Miyachi Unitek 1-292-01 Operator'S Manual Download Page 2

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OPERATOR MANUAL 990-228

Revision D September 2007

UNIFLOW

PULSED THERMODE CONTROL

(BIPOLAR LOGIC)

MODEL NUMBERS

1-292-01 1-292-01-01

1-292-01-02

Summary of Contents for 1-292-01

Page 1: ...l service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE INSPECTION Remotely inspect equipment before purchasing with our interactive website at www instraview com LOOKING FOR MORE INFORMATION Visit us on the web at www artisantg com for more information on ...

Page 2: ...OPERATOR MANUAL 990 228 Revision D September 2007 UNIFLOW 2 PULSED THERMODE CONTROL BIPOLAR LOGIC MODEL NUMBERS 1 292 01 1 292 01 01 1 292 01 02 ...

Page 3: ...eproduced copied exhibited or otherwise used without the written authorization of UNITEK MIYACHI CORPORATION Printed in the United States of America REVISION RECORD Revision EO Date Basis of Revision A 19896 12 03 Original Release B 19957 2 04 Added Communication Appendix D Communication and Appendix E Guide to Reflow Soldering C 20174 11 04 Updated technical information D 21578 9 07 Added checksu...

Page 4: ... Keypad 1 4 Cursor Keys 1 4 Graph Key 1 4 DATA Key 1 5 PROFILE NUMBER Keys 1 5 COUNTERS Key 1 5 DATA EDIT Keys 1 6 HEATING RATE Key 1 6 SETUP Key 1 6 HEAT NO HEAT Switch 1 7 Chapter 2 Installation and Setup Section I Planning for Installation 2 1 Space Requirements 2 1 Utilities 2 1 Section II Connections To External Equipment 2 2 Overview 2 2 Input Power Connections 2 3 Control to Head Connection...

Page 5: ...er 3 5 DATA EDIT Keys 3 5 Saving Changed Values 3 5 HEATING RATE Key 3 6 SETUP Key 3 7 HARDWARE SETUP Page 1 3 8 HEAD COOL VALVE IS Page 1 3 8 SOLDER COOL VALVE IS Page 1 3 8 FOOTSWITCH RESPONSE MODE Page 1 3 8 LIST OF HARDWARE Page 1 3 9 HARDWARE SETUP Page 2 3 9 DISPLAY CONTRAST Page 2 3 9 BUZZER LOUDNESS Page 2 3 9 END OF CYCLE BUZZER Page 2 3 9 SET OUTPUT RELAYS Page 2 3 10 COMMUNICATIONS 3 11...

Page 6: ...er 5 Maintenance Section I Before You Start Precautions 5 1 STATUS Messages 5 1 Section II Troubleshooting 5 2 Section III Maintenance 5 5 Thermode Maintenance 5 5 Repair Service 5 5 Chapter 6 Calibration Overview 6 1 Required Equipment 6 1 Calibration 6 1 Appendix A Technical Specifications A 1 Appendix B Electrical And Data Connectors B 1 Appendix C System Timing C 1 Appendix D Communications D ...

Page 7: ...ping company immediately to file a claim and notify Unitek Miyachi at Unitek Miyachi 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info unitekmiyachi com The contents of this manual are subject to change without notice If you have any questions or find any errors or omissions in this manual please contact us Unitek Miyachi is not respon...

Page 8: ...of the 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 term...

Page 9: ...fe operation x 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 REPAI...

Page 10: ...ist 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 Unitek Miyachi 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 Unitek ...

Page 11: ... 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 ...

Page 12: ...e of repair The operator is coached by visual displays on a Liquid Crystal Display LCD screen if out of range entries are made or when alarm error conditions occur Up to 15 heat profiles the records containing the joining parameters to be used during the joining cycles can be programmed stored and recalled for use Reflow soldering is a multi step metal joining process where xTwo solder coated part...

