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Bravo 8105®

CONVECTION REFLOW SYSTEM

PROGRAMMING AND OPERATIONS GUIDE

Bravo™ 8105 Technical Manual P/N 110–00–0

Bravo™ 8105 Programming and Operations Guide P/N 3–9317–372–00–0

Summary of Contents for Bravo 8105

Page 1: ...Bravo 8105 CONVECTION REFLOW SYSTEM PROGRAMMING AND OPERATIONS GUIDE Bravo 8105 Technical Manual P N 110 00 0 Bravo 8105 Programming and Operations Guide P N 3 9317 372 00 0 ...

Page 2: ...Bravo 8105 Programming and Operations Guide ...

Page 3: ...0 Bravo 8105 Programming and Operations Guide iii Preface Overview In this section This preface covers the following information Topic See Page To Our Customers iv Customer Support Structure iii Before You Call viii ...

Page 4: ...ations overview program development instructions standard operating instructions advanced operating instructions process troubleshooting scheduled maintenance overview and a list of error messages and audible alarms with solutions Other Guides in the Set The following guides comprise the set of user manuals Not yet released Guide Name Part Number Bravo 8105 Installation Guide 3 9317 370 00 0 Bravo...

Page 5: ...ine Technologies Inc Electrovert Main Sales and Service Office Technical Service Support Group P O Box 709 Hwy 5 South Camdenton MO 65020 0709 Fax 573 346 6878 Tel 573 346 3341 or call Toll Free Tel 1 800 737 8110 e mail electrovert_tsc speedline cookson com Speedline Distribution Center Parts Sales 1605 Dundee Elgin IL 60120 Fax 847 468 1029 Local Tel 847 695 5750 Toll Free 1 800 737 8110 Cookson...

Page 6: ...8757 Phone 603 883 2488 South East Regional Service Center 1055 Windward Ridge Pkwy Suite 140 Alpharetta GA 30005 Fax 770 442 1987 Phone 770 619 5250 ext 16 North Central Regional Service Center 580 A Tolllgate Road Elgin IL 60123 Fax 847 289 3797 Phone 847 695 5750 North West Regional Service Center 2968 Scott Blvd Santa Clara CA 95054 Fax 408 727 0672 Phone 408 727 4650 South West Regional Servi...

Page 7: ...erstrasse 1E 63303 Dreieich Germany Fax 49 6103 832 299 Phone 49 6103 832 0 Speedline Technologies Italy Via Liguria 2 28 I 20068 Peschiera Borromeo MI Italy Fax 39 2 5530 8468 Phone 39 2 5530 8339 Speedline Technologies Singapore 150 Kampong Ampat KA Centre 05 08 Singapore 368324 Fax 65 289 9411 Phone 65 286 6635 Speedline Technologies Taiwan 1F No 11 Ching Kuo Road Taoyuan Taiwan ROC Fax 886 335...

Page 8: ...overt support your machine in a timely fashion have the following specific information available when calling in System Software Version Serial Tag Information Machine Serial Tag The machine serial tag is located on side of the rear electrical panel It provides important information that will be helpful in servicing your machine ...

Page 9: ...her Hazards 9 Heavy Objects 9 Skin Irritation 9 Recommended Precautions 10 Safety Lock Out Tag Out Procedures 10 No Smoking 10 Fire Extinguisher 10 Flammables 10 Electrical Precautions 10 Sound Level 11 Safety Perimeter 11 Chemical Precautions 12 Protective Gear 12 Exhaust Ventilation 12 Document Reference 12 Good Housekeeping 12 Attach Facility Lock Out Tag Out Device 14 Attach Machine Lock Out T...

Page 10: ...Control 33 Process Graphic Screen 35 Nitrogen Controls 35 Software Screen 35 Turning Nitrogen On and Off 35 Process Tabular Screen 36 Machine Options Configuration for a Nitrogen Machine 37 Inert vs Air Calibrations 37 Coolant Solenoid Control 37 Alarms Configuration for the Nitrogen Machine Option 39 Alarm Event Description 39 Disable Deviation Alarms During Startup 40 Recipe Parameters Unique to...

Page 11: ... 63 Width Adjust in Process Graphic Screen 63 Width Adjust in Process Tabular 64 Width Adjust in the Setup Screen 64 Chapter 6 Recipes Creating Editing and Changing Recipes 67 Accessing the Recipe Screen 67 Editing a Recipe 68 Loading a Different Recipe 68 Loading a Different Recipe Continued 68 Creating a New Recipe 68 Naming a Recipe 69 Importing the Current Machine States to a Recipe 69 Making ...

Page 12: ...th Setup Software Screen 88 Chapter 9 Configuration Screens PC Settings Configuration 90 Comm Port 90 Comm Time Out 90 Comm Update Timer 90 Graphic Update Timer 90 Log Alarms 90 Log Actions 91 Log Data Every __ Seconds 91 Pop Alarm Window on Unacked Alarm 91 Options Configuration 92 Software Screen 92 Conveyor 92 Machine 92 Rail 92 Miscellaneous 93 Programmable Output Relay Configuration 94 Softwa...

Page 13: ...esired Function 109 Alarm Levels 109 Buzzer Lamp Test 110 Clear All PCBs 110 PLC Status 111 Chapter 11 Accomplishing the Reflow Process Understanding Process 113 Understanding Process 113 Board Design Stencils and Solder Paste 114 Solder Paste Considerations 115 Factors to Consider 115 Before Using Solder Paste 115 Inspection before Reflow 116 After Printing 116 Throughput 117 Determining Throughp...

Page 14: ...T A B L E O F C O NT E N T S xiv Bravo Programming and Operations Guide Rev 2 ...

Page 15: ...onal safety and avoid equipment damage observe the following ATTENTION The information provided in the safety section of this document is not intended to supersede rules and regulations governing health and safety in the local area or at the installation site Whenever there is a conflict between the information in this section and local information the local rules and practices govern In this chap...

