 5 OPEN WHEN NOT ACTIVE 6 RELAY 6 OPEN WH...

Page 73: ...CLOSED when COOL1 temperature is reached 7 END OF REFLOW Relay is OPEN CLOSED when COOL1 is reached if no Postheat cycle otherwise COOL2 8 CYCLE PWR ALARM Relay is OPEN CLOSED when a more severe alarm as indicated by Cycle Power text in the alarm message occurs 9 NOT ACTIVE Relay is not active If the desired relay state is not on the first Relay State screen press the key to select the second rela...

Page 74: ...ooling stage will end at COOL 2 temperature if there is a POSTHEAT time Note Cycling Power Also clears alarm Once Alarm is reset Up Arrow key can be used to abort process step of Cooling to Base or Preheat Temperature When the Up Arrow is pressed unit will go to System Ready condition and allow next reflow MAX TEMP ALARM The first Digital Input Reset J4A 7 will clear alarm relay and stop graph lin...

Page 75: ...raph or Data screen or reset by applying a signal at the digital input J4A 7 8 IDLE HEAT Relay is OPEN CLOSED if idle temperature is ON See Appendix B Electrical and Data Connections for the relay description that includes the timing diagram showing the sequence of the status options COMMUNICATIONS The SETUP key returns you to the SETUP MENU screen The 2 key on the SETUP MENU brings up the COMMUNI...

Page 76: ...ings up the BAUD RATE screen Use the keypad to select the required data transfer rate from 1200 to 38 4K baud The Default value is 38 4K BAUD RATE 1 1200 5 19 2K 2 2400 6 38 4K 3 4800 4 9600 Number Select Page Graph Data I D NUMBER Press the 4 key to bring up the RS485 ID NUMBER screen Use the keys to adjust Unit IDs range from 01 31 The Default ID value is 01 RS485 ID NUMBER RS485 Unit ID Number ...

Page 77: ...cycle Selecting OFF turns off the Idle temperature function no matter REFLOW TEMPERATURE SETUP 1 IDLE TEMPERATURE IS OFF 2 SET SAFETY TIMER 10 SEC 3 SET RELEASE TIMER 00 SEC 4 MAX TEMPERATURE LIMIT 600 C 5 MAX AUX TEMPERATURE LIMIT 600 C 6 MAX IDLE TEMPERATURE LIMIT 300 C 7 DISPLAY AUX TEMP NUMBER OFF 8 DISPLAY AUX TEMP LINE OFF Number Select Page Graph Data what temperature value is set in the cu...

Page 78: ...ing reflow temperatures in profiles the new reflow temperature must be below the user set MAX TEMPERATURE LIMIT MAX TEMPERATURE LIMIT MAX TEMPERATURE LIMIT 600 After edit Page to accept new value Number Change Adjust Graph Data The default temperature of 600 C is shown on the screen above A maximum temperature up to 999 C can be entered Use the keys to edit the value MAX AUX TEMPERATURE LIMIT Pres...

Page 79: ...e Auxiliary Temperature DISPLAY AUX TEMP LINE Press the 8 key to toggle between ON and OFF Selecting ON will display the planned and actual temperature lines for the Auxiliary thermocouple temperature reading on the GRAPH and DATA Screens Select OFF if you do not wish to display the Auxiliary Temperature lines SYSTEM SECURITY From the SETUP MENU screen the 4 key will bring up the SYSTEM SECURITY s...

Page 80: ...m making changes to menu items PROFILE TUNING LOCK prevents modifying any reflow parameters but allows users to select different profile schedules NOTE The SYSTEM SECURITY LOCKS prevent keypad actions When SYSTEM SECURITY LOCKS are active inputs received through the Profile Binary Inputs and Serial Ports will still be executed COPY PROFILE On the SETUP MENU screen the 5 key will bring up the COPY ...

Page 81: ...Number Select Page Graph Data If you press the COUNTERS or HEATING RATE keys while this screen is displayed this function will be aborted SYSTEM DEFAULTS SET If the 1 key was pressed on the RESET TO DEFALUTS screen this screen will be displayed to confirm the defaults were reset SYSTEM DEFAULTS SET ALL PROFILE AND SYSTEM PARAMETERS HAVE NOW BEEN SET TO THEIR DEFAULT VALUES Page Graph Data LANGUAGE...

Page 82: ...s for further description of the Inputs and Outputs on this screen If you press the GRAPH DATA COUNTERS or HEATING RATE keys you will exit this screen I O STATUS SCREEN INPUTS OUTPUTS J4A 3 NOHEAT 0 J6A 1 2 RELAY1 0 J4A 6 AIRHEAD 1 J6A 3 4 RELAY2 0 J4A 7 RESET 0 J6A 5 6 RELAY3 0 J4B 7 SCHED0 0 J6A 7 8 RELAY4 0 J4B 8 SCHED1 0 J6A 9 10 RELAY5 0 J4B 9 SCHED2 0 J6B 3 4 RELAY6 0 J4B 10 SCHED3 0 J6B 5 6...

Page 83: ...ontrol functions for your specific applications For more information see Chapter 3 Using Programming Functions General Operator Safety WARNING To prevent blindness or eye injury wear safety goggles at all times during reflow soldering Be careful of moving parts You can be injured by moving parts during the reflow Do not wear loose clothing or jewelry around moving parts They could get caught and c...