Page 13: ...01 01 Front panel Has front panel controls and display for local operator programming 24 VAC valve outputs 240 4 KVA For thermodes up to 4 100 mm long 1 292 01 02 Front panel Has front panel controls and display for local operator programming 24 VDC valve outputs 240 4 KVA For thermodes up to 4 100 mm long Heads Thermodes and Accessories For details of solder reflow and heat seal heads thermodes a...

Page 14: ...ays both graphic and alphanumeric data depending on the function chosen by the Operator SETUP MENU 1 HARDWARE SETUP 4 SYSTEM SECURITY 2 COMMUNICATIONS 5 COPY PROFILE 3 REFLOW SETUP NUMBER Select an item Graph or Data Graphic Data Alphanumeric Data NOTE These screens their functions and displays are described in Chapter 3 Using Uniflow 2 Programming Functions ...

Page 15: ...You use the Left and Right keys to decrease or increase a numeric field value Graph Key This key displays the graphic screen for editing the heat profile parameters with the keypad or cursor keys After editing the heat profile parameters pressing the GRAPH key saves the new parameters to the heat profile noted on the display Pressing the GRAPH key while in the setup counter or heating rate menus r...

Page 16: ... display these keys will increment decrement the heat profile 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 displa...

Page 17: ...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 TUNING 1 Set Coarse Heating Rate MEDIUM 2 Set Fine Heating Rate 98 NUMBER Select an item Graph or Data SET COARSE HEATING RATE 1 Very Slow 2 Slow 3 Medi...

Page 18: ... 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 to initiating a heating cycle ...

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Page 20: ...ve gases salt and moisture x Allow sufficient clearance around both sides and back of the Control for power and signal cabling runs and to ensure adequate inflow and exhaust of air for the cooling system x Allow ample workspace around the Control so that it will not be jostled or struck while in use x The work surface must be level stable free from vibration and capable of supporting the combined ...

Page 21: ... the Control and external 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 specificati...

Page 22: ...t to the power cables together in order to reduce noise pickup x If you are using two individual thermocouple wires they must be twisted together in order to reduce noise pickup x 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 2 Plug the green CONTROL INPUT JUMPER plug mark...

Page 23: ...CHAPTER 2 INSTALLATION AND SETUP UNIFLOW 2 PULSED THERMODE CONTROL 2 4 990 228 5 Connect the two transformer cables from the head to the transformer terminals on the Control front panel ...

Page 24: ...d emergency stop switch to connector EMO pins 1 and 2 on the Control rear panel See Appendix B Electrical and Data Connections for more details NOTE If Connector EMO Pins 1 and 2 on the rear panel are not shorted either by an EMO switch or the jumper plug this screen will include the message NOTE EMO JUMPER NOT INSTALLED 5 Set the HEAT NO HEAT switch on the Control front panel to the NO HEAT posit...

Page 25: ...ch to connector EMO pins 1 and 2 on the Control rear panel See Appendix B Electrical and Data Connections for more details When this switch is operated open it will immediately stop the heating cycle and retract the thermode from the parts NOTE If Connector EMO Pins 1 and 2 on the rear panel are not shorted either by an EMO switch or the jumper plug this screen will include the message NOTE EMO JU...

Page 26: ...e first level and hold the foot switch at the first level The thermode should descend to the parts 12 If the parts are properly positioned under the thermode press the foot switch to the second bottom level The Control should begin a process cycle without applying heat and the head should immediately retract If the head does retract go to Step 14 If the head does not retract go to Step 13 13 Incre...

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Page 28: ...It also shows the results of a heating cycle following its completion The display has several functions depending on the active mode of the Control Run Mode Press the GRAPH or DATA key to enter the RUN mode With the graphic screen on the display x Reports the current thermode temperature in the upper right hand corner the heat profile number the time and temperature settings of the current heat pr...

Page 29: ...l 1 150 350 180 Celsius 01 0 1 0 03 0 Seconds 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 displayed as 150qC note the Celsius units at the right hand side of the screen and...