Page 16: ...rator may encounter while operating an Bravo System This section also describes warning tags installed on the system and ways to avoid the hazards encountered In this section Refer to the following hazard descriptions Topic See Page Hot Surface Hazards 1 3 Flammable Hazards 1 4 Electrical Hazards 1 5 Mechanical Hazards 1 6 Breathing Hazards 1 7 Inerting Hazards 1 8 Other Hazards 1 9 ...

Page 17: ... hazards and can cause severe skin burns The heat exposed surfaces of the system rails conveyor surfaces etc can become very hot Hot Surface Use extreme caution when working around or with hot components Allow hot components to cool before handling whenever possible Always wear heat resistant gloves and protective clothing on or around the active system Do not touch the cover of the system or hand...

Page 18: ... fires Keep flammable materials and solvents clear of the Bravo System Never stop the system with boards in the machine Flammable Motors Fire and Smoke Hazard Under normal circumstances motors tend to create sparks during operation Should a serious problem ever develop in a motor sparking may ignite flammable materials Flammable Heaters Fire and Smoke Hazard If boards are stationary inside the sys...

Page 19: ...s are present on various parts of the system Safety To ensure personal safety and avoid equipment damage observe the following Electrical Hazard Installation of this equipment involves exposure to High Voltage High Voltage can shock burn or cause death Use extreme caution when performing voltage and amperage tests on live voltage These procedures must be performed only by an authorized electrician...

Page 20: ...working on or near moving parts and wear safety gear Safety To ensure personal safety and avoid equipment damage observe the following Entanglement Hazard All moving parts of the Bravo System represent potential hazards Use caution and avoid having hands or fingers caught in any moving mechanism Long hair jewelry and other parts of loose attire could be caught in moving mechanisms and cause injury...

Page 21: ...ecifications Safety To ensure personal safety and avoid equipment damage observe the following Respirator All operators should be provided with an NIOSH or MSHA approved Respirator to provide effective protection from airborne residue resulting from certain saponifiers defoamers descalers cleaning solvents or other chemicals used during operation CAUTION Noxious fumes are created during the normal...

Page 22: ... any of these symptoms move to an area that is ventilated with fresh air immediately Compressed Gas Hazard Compressed Nitrogen Excessive pressure could cause explosion of Nitrogen Flow Meters Do not connect the Nitrogen Flow Control unit to a nitrogen source that exceeds 690 kPa 100 psi Exploding flow meters are a potential hazard to workers stationed in front of the control panel Compressed gas c...

Page 23: ...hen attempting to move heavy equipment or components it is imperative to use the proper rigging equipment Do not attempt to move skids or large assemblies without the use of a fork lift or other rigging equipment Hand lifting will cause serious personal injury Skin Irritation When using certain chemicals such as lubricants or solvents it is important to follow the MSDS Material Safety Data Sheet g...

Page 24: ... work area and provide measures for enforcement Fire Extinguisher Keep an approved fire extinguisher near the machine at all times Familiarized all personnel with the operation and use of the fire extinguisher Flammables Never store flammable material on or around the Bravo machine Exposing flammables to heating elements or hot surfaces presents a fire hazard due to the operating temperature of th...

Page 25: ...levels are measured at 914 4 mm 36 in height and distance from the front rear load and unload sides of the machine All noise levels consistently remain 70 dBa Safety Perimeter The machine is designed with a maximum length width and height An access clearance of 914 4 mm 36 in around the machine is required to maintain and operate efficiently ...

Page 26: ...an National Standard Institute approved Safety Goggles NIOSH National Institute for Occupational Safety and Health OR MSHA Mine Safety and Health Administration approved Respirator Steel Toe Safety Shoes High Temperature Acid and Water Resistant Gloves Apron Long Sleeved garment Exhaust Ventilation Ensure an adequate exhaust system is installed that filters and monitors the system Clean and monito...

Page 27: ...must establish their own specific policies and procedures Safety To minimize system down time and ensure staff safety observe the following ATTENTION If procedures must continue past the shift of the person who applied the lockout device ensure that an employee who is working the next shift applies their lockout device and the previous person removes the initial lockout device In this Section Refe...

Page 28: ...authorized electrician electrical engineer or service technician familiar with testing live voltage ATTENTION If procedures must continue past the shift of the person who applied the lockout device ensure that an employee who is working the next shift applies their lockout device and the previous person removes the initial lockout device Procedure Refer to the following steps to lock out and tag o...

Page 29: ...ent damage observe the following Electrical Hazard Electrical current used can kill DO NOT TOUCH live electrical components inside the electrical enclosure These procedures must be performed only by an authorized electrician electrical engineer or service technician familiar with testing live voltage ATTENTION If procedures must continue past the shift of the person who applied the lockout device ...

Page 30: ...se procedures must be performed only by an authorized electrician electrical engineer or service technician familiar with testing live voltage Hot Surface Components in the system become hot during normal system operation Heated sections of the machine produce steam To prevent burns allow heated sections or hot components to cool or wear required safety clothing when accessing heated areas of the ...

Page 31: ...llation upgrade or repair operations Safety To ensure personal safety and avoid equipment damage observe the following CAUTION If items removed during maintenance installation upgrade or repair procedures are not properly replaced damage to the equipment can occur ATTENTION The person who attaches a lock out device is responsible to remove the device Procedure Use the following steps to remove fac...

Page 32: ...S A F E TY IN F O R M A T IO N Remove Lock Out Tag Out Devices 1 18 Bravo 8105 Programming and Operations Guide Rev 2 1 ...

Page 33: ...ion This chapter provides the information the customer needs to prepare their facility for Bravo installation as well as operate the machine In this chapter This chapter consists of the following Topic Section Facility Requirements and Specifications 2 20 Machine Components 2 23 System Dimensions 2 27 ...

Page 34: ... Proper exhaust ensures correct machine operation and safety Contact your local HVAC specialist for blower requirements and ventilation hook up Tables The following table identifies the facility requirements for Bravo 8105 operation Exhaust Requirements Recommended venting material 152 4 mm 6 0 in diameter Standard HVAC exhaust flex hose Standard Air Machine Requirements Load End Unload End Middle...