Page 84: ...READY message NOTES If the EMO jumper plug is not installed as described in Chapter 2 Installation and Setup the LCD Screen will display a message saying that an emergency stop is in effect The Control will not operate until the jumper is installed If the Control has been setup with the Idle temperature on the message WARM UP IN PROGRESS PLEASE WAIT will be displayed while the Control heats to the...

Page 85: ...esents the expected temperature plot for the Auxiliary thermocouple This line begins at the start of Rise1 and ends at the end of the Reflow process cycle Graph Actual Temperature and Envelope Limits A bold solid line represents the actual temperature as measured by the Main thermocouple A dashed solid line represents the actual temperature as measured by the Auxiliary thermocouple In the screen p...

Page 86: ... right side of the screen indicates the peak and average temperature results PP Peak Preheat Temperature PA Average Preheat Temperature RP Peak Reflow Temperature RA Average Reflow Temperature Close UP View The actual temperature is displayed in the middle column as soon as the particular process cycle is over The four columns on the right indicate if the process was outside the peak and average t...

Page 87: ...The second line from the bottom of the screen indicates the temperature for each process cycle of the current Profile Close UP View The third line from the bottom is a status or alarm message This line will either display the Control status present process cycle step or an alarm message GRAPH Screen Detail 4 The numeric value in the upper left of the screen is the length of time represented by the...

Page 88: ...ratures for the Preheat and Reflow process cycles of most recent reflow The next table down displays the actual times for each process cycle The Coarse and Fine heating rates and PID Control setting for the current profile are displayed The status of the Clean and Replace Counters Data Screen Abbreviations and Time Calculations ABBREVIATION DESCRIPTION PREHET Main Thermocouple Preheat Temperature ...

Page 89: ... This setting is made in the Schedule Setup If TIME is selected for Preheat and Reflow Control the Control will execute the full Rise1 and Rise2 user set times before starting the Preheat and Reflow user set times The Control will follow the programmed Rise1 and Rise2 ramp slopes for the full Rise1 and Rise2 times The Control will also execute the full Preheat and Reflow times If TEMPERATURE is se...

Page 90: ...ring the entire RISE1 period at the ramp rate you set and it switches control to the Preheat temperature at the end of the full RISE1 time As for the display on the DATA screen if the time from the start of Rise1 to 140 C is 1 7 seconds then 1 7 seconds will display for the time of Rise1 The length of Preheat will be 3 3 seconds so the total time of Rise1 Preheat will be 5 seconds If you select Te...

Page 91: ...eat and Reflow Control the Postheat will begin at the Cool1 temperature and last for the exact Postheat time you specified The DATA screen will display the exact Postheat Time you selected as the Postheat time If you select Temperature for Preheat and Reflow Control heating for postheat will begin at the Cool1 temperature Once a temperature equal to the Postheat temperature you selected less the R...

Page 92: ...flow default 60 to 600 C Reflow extended mode operation 60 to 999 C Cool1 25 to 300 C Postheat 25 to 600 C Cool2 25 to 300 C Maximum Temperature 300 to 999 C Time Setting Ranges Base 0 to 99 9 seconds Rise1 0 0 to 9 9 seconds Preheat 0 to 99 9 seconds Rise2 0 0 to 9 9 seconds Reflow 0 1 to 99 9 seconds Postheat 0 to 99 9 seconds Process Cycle Steps No Postheat Process Cycle Steps With Postheat ...

Page 93: ...ush the PROFILE NUMBER up down keys until the profile you want 1 63 is displayed on the LCD screen NOTE The PROFILE NUMBER up down keys are disabled when any screen other than the graphic screen or data screen displays on the LCD 2 Set the HEAT NO HEAT switch to HEAT The Control is now ready to use Direct Input CAUTION You can accidentally overwrite erase an existing stored profile when using the ...

Page 94: ... any period temperature or time value the graphic screen trace will automatically re size 5 Press the RISE1 key to select the RISE1 time field for editing Use the keypad to enter a RISE1 time to 1 5 1 5 seconds then press the key 6 Press the PREHEAT key to select the PREHEAT temperature value for editing Use the keypad to enter a temperature 150 C then press the key 7 Press the PREHEAT key twice t...

Page 95: ...ing cycle For manual reflow soldering heads release the foot pedal when the alarm beep sounds indicating that the thermode has reached the COOL temperature For air actuated reflow solder heads release the foot switch after the head has automatically retracted the thermode 15 If the joint is good use the present Control settings for your soldering application If it is not good go to Step 16 16 Repe...

Page 96: ......

Page 97: ...ges Message Description Baseheat Time The Control is operating in the Baseheat Time period Cooling The Control is operating in the Cool 1 or Cool 2 periods Cooling to Base or Preheat Temperature The Control has either passed a the Cool 1 Temperature at the end of the reflow where there is no Postheat period and is cooling down to the Base or Preheat Temperature whichever is lower OR b the Cool 2 T...

Page 98: ...e Reflow Time period Rise1 Time The Control is operating in the Rise1 Time period Rise2 Time The Control is operating in the Rise2 Time period System Ready The Control is ready to begin a reflow process cycle System Ready PROCESS WARNING The Control is ready to begin a reflow process cycle A temperature was Out Of Limits or Envelope during the previous process System Ready WARNING IDLE HEAT ON The...