Page 30: ...pon reaching the Cool temperature The Cool parameter shows 180qC The Cool time is not controlled Profile Number The large 1 shown at the right hand side of the screen is the number of the currently displayed heat profile The number of the profile to be displayed is selected with the PROFILE NUMBER keys and may range from 1 to 15 Present Temperature The present temperature of the thermode shown in ...

Page 31: ...h this and all other menu screens on the display you will not be able to initiate the heating cycle REFLOW COUNTERS 1 TOTAL USAGE COUNTER 0000020 2 GOOD REFLOW COUNTER 0000010 3 CLEAN COUNTER 999999 4 REPLACE COUNTER 999999 NUMBER Select an item Graph or Data Total Usage Counter Press the 1 key to edit the total usage counter With the numeric keys you may select a number up to 9999999 The selected...

Page 32: ...when the graphic screen is displayed Example To change the temperature of the Reflow period for Heating Profile 1 to 500qC 1 Press the GRAPH key to display the graphic screen 2 Press the data edit REFLOW qC key The Reflow temperature value of 350 40qC 1 Last Profile 150 350 180 Celsius 01 0 1 0 03 0 Seconds will now be highlighted 3 Enter 500 with the keypad 4 Press the GRAPH key to store the new ...

Page 33: ...SET COARSE HEATING RATE screen SET COARSE HEATING RATE 1 Very Slow 2 Slow 3 Medium 4 Fast NUMBER Select Page Graph or Data The progression from Very Slow to Fast provides more energy to heat the thermode The table below is a guide to optimize the coarse heating rate Change COARSE HEATING RATE to optimize temperature profile output The default value is Medium which is appropriate for 90 of all ther...

Page 34: ...eady mode in the graphics or data display screens For example pressing the GRAPH key to returns you to the graphic display Selecting 2 on the MANUAL TUNING screen will bring up the SET FINE HEATING RATE screen SET FINE HEATING RATE SET FINE HEATING RATE 98 The default value is 98 maximum which is appropriate for 90 of thermodes A larger percentage means that more energy is available to heat the th...

Page 35: ...etails SOLDER COOL VALVE IS Page 1 Press the 2 key to toggle between OFF and ON Selecting ON will activate the solder cool valve starting at the end of the Heat period and de activating when the thermode reaches the Cool temperature The solder cool valve is used to direct the cool air onto the thermode to force it to cool faster The solder cool valve supplies a connector selectable 24 VAC or 24 VD...

Page 36: ...ZER ON 4 SET OUTPUT RELAYS NUMBER Select Page Graph or Data DISPLAY CONTRAST Page 2 DISPLAY CONTRAST DISPLAY CONTRAST 50 Press the 1 key to bring up the DISPLAY CONTRAST adjustment screen With this screen you may adjust the contrast of the display with the left right cursor keys for comfortable viewing 0 10 20 30 40 50 60 70 80 90 Adjust Page Graph or Data BUZZER LOUDNESS Page 2 BUZZER LOUDNESS BU...

Page 37: ... option screen The 1 through 9 keys on the keypad set the RELAY 1 status options 1 REFLOW Relay is NC NO during the reflow process cycle RELAY 1 1 REFLOW 6 END OF REFLOW 2 PREHEAT ON 7 HEAD IS UP 3 ALARM 8 SYSTEM READY 4 CLEAN THERMODE 9 NOT ACTIVE 5 REPLACE THERMODE NUMBER Select Page Graph or Data 2 PREHEAT Relay is NC NO for continuous preheat 3 ALARM Relay is NC NO for alarm conditions Auto re...

Page 38: ...to the host computer after each heating cycle When SLAVE is selected the Control will send data to the host computer only when requested by the host computer The Default value is SLAVE RS232 485 SELECT Pressing the 3 key will alternately select either RS232 or RS485 communications Default value is RS232 BAUD RATE The 2 key on the COMMUNICATION menu brings up the BAUD RATE screen Use the keypad to ...