Page 35: ... VAC 3 phase 50 Hz 4 wires 3 phase 1 neutral plus 1 ground 440 480 VAC 3 phase 60 Hz 3 wires 3 phase plus 1 ground Start Up Power Requirements Table Refer to the following table for system start up power requirements Process Ready Power Requirements Table Refer to the following table for system process ready power requirements kV A 220 VAC 240 VAC 380 VAC 415 VAC 440 VAC 480 VAC 73 164 Amp 177 Amp...

Page 36: ...tional Electrical Code NEC ANSI NFPA 70 93 Electrical Standard for Industrial Machinery CE Compliance Delcaration of Conformance is based on compliance to European Directives 89 392 EEC 91 368 EEC 93 44 EEC 93 68 EEC 89 336 EEC based on the following European Harmonized Standards EN 292 1 Basic concepts general principles for design basic terminology methodology EN 292 2 Basic concepts general pri...

Page 37: ...rs on typical assemblies Heating Chamber Length 2667 mm 105 in Air Diffuser Panel Dimensions Length 254 mm 10 in Width 508 mm 20 in Heater Power Rating 4000 W per panel in zones 2 through 6 5000 W per panel in zones 1 7 and 8 1000 W per Rail Heater Maximum Heating Capacity 245 893 BTU hr 72kW Heater Temperature Range Ambient to 300 C 572 F Typical Time to Ready State 15 minutes Blower Rating at 0 ...

Page 38: ...A T A Electrical Information 2 24 Bravo 8105 Programming and Operations Guide Rev 2 2 Forced Convection Air Cooling Module Table Cooling Chamber Length 762 mm 30 in Cooling Temperature Alarm Range 50 to 115 C 122 to 239 F ...

Page 39: ... to Right Conveyor Travel Conveyor Module Options Specifications Optional Features Alternate Right to Left Conveyor Travel Pin Chain Conveyor with Manual Width Adjust Pin Chain Conveyor with Computerized Motorized Width Adjust Combination Conveyor Mesh Belt and Pin Chain Blower Rating at 0 Static Pressure 595 m3 hr 350 cfm TOTAL FORCED CONVECTION 60 Hz 50 Hz Cooling Zone 1 1 Blower 595 m3 Hr 350 c...

Page 40: ... 1 in min Rail Parallelism 0 5 mm 0 020 in Process Width Mesh Belt 457 mm 18 in Pin Chain 50 mm to 432 mm 2 in to 17 in Process Height Mesh Belt 64 mm 2 5 in Pin Chain 32 mm 1 25 in Above 25 mm 1 0 in Below Conveyor Height from Floor Adjustable Mesh Belt 813 mm 32 in to 965 m 38 in Pin Chain 838 mm 33 in to 991 mm 39 in Torque Limit on Motor Mesh Belt 11 3 Newton m 100 in lb Pin Chain 11 3 Newton ...

Page 41: ...4 cm 194 5 in System Width 116 cm 46 0 in Height 145 cm 57 0 in Mesh Belt Conveyor Height 81 3 cm to 96 5 cm 32 0 in to 38 0 in Pin Chain Conveyor Height 83 8 cm to 99 1 cm 33 0 in to 39 0 in Access Clearance Front 67 3 cm 26 5 in Access Clearance Rear 25 4 cm 10 0 in Machine Weight Per Leg 395 kg 870 lbs Machine Weight Total 2359 kg 5200 lbs Noise Levels All positions at or below 70 dbA ...

Page 42: ...T E C H N IC A L D A T A Electrical Information 2 28 Bravo 8105 Programming and Operations Guide Rev 2 2 ...

Page 43: ...Software Navigation Overview The following chapter contains information pertaining to the operating software on the Bravo 8105 Refer to this table for section contents Section Page Section A Standard Machine Software 3 30 Section B Nitrogen Inert Machine Software 3 34 ...

Page 44: ...he Cooling Zone On Off Turn the Bravo On by pressing Function Key F2 when in Auto Start Mode In Manual Mode each component is started individually Turn the Bravo Off by pressing Function Key F3 when in Auto Start Mode In Manual Mode each component is stopped individually Note that the blowers in the Heating Chamber remain On until the temperature falls below 95 C 203 F Software Representation Figu...

Page 45: ...key The bar above each Heater Display indicates the actual temperature of the heater The bar and the Actual Temperature Display above the bar appears Gray when the Heater is Off When the Heater is not yet to Ready temperature the bar and display appears Blue When the Heater is at Ready state temperature they appear Green If an over temperature condition exists they appear Red Software Representati...

Page 46: ... Conveyor is at Ready State speed the display is Green and if there is a setpoint deviation the display is Red If the Bravo is started in Auto Mode the Conveyor turns On according to the specified recipe The Conveyor Setpoint Speed displays above the On Off button If it is desired to change the speed highlight the speed and press enter The bar graph above the setpoint speed displays actual conveyo...

Page 47: ...he Blowers are turned On and Off by clicking the toggle button located between the Blower Speed Setting drop down menus The Blowers have four 4 speed settings Low Medium Low Medium High and High Zones 1 4 and Zones 5 8 are controlled separately for speed but toggling the On Off button controls all blowers Software Representation Figure 3 4 ...

Page 48: ... and Operations Guide Rev 2 3 Section B Nitrogen Inert Machine Software Operation Overview Introduction The nitrogen inert option software is a slightly modified version of the standard machine control software The following section details any differences that are present ...

Page 49: ...ure measured by the thermocouple in the Cooling Zone displays on the Process Graphic Screen It appears toward the center of the screen to the right of the heater display Refer to Figure 3 5 for a screen capture of the Process Graphic Screen showing the inert option Software Screen Figure 3 5 Turning Nitrogen On and Off The Nitrogen On Off control is saved specific to a recipe If Nitrogen is select...

Page 50: ...n The Process Tabular Screen shows much the same information as the Process Graphic Screen but in a format of rows and columns Nitrogen On Off control may be performed through the tabular screen IFM On Off control may also be performed The cooling zone temperature does not display on the tabular screen Refer to Figure 3 6 Software Screen Figure 3 6 ...