Page 99: ...t reached the PREHEAT TEMPERATURE DELTA or REFLOW TEMPERATURE DELTA within the length of the programmed RISE1 PREHEAT time or RISE2 REFLOW time Change COARSE and or FINE HEATING RATE PID CONTROL SETTING or Process Temperatures ABORT REFLOW Safety Timer expired Thermode is taking longer than the user set SAFETY TIMER time to reach Reflow temperature Verify that all electrical connections between th...

Page 100: ...lower Reflow value increase the maximum temperature in the Reflow Setup Screen and then enter the desired higher Reflow temperature FIRING SWITCH NOT ACTUATED Air Actuated Reflow Soldering Head Firing Switch has not actuated Switch must actuate within 20 seconds after initiating a new reflow process cycle When this message is displayed the Alarm Relay state will be active and the System Ready Rela...

Page 101: ...e is displayed for Over Power Condition when fine heat rate is greater than or equal to 45 Note The OVER POWER ALARM can be caused if the TC polarity is reversed See Appendix B Main Thermocouple Input Connector J9 for the correct connection Make sure that the Thermocouple is plugged in is undamaged and is still bonded to the Thermode Also check Thermocouple polarity Then recycle the Power on the C...

Page 102: ...oose connections Increase the diameter of the cables between the Control output and the Reflow Soldering Head REFLOW BELOW COOL TEMP SETTING New Reflow temperature value is lower than Cool1 temperature Re enter a Reflow value that is greater than the Cool1 temperature REPLACE THERMODE Press 0 to reset count Replace Thermode Counter has reached zero Reset Replace Thermode Counter Replace Thermode C...

Page 103: ...w key can be used to abort process step of Cooling to Base or Preheat Temperature When Up Arrow is pressed unit will go to System Ready condition and allow next reflow MAX TEMP ALARM The first Digital Input Reset J4A 7 will clear alarm relay and stop graph lines from plotting Unit will go to Cooling Cooling to Base or Preheat Temperature or System Ready depending on Main thermocouple temperature N...

Page 104: ...ated with heavy flux adhesive or polyimide ribbon flex cable residue Clean the thermode surface either chemically with your vendor recommended solvents or mechanically using number 600 grit or finer silicon carbide paper Replace thermodes that have become warped or cracked Warped thermodes will not adequately transfer heat to the parts Cracked thermodes will not heat or they may overheat in the cr...

Page 105: ...ype thermocouple cable Amada Miyachi America Part Number 10 359 01 NOTE The appropriate thermocouple and connector for the selected thermocouple type must be used to get accurate readings Before You Start Ensure that reflow cable is disconnected from the weld head thermode Calibration 1 Install a J K or E type thermocouple cable between J9 of the unit and the Calibrator output 2 Turn the unit ON 3...

Page 106: ......

Page 107: ...el Part Numbers except 1 298 02 180 to 264 VAC Line Frequency 50 or 60 Hz Line Phase Single Input Circuit Breaker Rating 15 A Power Cord Connection European CE Harmonized Wiring Code or NEMA Wiring Code Dimensions STANDARD Version Including all projections from the housing but excluding cabling Weight 4 KVA models 60 pounds 27 2 kg 2 KVA models 48 pounds 21 8 kg ...

Page 108: ...TROL A 2 990 908 REMOTE Version Including all projections from the housing but excluding cabling Remote Controller Weight All models 19 pounds 8 6 kg REMOTE 2KV Transformer Including all projections from the housing but excluding cabling Weight 31 pounds 14 1 kg ...

Page 109: ...lative Humidity Maximum 93 at 104 F 40 C Performance User Programmable Heat Profiles 63 Flash Memory NOTE Software versions 3 00A through 3 05F only have 15 profiles Versions 3 06G and later have 63 profiles Thermocouple Inputs automatic recognition Type E For temperatures below 900 C Type J For temperatures below 750 C Type K For temperatures below 1000 C Thermocouple Calibration Input Standards ...

Page 110: ...eat 0 to 99 9 seconds Heating Rate Control Coarse Fast Medium Slow Very Slow The user selected Coarse heating rate selects the secondary voltage setting for the transformer Switched Input Electrical Requirements Form and Rating Switch or sensor inputs must be normally open SPST switches transistors or opto isolators rated at 24 VDC 20 mA minimum Heat Profile Select Select 63 heat profiles using fo...

Page 111: ...Slow 2 kVA transformer 180 264 VAC single phase input Secondary Voltage 3 81V Fast 1 9V Medium 1 27V Slow 0 95V Very Slow 2 kVA transformer 180 264 VAC single phase input Secondary Voltages 7 62V Fast 3 8V Medium 2 54V Slow 1 90V Very slow Model Part Number 1 298 02 Model Part Number 1 298 02 01 1 298 02 02 1 298 02 03 Model Part Number 1 298 02 05 1 298 02 06 1 298 02 07 Model Part Number 1 298 0...

Page 112: ...f if idle temperature On Baseheat On Off during baseheat process cycle Rise1 On Off when 50 of the programmed Rise1 time has elapsed At the end of the programmed Rise1 time the relay will switch back to Off On Preheat On On Off during preheat process cycle Rise2 On Off when 50 of the programmed Rise2 time has elapsed At the end of the programmed Rise2 time the relay will switch back to Off On Refl...

Page 113: ...factory before the Control is shipped While the voltage can be changed doing so should only be performed by a qualified MUC technician These procedures require loosening of the motherboard which will void the warranty and may cause permanent damage to the Control If you need to change the voltage setting contact Amada Miyachi America using the phone e mail or mailing information on the CONTACT US ...