Page 39: ...MPERATURE LIMIT 050qC 3 LOWER TEMPERATURE LIMIT 050qC 4 AUTOSCALING FEATURE OFF Number Select Page Graph or Data UPPER TEMPERATURE LIMIT Press the 2 key to bring up the UPPER TEMPERATURE LIMIT screen Use the keys to adjust the limit UPPER TEMPERATURE LIMIT UPPER TEMPERATURE LIMIT 050 NUMBER Change Adjust Graph Data The upper temperature limit covers the entire heating period as shown in the diagra...

Page 40: ...UTOSCALING FEATURE Press the 4 key to toggle between OFF and ON Selecting OFF means that the actual graphic temperature display will fill in over the Ideal Profile on the screen until the fill reaches the end of the display Selecting ON causes the graphic display to automatically re scale at Cool time to capture more of the reflow including a longer portion of the cooling cycle REFLOW TEMPERATURE ...

Page 41: ...nd the release timer has expired Use the number or keys to select a release timer value of 00 to 99 seconds SET RELEASE TIMER SET RELEASE TIMER 00 After edit Page to accept new value Number Change Adjust Graph or Data MAX TEMPERATURE LIMIT Press the 3 key to bring up the MAX TEMP ERATURE LIMIT screen With this screen you may set the maximum temperature required for an application The default tempe...

Page 42: ...nge to ON CHANGE PASSWORD PASSWORD Enter NUMBERS followed by the arrow Page Setup or Data Once you have returned to the graph or data screens you can only unlock system security by entering the password again via the CHANGE PASSWORD screen PROFILE LOCK inhibits the user from modifying any reflow parameters and from selecting different profile schedules SYSTEM LOCK prevents the user from making cha...

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Page 44: ...onnected properly See Chapter 2 Installation and Setup and the instructions supplied with the Reflow Head x You must be familiar with how to select and use the Control functions for your specific applications For more information see Chapter 3 Using Programming Functions General Operator Safety WARNING x To prevent blindness or eye injury wear safety goggles at all times during reflow soldering x ...

Page 45: ...l will not operate until the jumper is installed When the SYSTEM READY screen displays the Control is ready for operation using either of the following options x Pre Defined Reflow Profiles For convenience you may quickly select a profile stored in the Control that has been pre defined for your most common reflow applications x Direct Input You may use the front panel controls to input the paramet...

Page 46: ... deliver heating energy to the thermode when you initiate the heating cycle 2 Press the PREHEAT qC key to select the PREHEAT temperature value for editing NOTE The PREHEAT temperature value will be highlighted when it is selected 40 C 1 Ideal Profile 100 250 100 Celsius 01 5 1 5 03 5 Seconds 3 Set the temperature value to 100qC with the number keys on the keypad then press the GRAPH key 4 Press th...

Page 47: ...OL temperature of 100qC then press the GRAPH key 9 Make a test joint by pressing the foot pedal or foot switch to initiate a complete heating cycle x For manual reflow soldering heads release the foot pedal when the alarm beep sounds indicating that the thermode has reached the COOL temperature x For air actuated reflow solder heads release the foot switch after the head has automatically retracte...

Page 48: ... detergent or alcohol Status Messages Message Description Auto Scaling The LCD Graph display automatically re scales during the entire reflow soldering process to provide the user with a complete picture of the entire process This feature can be turned on or off by the user Calibration set to default The Control must be re calibrated after calibration parameters have been reset to default value Co...

Page 49: ...REMOTE PROFILE SELECTED Operator has attempted to change profile numbers at the Unit s panel while the remote inputs are already specifying a profile Ignore or remove the remote profile selection before changing profile numbers at the panel ACCESS DENIED SYSTEM SECURITY ON The operator has attempted to change a system or profile value that is locked out by the Security Screen Set the appropriate l...