Page 51: ...ory and are depicted in Figure 3 8 Note that the blower in Zone 1 operates at a different speed than the other blowers This is to promote low ppm levels of oxygen and enhance the inerting effect When the machine operates in a nitrogen environment optimal performance is achieved if the blower in Zone 1 is calibrated separately If nitrogen is not going to be used selecting the box next to Operate as...

Page 52: ...s Guide Rev 2 3 CAUTION Increasing the temperature parameters in the Coolant Solenoid Control fields may cause the heat exchangers to overheat Pressure build up will make the quick disconnects very difficult to release Additionally a burn hazard exists if the overheated water sprays from the disconnects Software Screen Figure 3 8 ...

Page 53: ...o pass the board downstream Output Photocell PCB Dropped An alarm indicates if the PCB does not reach the output photocell when expected Output Photocell PCB Jammed An alarm indicates that the PCB remains beneath the output photocell longer than expected UPS Power Fail The UPS is supplying power to the machine due to a power failure IFM Low Coolant Flow If the cooling fluid in the IFM operates bel...

Page 54: ...tion Alarms During Startup If Disable Deviation Alarms During Startup is selected the deviation alarms for the heaters and the blowers do not activate while the machine is progressing to Ready state Enter a value bewteen zero 0 and sixty 60 into Startup Time in Minutes The Disable has no effect on alarms related to the inert option Software Screen Figure 3 9 ...

Page 55: ...onfiguration Introduction The nitrogen parameters are saved specific to a recipe When a recipe is Auto Started the nitrogen starts accordingly If the box next to the Nitrogen and IFM options are checked they automatically run with the recipe Access the Recipe Edit Screen by selecting Recipe Recipe from the menu bar at the top of the screen or by pressing Function Key F7 Software Screen Figure 3 10...

Page 56: ...S O F T W A R E N A V I G A T IO N Recipe Parameters Unique to Inert Option Configuration 3 42 Bravo 8105 Programming and Operations Guide Rev 2 3 ...

Page 57: ...eration First Time Power Up Do not attempt to power up the Bravo until all of the installation requirements are met Refer to the Bravo Installation Manual Failure to properly install the machine may result in malfunction Photograph Figure 4 1 depicts the Bravo 8105 System Figure 4 1 ...

Page 58: ...e Main Power Disconnect Switch is located on the lower Unload End of the Bravo The machine starts The computer turns On Photograph Figure 4 2 depicts the Main Disconnect Switch in the Off 0 position Figure 4 2 After Power is Applied The Bravo System Software opens Selecting either the Graphic button also Function Key F9 or the Tabular button also Function Key F8 at the top of the screen opens a Pr...

Page 59: ... S Y S T E M O P E R A T I O N Powering Up the Bravo 2 9317 372 00 0 Bravo 8105 Programming and Operations Guide 4 45 Software Representation Figure 4 3 depicts the opening screen of the Bravo software Figure 4 3 ...

Page 60: ...Operation Functions it is necessary to have the appropriate security level active Security levels can only be set when the Administrator level is active Logging Onto Bravo Software Set the level to Administrator by entering the Administrator password when prompted or by pressing F11 and selecting Administrator Level To view the parameters for the current level when operating the Bravo select the S...

Page 61: ...ds Introduction The five 5 Security levels must be configured before the Bravo System is used Refer to the following section to configure or change the access parameters and the passwords ATTENTION Speedline Electrovert recommends changing the Administrator password after the five 5 user levels are configured By default Administrator level Security access allows access to all functions ...

Page 62: ...mming and Operations Guide Rev 2 4 Software Representation The following screens are accessed to configure Security parameters Figure 4 4 illustrates the selection of Administrator Security Level Figure 4 5 illustrates the Security Access parameters that are set by the Administrator Figure 4 4 Figure 4 5 ...

Page 63: ...e Functions Allows user to access the Configure Menu Note that unless Computer Func tions is also selected the first option on the Configure Menu PC Settings is not accessible SetUp Functions Allows user to access the SetUp Menu Calibration Functions Allows user to access the Calibration Menu The Width Sensors and the Blowers are calibrated through the Calibration Menu Motorized Width Allows chang...

Page 64: ...llows a password to remain open indefinitely If a time limit is desired in the Security Access window the number in minutes of that limit displays next to the Time Out in Minutes field and the time remaining until the password deactivates displays next to the Time Remaining field When a Password deactivates the default level of security becomes the active access level Software Representation Figur...

Page 65: ...TTENTION Ensure that Password Required is selected on the Security Administration Screen or a password error message appears even if the correct password is entered Default Names and Passwords Table The following table lists the default User names and passwords ATTENTION Passwords are case sensitive User1 must be typed exactly as it appears i e user1 is NOT recognized by the program User Name Pass...

Page 66: ... and User_5 were changed from their default names Figure 4 7 Step Action 1 Select Security Administration from the dropdown menu at the top of the screen 2 Enter the Administrator password 3 Select the desired user by clicking on the triangle to the right of the Select User field A drop down menu appears to allow selection 4 Highlight the current password under User Data next to User Password NOTE...

Page 67: ...nded as a starting point for user profiles Modify it according to need and use User Profile Operator Access An Operator needs access to Start and Stop functions but not maintenance or configuration functions A suggested Operator configuration would include Load Recipe Relative Board Change Machine Start and Stop and Motorized Width Control Refer to Figure 4 8 Software Representation Figure 4 8 dep...

Page 68: ...ce Personnel need to access the functions required for scheduled downtime A typical Maintenance configuration includes Recipe Load Machine Start and Stop Maintenance Functions SetUp Functions Calibrate Functions and Motorized Width Refer to Figure 4 9 Software Representation Figure 4 9 depicts a typical Maintenance configuration for Security Access Figure 4 9 ...

Page 69: ... Representation A depicts a typical Process Engineer s configuration Figure 4 10 ATTENTION Although it may appear that the above Process Engineer configuration is the same as the Administrator configuration the Process Engineer configuration does not allow access to the Security Administration Window The Security Administration Window is accessible only in Administrator Security Level Summary Chan...