Page 114: ...e BROWN wires is installed on connector J7 as shown STANDARD Version 230 VAC Configuration Switch S1 is set with 230V visible on the switch The factory supplied 115V 230V jumper with the BROWN wires is installed on connector J7 as shown REMOTE Version 230 VAC Configuration Switch S1 is set with 230V visible on the switch The factory supplied 230V jumper with the BLUE wires is installed on connecto...

Page 115: ...No Connection 2 RS 232 Transmit 3 RS 232 Receive 4 Data Set Ready 5 Signal Ground 6 Data Terminal Request 7 Clear To Send 8 Request To Send 9 Ring Indicator 1 Signal Ground 2 No Connection 3 No Connection 4 RS 485 Transmit Data 5 RS 485 Transmit Data 6 No Connection 7 No Connection 8 RS 485 Receive Data 9 RS 485 Receive Data ...

Page 116: ...ejumpering connector J4 on the rear panel In the rejumpered configuration an internal resistor pulls an unterminated input terminal to common and the input is considered as inactive Supplying 24 volts to the input terminal will make it become active NOTE For jumper information see pages B 4 B 9 The inputs that have bipolar logic selection capability are in two groups Input switches and control swi...

Page 117: ...TRICAL AND DATA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL 990 908 B 3 Control Input Interface NOTE The Control Input Interface may be connected to a PLC or other interface in the configurations shown on pages B 4 B 9 ...

Page 118: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL B 4 990 908 Switch Contact Input Internal Power ...

Page 119: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL 990 908 B 5 Switch Contact Input External Power ...

Page 120: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL B 6 990 908 Common Negative Input Internal Power ...

Page 121: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL 990 908 B 7 Common Negative Input External Power ...

Page 122: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL B 8 990 908 Common Positive Input Internal Power ...

Page 123: ...LOW 4 PULSED HEAT CONTROL 990 908 B 9 Common Positive Input External Power Force Valve Drive Connections Valve Driver Outputs and Relays 6 and 7 Relay 6 and 7 Rating and Configuration Refer to Relay ratings and configuration information on page B13 ...

Page 124: ... B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL B 10 990 908 Valve Driver Output Rating and Configuration Output Rating 24 VAC VDC 0 3 A max for STANDARD VERSION 24VDC 0 3 A for REMOTE VERSION ...

Page 125: ...you must make one of two connections Either jumper HEAD VALVE CONNECTOR pin 2 and pin 4 Or jumper J4A pin 6 AIR HEAD to 0V OUT see J4A B pin out For Standard Version to change from 24VAC output power to 24 VDC output power the white AC connector with black jumper should be replaced with the white DC plug with red jumper in connector J8 on the Main Circuit Board These color coded connectors will ju...

Page 126: ...erheating The solder cool valve is user programmable to be ON or OFF If the Profile does not have a Postheat process cycle selecting ON will activate the solder cool valve starting at the end of the Reflow period and de activating when the thermode reaches either the COOL1 PREHEAT or BASE temperature which ever is lower If the Profile does have a Postheat process cycle selecting ON will activate t...

Page 127: ...f when head is retracted Alarm On Off for any alarm condition Out of Limit On Off for any out of limit condition Clean Thermode On Off when clean thermode counter expires Replace Thermode On Off when replace thermode counter expires Idle On Off if idle temperature On Baseheat On Off during baseheat process cycle Rise1 On Off when 50 of the programmed Rise1 time has elapsed At the end of the progra...

Page 128: ...A CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL B 14 990 908 Relay State Timing Without Postheat process cycle NOTE If any out of limits conditions occur the Out of Limits relay state updates at the end of Preheat and the end of Reflow ...

Page 129: ...TA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL 990 908 B 15 Relay State Timing With Postheat process cycle NOTE If any out of limits conditions occur the Out of Limits relay state updates at the end of Preheat and the end of Reflow ...

Page 130: ...witch before pressing it to the second level the Control will automatically return the thermode to the home position so that you may reposition the work pieces If you do not release the foot switch and proceed to the second level the force firing switch in the head will close Heating current will flow and the Control will return the thermode to the home position following the heating cycle Connect...

Page 131: ...inactive 0000 the Profile Number 1 63 can be selected from the Front Panel When any of the SCHED Inputs are active the Profile Number Keys on the Front Panel become disabled and the Profile Number is selected through the Profile Remote Inputs SCHED 0 SCHED 1 SCHED 2 SCHED 3 SCHED 4 and SCHED 5 The Profile Number Zero 0 is not a displayable selection REMOTE PROFILE INPUTS Profile Number SCHED 0 Pin...

Page 132: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL B 18 990 908 Remote Profile Selection with Switches or Opto Couplers Remote Profile Selection with PLC ...

Page 133: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 4 PULSED HEAT CONTROL 990 908 B 19 Operator Initiation Switch and Firing Switch Inputs Input Signal 0 or 24 VDC ...

Page 134: ...mally closed pushbutton Timing When the EMERGENCY STOP switch is pressed it removes 24 volt power from the reflow head causing it to retract immediately Manual Alarm Reset Input Signal 0 to 24 VDC Timing By applying a signal at J4A 7 a PLC or external computer can readily reset all alarms and out of limits conditions before proceeding with the next reflow process ...

Page 135: ... is damaged the temperature displayed for the main thermocouple may slowly decrease as the Control applies heat to the thermode during a process This may cause an error message or may damage the thermode due to overheating Pins 1 2 and 3 on connector J9 are jumpered to inform the Control of the type of thermocouple used for both the Main and Auxiliary thermocouples Both thermocouples must be of th...

Page 136: ...thermocouples Polarity Type E Type J Type K J15 Pin 4 Chromel purple Iron white Chromel yellow J15 Pin 5 Constantan red Constantan red Almel red If the Auxiliary thermocouple is not wired correctly on Pins 4 and 5 of J15 or the thermocouple is damaged there will not be any error message on the Control and the temperature displayed will remain at approximately ambient room temperature Temperature A...

Page 137: ...UNIFLOW 4 PULSED HEAT CONTROL 990 908 C 1 APPENDIX C SYSTEM TIMING No Post Heat Pulse TCOOL1 Cool1 Temperature Setpoint ...

Page 138: ...APPENDIX C SYSTEM TIMING UNIFLOW 4 PULSED HEAT CONTROL C 2 990 908 Process With Post Heat Pulse TCOOL2 Cool2 Temperature Setpoint ...

Page 139: ...YWORDS BOLD VARIABLE italics REQUIRED PARAMETERS enclosed in braces one required and only one parameter allowed CHOICE OF PARAMETERS separated by vertical bar indicates one or another of choices presented ON 1 ASCII OFF 0 ASCII Baud Rate is adjustable at 9600 19 2k and 38 4k Baud 8 Data bits 1 Stop No Parity ...

Page 140: ...t of data bytes to follow converted into a ASCII decimal number 000 999 data n BYTES This is optional ASCII data formatted into fields with each field separated by a comma cksum 2 BYTES This is a two charter ASCII HEX string calculated from the sum of all bytes except soh cksum and eot and then masked with 255 0xFF eot 1 BYTE This terminates the transmission End transmit 0x04 Response to Errors or...

Page 141: ...host side of the interface 1 For a host read command e g read profile data the host must timeout if the unit does not send a complete response within a reasonable amount of time Host can also check the number of bytes received against the expected number for that message range check the received data or do whatever else is thought necessary to have confidence in the received data 2 Following a hos...

Page 142: ...t on the back of the Control If RS 232 is the selection this socket would be labeled RS 232 Likewise if RS 485 is selected the serial link to the host should be plugged into the socket labeled RS 485 NOTE Due to the way RS 232 handles line logic states it will work even if RS 485 is selected and even if the serial link is plugged into the RS 485 socket The reverse is not true however RS 485 will w...

Page 143: ...Cntrs stReplace sdCnt Replace counter 000000 999999 6 Bytes 1 Byte ReflowCntrs stClean fStatus Clean counter status 0 OFF 1 ON 1 Byte 1 Byte ReflowCntrs stReplace fStatus Replace counter status 0 OFF 1 ON 1 Byte 1 Byte ReflowCntrs stClean enAction Clean counter action 0 1 1 Byte 0 STOP 1 CONTINUE 1 Byte ReflowCntrs stReplace enAction Replace counter action 0 1 1 Byte 0 STOP 1 CONTINUE 37Bytes Tota...

Page 144: ...TEMP 32 PASSWORD 33 PIDPARAMS 34 PIXELONTEST 35 PIXELOFFTEST 36 REFLOW 37 UNUSED_SCREENID3 38 REFLOW_COUNTERS 39 RELAY 40 RELAY1 41 RELAY2 42 RELAY3 43 RELAY4 44 RELAY1WHENSCR 45 RELAY2WHENSCR 46 RELAY3WHENSCR 47 RELAY4WHENSCR 48 RELEASE_TIMER 49 REPLACE_CNTR 50 REPLACE_CNTR_SETUP 51 SETTODEFAULTS 52 SAFETY_TIMER 53 SETUP 54 SHOWPASSWD 55 SYSTEM_SEC 56 SYSTEMTESTS 57 TESTRELAYS 58 TOTAL_USAGE 59 U...

Page 145: ...RELAY7 89 RELAY5WHENSCR 90 RELAY6WHENSCR 91 RELAY7WHENSCR 92 RELAY1WHEN2SCR 93 RELAY2WHEN2SCR 94 RELAY3WHEN2SCR 95 RELAY4WHEN2SCR 96 RELAY5WHEN2SCR 97 RELAY6WHEN2SCR 98 RELAY7WHEN2SCR 99 SCHEDULE3 100 SCHEDULE4 101 SCHEDULE5 102 AUX_PREHEAT_PEAK_DELAY_TIME 103 AUX_PREHEAT_AVG_DELAY_TIME 104 AUX_PREHEAT_PEAKHI_TEMP 105 AUX_PREHEAT_PEAKLO_TEMP 106 AUX_PREHEAT_AVGHI_TEMP 107 AUX_PREHEAT_AVGLO_TEMP 10...

Page 146: ... Reflow time 000 999 3 Bytes 1 Byte BaseTemp Base temperature 025 300 3 Bytes 1 Byte PostheatTemp Postheat temperature 025 600 3 Bytes 1 Byte Cool2Temp Cool2 temperature 025 300 3 Bytes 1 Byte IdleTemp Idle temperature 025 100 3 Bytes 1 Byte BaseTime Preheat time 000 999 3 Bytes 1 Byte PostheatTime Postheat time 000 999 3 Bytes 1 Byte Rise1Time Rise1 time 00 99 2 Bytes 1 Byte GRAPH Time Span 000 9...