Page 70: ...rt button associated with Machine Mode or press Function Key F2 To AUTO Stop the Bravo System click on the Stop button or press Function Key F3 Note that the Machine Mode parameter is saved to each recipe If a new recipe is loaded that does not have AUTO Mode configured the machine converts to Manual Mode until it is changed in one of the Process Screens or until the Recipe is changed and re loade...

Page 71: ...n Off the nitrogen unless Lock Out Tag Out is performed Procedure for Turning Nitrogen On Manually open the On Off inlet fully counterclockwise Ensure that the Nitrogen is turned On in the software Turn the pressure gauge clockwise until the pressure increases to 44 psi 3 bar At this pressure the nitrogen flow rates can be read directly from the flow meters Adjust the controls above the flow meter...

Page 72: ...B R A V O S Y S T E M O P E R A T IO N Nitrogen Option On Off Control 4 58 Bravo 8105 Programming and Operations Guide Rev 2 4 ...

Page 73: ...e row containing the PCB Length label In the Recipe Screen it is entered into the PCB Length field Note that the Rec ipe must be loaded by pressing the Load button at the bottom of the screen before a change takes effect In the Setup PCBs Window it is entered into the Length parameter by highlighting the current value and entering a new value PCB Width It is apparent that with a standard Mesh Belt...

Page 74: ...the machine is turned Off It is recipe dependent changing recipes will change the Relative Board count IF the count is different in the new recipe PCBs in Machine PCBs in the machine are the number of machines inside the machine chamber at any given time If the Photocell is inadvertently triggered it is possible to reset the PCB count to zero 0 by selecting Maint Diags Clear all PCBs from the menu...

Page 75: ...of a crank An optional software controlled Motorized Width Adjust is available with the optional Pin Chain Conveyor It moves the rear rail through the use of a motor Photograph Figure 5 1 depicts the optional Combination Conveyor consisting of the standard Mesh Belt Conveyor and the Pin Chain Conveyor Figure 5 1 Manually Adjusting the Pin Chain Conveyor Introduction The manual adjustment is perfor...

Page 76: ...stored in the recess of the swing out panel 2 Insert the crank into the hex nut and rotate it as necessary A clockwise direction decreases the width A counterclockwise direction increases the width Refer to Figure 5 2 3 A small hole is also drilled into the swing out panel so that the hex nut is accessible without opening the panel Insert the crank through the hole and turn the hex nut as in Step ...

Page 77: ...Refer to the following section to perform width adjust using the software option Width Adjust in Process Graphic Screen The Setpoint displays in the bottom parameter of the Width Adjust display on the Process Graphic Screen Refer to Figure 5 4 The Actual Width displays above the Setpoint display To change the width setting highlight the width parameter in the Setpoint field and enter a new number ...

Page 78: ...to Figure 5 5 To change the Setpoint highlight it and enter a new value Click on the Set button To stop the Rail Width Adjust while it is in progress click on the Stop button Software Representation Figure 5 5 Width Adjust in the Setup Screen Access the Setup Screen by selecting Setup Motorized Width from the Menu Bar at the top of the screen The Setup Window displays The Setpoint appears next to ...

Page 79: ... IR C U IT B O A R D S P E C IF I CA T I O N Adjusting the Pin Chain Conveyor using the Motorized Width Adjust Option 2 9317 372 00 0 Bravo 8105 Programming and Operations Guide 5 65 Software Representation Figure 5 6 ...

Page 80: ...P R IN T E D C IR C U IT B O A R D S P E C IF IC A T IO N Adjusting the Pin Chain Conveyor using the Motorized Width Adjust Option 5 66 Bravo 8105 Programming and Operations Guide Rev 2 5 ...

Page 81: ... A The Recipe Screen Creating Editing and Changing Recipes Accessing the Recipe Screen Access the Recipe Screen by pressing function key F7 or by selecting Recipe from the Menu Bar at the top of the screen The Recipe Screen is depicted in Figure 6 1 Software Representation Figure 6 1 ...

Page 82: ...down menu under Recipe Select Select the desired recipe and click on it to load it into the Recipe Editor Refer to Figure 6 2 Software Representation Figure 6 2 Loading a Different Recipe Continued The Recipe is not active until the Load Recipe button is selected at the bottom of the screen If it is desired to edit the recipe but not make it the active recipe select and edit the recipe then click ...

Page 83: ...p of the screen or press Function Key F7 In the Recipe Editor Screen select the Add Machine button from the bottom of the screen Refer to Figure 6 5 The current machine parameters are loaded into the Recipe Editor To save the recipe ensure the desired name is in the Recipe Name field and press the Save button located at the bottom of the screen Software Representation The arrow points to the Add M...

Page 84: ... P E S Creating Editing and Changing Recipes 6 70 Bravo 8105 Programming and Operations Guide Rev 2 6 Software Representation The arrow points to the Load Recipe button at the bottom of the screen Figure 6 6 ...

Page 85: ...The Current Alarms screen depicted in Figure 7 1 displays any active alarm condition If an alarm is acknowledged and no longer active it is removed from the Current Alarms screen However if an alarm is acknowledged but the alarm condition remains active the alarm is not removed from the Current Alarms screen Software Representation Figure 7 1 ...

Page 86: ...ither by pressing the space bar on the keyboard or by clicking on the ACK button by placing the mouse cursor over it and clicking on it The Current Alarms Window displays the date and time the alarm occurred and a description of the alarm The Acknowledge ACK column indicates if an alarm is acknowledged but still active If an alarm is acknowledged but no longer active it is removed from the window ...

Page 87: ... Alarm History Window Figure 7 2 Navigating the Alarm History Window Open Todays Alarms Displays the Alarms that occurred since the midnight 00 00 of the previous night in the window to the left of the History File Selection box Open Selected File To display a file from a date other than the current file highlight a file in the History File Selection box and click on Open Selected File The content...

Page 88: ... window select Configure PC Settings from the Menu Bar at the top of the screen The PC Settings window appears Refer to Figure 7 3 The choices that affect the Log files are Log Alarms If Log Alarms is selected any alarm generated by the machine is recorded in the Log File including the time it was generated Log Actions If Log Actions is selected any action that changes the machine parameters is re...

Page 89: ... A L A R M S Alarm History 2 9317 372 00 0 Bravo 8105 Programming and Operations Guide 7 75 ATTENTION Refer to Chapter 7 Setup for information on configuring the Alarms setup ...

Page 90: ...A LA R M S Alarm History 7 76 Bravo 8105 Programming and Operations Guide Rev 2 7 ...

Page 91: ...s Alarms refer to the bandwidth allowed on either side of the Setpoint value before a deviation alarm activates The value is a plus or minus value For example consider a deviation value of 10 C and a setpoint value of 220 C If the temperature falls below 210 C or rises above 230 C an alarm activates The Conveyor Setpoint deviation is set in inches per minute If the conveyor speed exceeds either th...

Page 92: ...0 select Maint Diag Clear All PCBs from the Menu Bar at the top of the screen Fans Not OK Loss of Heat This indicates that the blowers are working but there is a problem with the heaters There are three 3 possible defaults if this alarm activates Analog Output Module Failure Thermocouple Input Module Failure High Temperature Safety Circuit Tripped Maintenance Timers 1 and 2 The time programmed to ...

Page 93: ... S E T U P S C R E E N S Alarms Setup 2 9317 372 00 0 Bravo 8105 Programming and Operations Guide 8 79 Standard Alarms Setup Software Screen Figure 8 2 ...

Page 94: ...ab Each Heating Zone Cooling Zone and Rail Heater has an independent thermocouple to monitor operating temperature If the thermocouple measures an over temperature condition the alarm response depends upon the configuration in this screen Refer to Figure 8 3 Thermocouple Alarm Setup Software Screen Figure 8 3 ...

Page 95: ...s supplying power to the machine due to a power failure IFM Low Coolant Flow If the cooling fluid in the IFM operates below the pressure required a warning alarm generates Low Nitrogen Pressure Nitrogen pressure is not adequate to maintain 44 psi 3 Bar at the flow meters Low Exhaust Pressure Exhaust pressure is not adequate to maintain 600 cfm 1019 m3 hr at the main stack Low Coolant Flow Coolant ...

Page 96: ...S E TU P S C R E E N S Alarms Setup 8 82 Bravo 8105 Programming and Operations Guide Rev 2 8 Options Alarms Setup Software Screen Figure 8 4 ...

Page 97: ...ical Support Communication Error The PLC to PC interface is not functioning properly Operational Error The PLC is not functioning due to a software problem If re starting the machine does not correct the problem contact Speedline Technical Support Low Battery The battery in the PLC is below an acceptable voltage level That low voltage level is entered by the user in the Maint Diag PLC screen Repla...

Page 98: ...ing inches for length and Fahrenheit for temperature Note that the units setup is not saved to a recipe Functions Affected by Units Setup Temperature Temperature selection is in Centigrade metric or Fahrenheit imperial Conveyor Conveyor affects the way that the speed displays Metric displays the speed in centimeters per minute Fahrenheit displays the speed in inches per minute PCB PCB affects the ...

Page 99: ...ne operation must be set higher than the duty cycle of the heaters or a Temperature Deviation Alarm occurs Power Limiting Options During Start Up Only Limits power consumption until machine reaches Ready state but not during run time During Run Only Limits power consumption after machine reaches Ready state but not during start up Always Limits power consumption anytime the machine is in operation...

Page 100: ...onds between when the Board Available signal is received and when the board is detected by the photocell If the board is not detected within this about of time an alarm activates The value entered must be less than 1000 Board Available Time in Seconds The Bravo sends a Board Available signal to the downstream machine It is sometimes desirable to send the Board available signal before the board exi...

Page 101: ...ps the machine at predetermined times The time is set in the Start Time and Stop Time columns Time is entered in 24 hour format 0000 to 2359 The Enable column must be selected to activate the automatic timer for each day Each day is configured individually If Load is selected the recipe appearing in that row loads when the machine starts If Load is not selected the recipe that was active when the ...

Page 102: ...o set the width of the Pin Chain Conveyor in the Motorized Width Option Setup Window enter the desired Setpoint in the Width Setpoint field Click on the Start button The indicator is Red when the Motorized Width motor is engaged and Gray when the Motorized Width motor is Off To adjust the Pin Chain Conveyor using the software without entering an exact setpoint parameter use the Manual Operation fu...

Page 103: ...ration Screens Overview Introduction The software is configured at the factory for optimal machine performance The settings should not be altered If specific process conditions require adjustment to any of the settings refer to the following section Software Screen Figure 9 1 ...

Page 104: ...lt is 1 Comm Time Out Comm Time Out is the number of times communication is attempted before an error occurs Default is 15 000 Comm Update Timer Comm Update Timer is the time between data exchanges between the PLC and the PC Default is 500 ms Graphic Update Timer The refresh rate in milliseconds for the video display is determined by the value entered in Graphic Update Timer Sometimes a slightly h...

Page 105: ...rded in the log history Log Data Every __ Seconds This field determines how often the log history is refreshed The lower the value the more system memory is used Valid entries are between 5 and 60 Pop Alarm Window on Unacked Alarm If this feature is selected the Current Alarms window automatically appears when an alarm condition occurs It disappears when the alarm is acknowledged If this feature i...

Page 106: ...refers to the semiconductor mesh belt conveyor It is a finer pitch than the standard in Mesh Belt Conveyor Machine Inerting refers to a machine that uses nitrogen in its process environment IFM is the Internal Flux Management system It is most often used with inerted machines Extended Cooling refers to an additional Cooling Zone This parameter is used by the optional Unload Exit Photocell for accu...

Page 107: ...otocol standardized by the industry Programmable Output Relays should not be used in conjunction with SMEMA as SMEMA uses two 2 of the three 3 available outputs The Programmable Outputs are configured in a separate screen Refer to A Exit Photocell is selected when the photocell is installed at the Unload End of the machine It determines if boards are lost or jammed in the machine The Light Tower i...