Page 147: ... Limit 000 999 3 Bytes 1 Byte Reflow Peak Lower Temperature Limit 000 999 3 Bytes 1 Byte Preheat Peak Delay 000 999 3 Bytes 1 Byte Preheat Avg Delay 000 999 3 Bytes 1 Byte Rise1 Envelope Delay 00 99 2 Bytes 1 Byte Rise2 Envelope Delay 00 99 2 Bytes 1 Byte Preheat Average Upper Temperature Limit 0 999 3 Bytes 1 Byte Preheat Average Lower Temperature Limit 0 999 3 Bytes 1 Byte Reflow Average Upper T...

Page 148: ...Byte Aux Preheat Average Lower Temperature Limit 0 999 3 Bytes 1 Byte Aux Reflow Average Upper Temperature Limit 0 999 3 Bytes 1 Byte Aux Reflow Average Lower Temperature Limit 0 999 3 Bytes 1 Byte Aux Enable Preheat Envelope Limits 1 yes 0 no 1 Bytes 1 Byte Aux Enable Reflow Envelope Limits 1 yes 0 no 1 Bytes 1 Byte Aux Preheat Upper Temperature Limit 000 999 3 Bytes 1 Byte Aux Preheat Lower Temp...

Page 149: ... As above 2 Byte 1 Byte Relays5 on_off As above 1 Byte 1 Byte Relays5 when As above 2 Byte 1 Byte Relays6 on_off As above 1 Byte 1 Byte Relays6 when As above 2 Byte 1 Byte Relays7 on_off As above 1 Byte 1 Byte Relays7 when As above 2 Byte 34 Bytes Total RESET RX Reset Resets system 0 Bytes SECURITY SR Read Read Security Locks 0 Bytes SS Set Password 0000000 9999999 7 Bytes Note Password is not set...

Page 150: ...e 00 99 2 Bytes 1 Byte ReleaseTimerTime 00 99 2 Bytes 1 Byte MaxTempLimit 300 999 3 Bytes 1 Byte Backlight Operation 0 AUTO 1 ON 1 Byte 1 Byte Max Aux Temp Limit 300 999 3 Byte 1 Byte Max Idle Temp Limit 025 300 3 Bytes 1 Byte Aux Temp Line 0 OFF 1 ON 1 Bytes 1 Byte Aux Temp Number 0 OFF 1 ON 1 Bytes 36 Bytes Total TEMP TR Read Read current temperature 0 Bytes TYPE TY Read Software release number ...

Page 151: ...99999 6 Bytes 1 Byte ReflowCntrs stClean fStatus Clean counter status 0 OFF 1 ON 1 Byte 1 Byte ReflowCntrs stReplace fStatus Replace counter status 0 OFF 1 ON 1 Byte 1 Byte ReflowCntrs stClean enAction Clean counter action 0 1 1 Byte 0 STOP 1 CONTINUE 1 Byte ReflowCntrs stReplace enAction Replace counter action 0 1 1 Byte 0 STOP 1 CONTINUE 39 Bytes Total LOAD LR Read Returns the current active pro...

Page 152: ...Y1WHENSCR 45 RELAY2WHENSCR 46 RELAY3WHENSCR 47 RELAY4WHENSCR 48 RELEASE_TIMER 49 REPLACE_CNTR 50 REPLACE_CNTR_SETUP 51 SETTODEFAULTS 52 SAFETY_TIMER 53 SETUP 54 SHOWPASSWD 55 SYSTEM_SEC 56 SYSTEMTESTS 57 TESTRELAYS 58 TOTAL_USAGE 59 UPPER_TEMP 60 NEW_IDLE_TEMP 61 LANGUAGE_SETUP 62 HEADUP_DELAY 63 SCHEDULE1 64 SCHEDULE2 65 Not Used 66 PREHEAT_PEAK_DELAY_TIME 67 PREHEAT_AVG_DELAY_TIME 68 PREHEAT_PEA...

Page 153: ...RELAY6WHEN2SCR 98 RELAY7WHEN2SCR 99 SCHEDULE3 100 SCHEDULE4 101 SCHEDULE5 102 AUX_PREHEAT_PEAK_DELAY_TIME 103 AUX_PREHEAT_AVG_DELAY_TIME 104 AUX_PREHEAT_PEAKHI_TEMP 105 AUX_PREHEAT_PEAKLO_TEMP 106 AUX_PREHEAT_AVGHI_TEMP 107 AUX_PREHEAT_AVGLO_TEMP 108 AUX_REFLOW_PEAKHI_TEMP 109 AUX_REFLOW_PEAKLO_TEMP 110 AUX_REFLOW_AVGHI_TEMP 111 AUX_REFLOW_AVGLO_TEMP 112AUX_PREHEAT_ENVHI_TEMP 113AUX_ PREHEAT_ENVLO...