Page 108: ...ion exists and has not been acknowledged either by pressing the Spacebar on the keyboard OR by selecting Alarms Current Alarms from the Menu Bar and clicking on AC The buzzer sounds until the alarm is acknowledged Hard Stop Active Machine has stopped due to hard stop activation Power is removed from the machine Soft Stop Active The machine is in a controlled shutdown due to a soft stop activation ...

Page 109: ...e process of a controlled shut down Ready No PCBs in Machine The relay state changes when the machine is at a Ready state but no PCBs are inside the machine Ready PCBs in Machine The relay state changes when the machine is at a Ready state and PCBs are inside the machine PCBs in Machine The relay state changes when ever there are PCBs in the machine regardless of Ready State Conveyor Running The r...

Page 110: ... that if a flashing state and a solid state of the same color are assigned to the same condition the solid color state overrides the flashing color state Software Screen Figure 9 5 Light Tower Conditions Unacknowledged Alarm An alarm condition exists that has not been acknowledged Press the spacebar Acknowledged Alarms Exist An alarm condition was acknowledged but the state causing the alarm still...

Page 111: ...Active Machine has stopped due to hard stop activation Everything under computer control stops immediately E Stop Emergency Shut Down Active Everything under computer control stops immediately due to an E Stop being pushed Note that the button must be reset by pulling it out before power can be restored to the machine Soft Stop Active The machine is in a controlled shut down due to soft stop alarm...

Page 112: ...s in thermocouple response and feedback heater response and heater watt density To compensate for these minor differences the Bravo system permits the heater temperature to be adjusted independently of the recipe input parameters This is an advantage if multiple ovens perform the same process If the offsets are changed specific to an oven the same process profile performs equally on multiple lines...

Page 113: ...sing TC Offsets To set the TC offset so that it increases the actual heater temperature enter a negative value To set the TC offset so that it decreases the actual heater temperature enter a positive value Refer to Figure 9 7 Figure 9 7 ATTENTION Note that the box next to Use TC Offsets must be selected for the offsets to be active ...

Page 114: ...r to the following to verify the factory settings or to restore default values Software Screen Figure 9 8 Conveyor Parameters Conveyor Length in CM Length of the conveyor as measured in centimeters It is used by the photocell to track boards through the machine Conveyor Length in Counts Number of pulses the encoder generates during the time it takes a given point on the conveyor to travel one leng...

Page 115: ...ut PhotoCell Window in CM The width in cm that is seen as an active window by the output photocell to detect boards Additional Counts for OPC Jam Detection The number of counts generated before an alarm sounds after the Photocell expects to detect a PCB It is used by the optional Exit Photocell Additional Length for Extended Cooling CM The length in centimeters needed to mount the Output Exit Phot...

Page 116: ...s necessary it should be performed by qualified Speedline Field Service Personnel Software Screen Figure 9 9 Timers Parameters Hard Stop Time Delay Time delay to ensure a Hard Stop condition exists before latching to that condition Soft Stop Time Delay Time delay to ensure that a Soft Stop condition exists before latching to that condition Warning Alarm Time Delay Time delay to ensure that a Warni...

Page 117: ...eviation alarms will be inhibited after a change in the heater setpoint Dev Alarm Inhibit on SP Change Conveyor Time that the deviation alarms will be inhibited after a change in the conveyor setpoint ConvBlower Change Heater Alarm Inhibit Time that the deviation alarms will be inhibited after a change in the convection blower setpoint PID Cycle Timer and PID Period Test PID period time used in PI...

Page 118: ...emperature of the Heating Chamber falls below this temperature in Centigrade High Temperature Alarm ShutDown in DegC This is the temperature in degrees Centigrade that is the maximum temperature allowed by the machine control software If the temperature of the Heating Chamber exceeds this temperature a High Temperature Alarm generates and the machines turns Off It is a necessary safety feature Do ...

Page 119: ...intenance and Diagnostics Screens should only be used by trained maintenance personnel They assist in determining corrective action if the machine is not functioning correctly Access the screens by selecting the Maint Diag tab from the menu bar at the top of the screen Refer to Figure 10 1 Software Screen Figure 10 1 ...

Page 120: ...re indicated by the red blocks in the photograph Refer to Figure 10 2 If a LED is red it indicates a tripped circuit Photograph Figure 10 2 Interpreting the Thermal Runaway Alarm Software Use the position guide represented in Figure 10 3 to determine the location of the tripped circuit Access the window by selecting Maint Diag Thermal Runaway from the menu bar at the top of the screen The display ...

Page 121: ...ent The error signal is produced when the measured value differs from the setpoint value Derivative refers to the controller producing a signal that is determined by the rate of change in the error signal i e how much time it takes the measured value to increase or decrease a given amount PID Tuning is preset at the factory The factory defaults for the PID values that are specific to the machine a...

Page 122: ... the window The Run Time Timers cannot be reset Maintenance Timers that can be reset are located in the Maint Diag Maintenance Timers Window Functions Power On Amount of time the power to the machine is On Convection Fans Amount of time the heating zone blowers operate Cooling Fans amount of time the cooling zone blowers operate Heaters Amount of time the heaters are On Conveyor Amount of time the...

Page 123: ...ed to activate the timer The Enable button is selected if the box next to the button is red Enter the time desired in hours next to the Alarm Point label that is the time desired between timer alarms To reset the timer to zero 0 select the Reset button associated with the applicable timer Alarm Levels Each timer can be set to a warning level of Hard Stop Soft Stop or Warning only To set the level ...

Page 124: ...reen To test either one of them press the applicable button on the Buzzer Lamp Test Window A red indicator signals that the test is in progress Refer to Figure 10 6 If Buzzer Test is selected a Buzzer sounds If Light Tower Test is selected the three 3 lamps in the Light Tower illu minate Software Screen Figure 10 6 Clear All PCBs Description Selecting Maint Diag Clear All PCBs resets the Board in ...

Page 125: ...e first line displays the ERROR status Normal is default and indicates proper function The second line displays the PLC error code 0000 is default and indicates proper function If a number other than 0000 displays the dropdown menu next to Description CODE provides an interpretation of the error code The PLC 3 6 V lithium battery status is monitored and voltage is dis played The Low Alarm Setpoint...