Page 154: ...IVATED 16 DECREASEHEATINGRATE 17 INCREASEHEATINGRATE 18 REPLACE 19 CLEAN 20 REPLACERESET 21 CLEANRESET 22 POWERMODE 23 NOHEATSWITCH 24 BASEHEATTIME 25 HEADDOWN 26 PREHEATTIME 27 RISE2TIME 28 HEATTIME 29 COOL1TIME 30 COOLIDLETIME 31 WELDCMPLT 32 MODIFYPROFILE 33 LASTPROFILE 34 IDEALPROFILE 35 EMERSTOP 36 MAXTEMP 37 NOPWR 38 OVPWR1 39 THERMODE 40 ACCESSDENIEDREM 41 FOOTSWOPEN 42 OVPWR2 43 POSTOFF4 4...

Page 155: ...e2 time 00 99 2 Bytes 1 Byte ReflowTime Reflow time 000 999 3 Bytes 1 Byte BaseTemp Base temperature 025 300 3 Bytes 1 Byte PostheatTemp Postheat temperature 025 600 3 Bytes 1 Byte Cool2Temp Cool2 temperature 025 300 3 Bytes 1 Byte IdleTemp Idle temperature 025 100 3 Bytes 1 Byte BaseTime Preheat time 000 999 3 Bytes 1 Byte PostheatTime Postheat time 000 999 3 Bytes 1 Byte Rise1Time Rise1 time 00 ...

Page 156: ...te Preheat Average Upper Temperature Limit 0 999 3 Bytes 1 Byte Preheat Average Lower Temperature Limit 0 999 3 Bytes 1 Byte Reflow Average Upper Temperature Limit 0 999 3 Bytes 1 Byte Reflow Average Lower Temperature Limit 0 999 3 Bytes 1 Byte Enable Preheat Envelope Limits 1 yes 0 no 1 Bytes 1 Byte Enable Reflow Envelope Limits 1 yes 0 no 1 Bytes 1 Byte Preheat Upper Temperature Limit 000 999 3 ...

Page 157: ...Reflow Envelope Limits 1 yes 0 no 1 Bytes 1 Byte Aux Preheat Upper Temperature Limit 000 999 3 Bytes 1 Byte Aux Preheat Lower Temperature Limit 000 999 3 Bytes 1 Byte Aux Reflow Upper Temperature Limit 000 999 3 Bytes 1 Byte Aux Reflow Lower Temperature Limit 000 999 3 Bytes 1 Byte Aux Start Temperature 000 999 3 Bytes 1 Byte Aux Preheat Temperature 000 999 3 Bytes 1 Byte Aux Reflow Temperature 00...

Page 158: ...he end of the reflow ProfileNum Profile number 01 63 2 Bytes 1 Byte StartTemp Starting Temperature 000 999 3 Bytes 1 Byte PeakTemp Peak Reflow Temperature 000 999 3 Bytes 1 Byte FinalTemp Final Reflow Temperature 000 999 3 Bytes 1 Byte AverageTemp Average Reflow Temperature 000 999 3 Bytes 1 Byte Cool1Time Actual Cool1 time 000 999 3 Bytes 1 Byte Cool2Time Actual Cool2 time 000 999 3 Bytes 1 Byte ...

Page 159: ... 13 FIRINGSWOPEN 14 SAFETYTIMER 15 FIRINGSWNOTACTIVATED 16 DECREASEHEATINGRATE 17 INCREASEHEATINGRATE 18 REPLACE 19 CLEAN 20 REPLACERESET 21 CLEANRESET 22 POWERMODE 23 NOHEATSWITCH 24 BASEHEATTIME 25 HEADDOWN 26 PREHEATTIME 27 RISE2TIME 28 HEATTIME 29 COOL1TIME 30 COOLIDLETIME 31 WELDCMPLT 32 MODIFYPROFILE 33 LASTPROFILE 34 IDEALPROFILE 35 EMERSTOP 36 MAXTEMP 37 NOPWR 38 OVPWR1 39 THERMODE 40 ACCE...

Page 160: ...lveStatus 0 OFF 1 ON 1 Byte 1 Byte SolderCoolValveStatus 0 OFF 1 ON 1 Byte 1 Byte FootSwResponseMode 0 ABORT 1 LATCH 1 Byte 1 Byte BuzzerLoudness 00 99 2 Bytes 1 Byte BuzzerAtEnd 0 OFF 1 ON 1 Byte 1 Byte Idle Temperature 0 ON 1 OFF 1 Byte 1 Byte SafetyTimerTime 00 99 2 Bytes 1 Byte ReleaseTimerTime 00 99 2 Bytes 1 Byte MaxTempLimit 000 999 3 Bytes 1 Byte Backlight Operation 0 AUTO 1 ON 1 Byte 1 By...

Page 161: ...from the start of firing to the end of reflow for the current actual temperature graph It returns a 4 digit count of points with a maximum of 4 096 datapoints followed by each 4 digit data point The count and each data point are followed by a carriage return line feed NOTE If the Controlreceives a Fire Command when the Controlis transmitting the GRAPH data the transmission of the GRAPH data will b...

Page 162: ... final check sum is 2500 256 9 196 decimal A better way is to take the final check sum and AND it with 255 0x0FF In hex taking the final check sum 0x9C4 and ANDing it with 0xFF 0xC4 or in decimal 2500 AND 255 196 2 Now we wish to change the profile we are on to number 5 The command would be soh 01LS00205F7 eot 01 is the unit address LS is the command 002 is the count 05 is the new profile to go to...