Page 126: ...M A IN T D IA G S C R E E N S PLC Status 10 112 Bravo 8105 Programming and Operations Guide Rev 2 10 ...

Page 127: ...sfactory results are obtained from production it is necessary to examine the entire process that produced the finished product Troubleshooting the reflow process is a learned skill resulting from experience and observation There is not always a clear cut connection between defects and causes Because each paste manufacturer produces paste specific recommendations and because printed circuit boards ...

Page 128: ...g angle is particularly affected by the physics involved in wetting the volume of the solder and the pad geometry Reducing the SMT footprint extension decreases the solder contact angle and aids in preventing defects with smaller components The stencil printing of solder paste is the most important step in PCB assembly If the process is not set up or operated correctly then the final assembly yiel...

Page 129: ... described as plus that screen size So if the solder wouldn t pass for example through a 500 mesh screen the solder is referenced as 500 Therefore a solder that passed through a 325 mesh screen but not a 400 mesh screen would be categorized as 325 500 Before Using Solder Paste Check the labels of the paste to ensure it is correct and ensure that the date is within allocated time If the solder is p...

Page 130: ...nt fine pitch should show the paste aligned with all pads Solder paste should conform to the size of pad aperture in the stencil The surface of the solder paste should be smooth and flat It may be considered acceptable if the solder paste is slightly misaligned but covers more than 50 of the solder pad surface If less than 50 of the pad is covered it is unacceptable for processing Chip solder past...

Page 131: ...duct size is 10 0 in For a 7 zone system s conveyor running 28 0 in per minute the throughput is 2 8 boards per minute Systems with longer heating modules generally run the conveyor at a faster speed than shorter machines A 10 zone system s conveyor may run the same profile at 40 0 in per minute In that case the throughput is increased to four 4 boards per minute Alternately the size of boards and...

Page 132: ...s well as the oven s capability to impart sufficient heat energy When designing a recipe profile refer to the data that the solder paste manufacturer provides The paste manufacturer generally provide peak reflow temperature full liquidus temperature pre reflow soak temperature and maximum duration information on their product data sheets If the paste specifications are not provided with the solder...

Page 133: ...is slope potential damage to components from thermal shock or cracking is risked Solder paste can also have a spattering effect If the rise rate or temperature level is too low evaporation of flux volatiles is incomplete Thermal Soak Zone The second section thermal soak is typically a 60 to 120 second exposure for removal of solder paste volatiles and activation of the fluxes The activated flux co...

Page 134: ... flux and possibly defective solder joints Experts usually recommend the shortest TAL possible however most pastes specify a minimum TAL of 30 seconds There appears to be no clear reason for that specific time One possibility is that there are places on the PCB that are not measured during profiling and therefore setting the minimum allowable time to 30 seconds reduces the chances of an unmeasured...

Page 135: ...ation Composition of paste alloy may be incompatible with process Solder particle size may be too small for the process Solder Balls Inadequate fluxing activity due to elevated temperatures or excessive times at that tem peraturef A slower preheat rate and or lower reflow peak may reduce the effect High gloss solder maskg Using a liquid photoimagable product may yield higher quailty passes Ambient...

Page 136: ...ay form voids v Excessive Intermetallic Compound Oxidation of the Paste Stayed in soak zone too longw Slump Formation Too rapid rise in preheat temperaturex High ambient temperature particularly on fine pitch where the ration of height to width is large y Coplanarity Warped boards Uneven solder surfaces Poor component fabrication or handling Bridging Excess solder deposition from inadequate or inf...

Page 137: ...um reflow temperature Reflow cycle too long a Dr Jennie S Hwang Pathways to SMT Soldering Surface Mount Technology Aug 1998 155 b Kurt Rajewski SMT Process Recommendations Defect Minimization Methods for a No Clean SMT Process January 13 1997 http www kester com smtrec htm January 25 1999 1 c Rajewski d Michael R McMonagle McMongIM KTELEC Pin in paste problem Feb 25 1999 TechNet dis tribution list...

Page 138: ...ircuits Assembly Online Online Exclusive http www cassembly com online 9811paste htm Feb 16 1999 z Chartrand aa Steven R Gregory SteveZeva Squeegee Speed Follow up Feb 23 1999 TechNet distribution list accessed Feb 25 1999 ab Chartrand ac Edward Brunker edward brunker Solder bridges Feb 4 1999 TechNet distribution list accessed March 9 1999 ad Rajewski ae Rajewski af Rajewski ag Marc Peo Optimize ...

Page 139: ...uration Screens 89 Conveyor Control 32 Conveyor Parameters Configuration 100 Customer Support v Customer Support Structure v E Electrical Calculate FLA 21 Lock Out Tag Out 15 17 Requirements 21 Exhaust Requirements 20 Ventilation 12 F Facility Exhaust Requirements 20 Lock Out Tag Out 14 17 Machine Clearance 20 Water Requirements 20 Fire Extinguisher 10 Flammables 10 G Good Housekeeping 12 H Hazard...

Page 140: ...ircuit Board Specification 59 Process 113 Board Design Stencils and Solder Paste 114 Cooling Zone 120 Inspection before Reflow 116 Preheat Zone 119 Process Zones 119 Reflow Profile 118 Reflow Zone 119 Solder Paste Considerations 115 Thermal Soak Zone 119 Throughput 117 Time above liquideous 120 Troubleshooting Bridging 122 Coplanarity 122 Cracked and Damaged Chip Capacitors and Connections 121 Cra...

Page 141: ... Security Access Screen 49 Security Access Sample Profiles 53 Serial Tag viii 15 Setup Screen 77 Skin Irritation 9 SMEMA Setup 86 Smoking Prohibition 10 Software Alarm History Display 73 Auto Mode 56 Configuring Security Access and Passwords 47 Conveyor Control 32 Display of Alarms 71 Displaying Log Content 74 Heater Control 30 Logging On 46 Manual Mode 56 Navigation 29 Process Graphic Screen 30 S...

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