Page 163: ... into intimate contact At a precise pressure the head signals the control to begin the heating cycle of the thermode The thermode conducts heat to the parts and the subsequent thermal transfer of heat melts the solder between the parts The molten areas begin to flow resulting in coalescence between the two solder masses When the reflow cycle is terminated by the Control the parts continue to be he...

Page 164: ...eat is conducted from the thermode through the solid polyimide surface to the exposed traces underneath The polyimide conducts heat through the insulation to the exposed traces and pads on the PCB The polyimide thickness in the joint area is limited to 0 002 enabling conduction If the polyimide has to be heated much past 260 C burning of the surface and thermode contamination can result This desig...

Page 165: ... the risk of short circuits due to misalignment Printed Circuit Boards Pcb And Other Substrates General Part Design Guidelines Most PCB materials such as FR2 and FR4 are very resilient to the local application of heat during the process Materials such as ceramic substrates have to be heated in a more controlled fashion to minimize the chance of cracking Excessive differences in the heat sinking ca...

Page 166: ... to the smallest width signal traces and spread equally under the pads on the PCB Any shielding on the PCB should have an equal effect along the joint area Amount Of Solder Required On Printed Circuit Board Pad The repeatability of solder deposit is critical in order to achieve good process control In many cases a certain amount of experimentation is required to achieve the ideal solder volume A g...

Page 167: ...004 0 36 x 1 2 0 014 x 0 047 0 36 x 1 6 0 014 x 0 063 150 micron 0 006 0 30 x 1 0 012 x 0 039 0 30 x 1 2 0 012 x 0 047 175 micron 0 007 0 26 x 1 0 010 x 0 039 0 26 x 1 2 0 010 x 0 047 Pad size 0 8 x 5 5 mm 0 031 x 0 216 Pitch 1 5 0 059 0 07 0 10 mm 0 0028 0 0039 100 micron 0 004 0 74 x 1 9 0 029 x 0 075 0 74 x 2 7 0 029 x 0 106 150 micron 0 006 0 6 x 1 5 0 024 x 0 059 0 6 x 2 2 0 024 x 0 086 175 m...

Page 168: ...x 2 3 0 043 x 0 091 175 micron 0 007 1 0 x 1 5 0 039 x 0 059 1 0 x 2 1 0 039 x 0 083 200 micron 0 008 0 9 x 1 4 0 035 x 0 055 0 9 x 2 0 0 035 x 0 055 Thermode Sizing And Positioning To Parts Thermodes should be sized according to the pad and flex sizes as shown in the figure below The thermode length must completely cover the traces and overlap by a minimum of one pad pitch on each side The thermo...

Page 169: ... 079 1 5 0 059 2 5 0 098 1 6 0 063 2 5 0 098 1 8 0 071 2 5 0 098 2 0 0 079 3 0 0 118 3 0 0 119 3 0 0 118 The dimensions above are guidelines only Some experimentation may be required due to different solder volumes Thermode Positioning When positioning a thermode on an exposed or windowed flex it is important that the thermode is not positioned too close to the edge of the main body of the flex So...

Page 170: ...g holes in the flex to be reinforced with copper trace for strength and accuracy If no tooling holes are possible the parts can be positioned and tooled from a square edge As the flex is not rigid vacuum holes in the part nest may be required to hold it flat For fine pitch flex an alignment x y stage and camera system may be useful It is important to take into account any tolerances or batch to ba...

Page 171: ...there are much less fumes generated Operators should still be prevented from touching the thermode during the cycle and should also be protected from entrapment hazards Soldering Method Process Steps 1 The base substrate is located in a fixture and flux applied to the pads 2 The flex is positioned in the parts fixture ensuring alignment of both sets of pads 3 A process start signal is given to the...

Page 172: ...t is preferred to use the minimum time and temperature to achieve the desired joint so as to minimize the parts exposure to heat and chance of damage Cool1 Cool1 in a process without a Postheat process cycle is a programmable temperature at which the control unit will actuate the head to the up position This temperature is set to just below the solder solidification temperature Therefore as soon a...

Page 173: ...led apart the resulting joint will have a granular appearance over the soldered area There should be no evidence of burning or delamination of the pads to board or flex Where a single sided flex is used there maybe marking or discoloration on the top of the polyimide but no burning or separation should be seen Any flux residues can be cleaned after the reflow process No clean low residue fluxes do...

Page 174: ...gn that promotes easy and equal heat generation Even more by a design that accommodates the flow of solder and can compensate for variations in the prior processing steps Good joint design and repeatable fine control over solder quantities are the keys to production success The growing need for product miniaturization and reduced weight are major drivers increasing the use of flexible circuit tech...

Page 175: ...chheim Germany TEL 49 89 839403 0 FAX 49 89 839403 10 AMADA MIYACHI TAIWAN CO LTD Rm 5 2F No 9 Dehui St Zhongshan Dist Taipei 10461 Taiwan R O C TEL 886 2 2585 0161 FAX 886 2 2585 0162 AMADA MIYACHI VIETNAM CO LTD M floor 400 Nguyen Thi Thap Street Tan Quy Ward District 7 Ho Chi Minh City Vietnam TEL 84 8 3771 7972 FAX 84 8 3771 7974 AMADA MIYACHI THAILAND CO LTD 40 14 Bangna Tower C 17th Floor Un...

Page 176: ...AMADA MIYACHI AMERICA INC 1820 South Myrtle Ave Monrovia CA 91016 U S A TEL 1 626 303 5676 FAX 1 626 358 8048 ...

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