Page 50: ...t the Thermocouple is connected c Check to see if the SCR has shorted When finished recycle the Power on the unit MINIMUM COOL TEMP OF 60 C REQUIRED New Cool temperature value is less than the 60 C limit Press the Cool C key and re enter a value that is more than 60 C MINIMUM PREHEAT TEMP OF 60 C REQUIRED New Preheat temperature value is less than the 60 C limit Press the Preheat C key and re ente...

Page 51: ...t temperature Press the Reflow C key and re enter a value that is more than the Preheat temperature REPLACE THERMODE Reset Replace Counter Replace Thermode Counter has reached zero Reset Replace Thermode Counter WARNING PREHEAT IS ALWAYS ON Thermode remains at Preheat temperature continuously when not in a reflow process cycle after being programmed to remain on Press the Setup key Select Reflow S...

Page 52: ...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 x Warped thermodes will not adequately transfer heat to the parts x Cracked thermodes will not heat or they may overheat in th...

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Page 54: ...K and E type thermocouple cable UMC 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 Select t...

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Page 56: ... Ambient Temperature Maximum 104qF 40qC Minimum 59qF 15qC Relative Humidity Maximum 93 at 104qF 40qC Dimensions Height x Width x Depth 12 5 in 317 mm 10 in 254 mm 20 75 in 527 mm Weight 4 KVA Models 58 lbs 26 31 kg 2 KVA Models 46 lbs 20 86 kg Performance User Programmable Heat Profiles 15 Flash Memory Thermocouple Inputs automatic recognition Type E For temperatures below 900qC Type J For tempera...

Page 57: ...s 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 15 heat profiles using four inputs activated in a binary coded pattern Operator Initiation Switch 1 level or 2 level foot switch Heat Initiation Sensor Heat force or Uniflow 2 head down sensor for initiating thermode heating No Heat Sw...

Page 58: ...alve ON at COOL period OFF at PREHEAT period Programmable Electromechanical Relays Relays Available 4 Power User provided Contact Rating 1 A at 250 VAC or 30 VDC Programmable Electromechanical Relays Functions Reflow On Off during heating process cycle Preheat On Off for continuous preheat Alarm On Off for any alarm condition Clean Thermode On Off when clean thermode counter expires Replace Thermo...

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Page 60: ...1 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 61: ...e logic active high by rejumpering 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 ...

Page 62: ...ICAL AND DATA CONNECTIONS UNIFLOW 2 PULSED THERMODE CONTROL 990 228 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 63: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 2 PULSED THERMODE CONTROL B 4 990 228 Switch Contact Input Internal Power ...

Page 64: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 2 PULSED THERMODE CONTROL 990 228 B 5 Switch Contact Input External Power ...

Page 65: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 2 PULSED THERMODE CONTROL B 6 990 228 Common Negative Input Internal Power ...

Page 66: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 2 PULSED THERMODE CONTROL 990 228 B 7 Common Negative Input External Power ...

Page 67: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 2 PULSED THERMODE CONTROL B 8 990 228 Common Positive Input Internal Power ...

Page 68: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 2 PULSED THERMODE CONTROL 990 228 B 9 Common Positive Input External Power ...

Page 69: ...or DC 24 volt output power is selectable by connecting the proper AC or DC plug as shown on the next page NOTES For AIR HEAD VALVE operation either 1 jumper HEAD VALVE CONNECTOR pin 2 and pin 4 or 2 jumper J4A pin 6 AIR HEAD to VALVE DRIVER COMMON or 0V OUT see J4A B pin out If using connection configuration SWITCH CONTACT INPUT INTERNAL POWER or COMMON NEGATIVE INPUT INTERNAL POWER J4A pin 4 is 0...

Page 70: ...ch is closed It automatically de activates when the COOL temperature is reached or in the event of a reflow alarm The head cool valve is user programmable to be ON or OFF It is independent of the reflow process cycle It is used to prevent the thermocouple holder from overheating The solder cool valve can be user programmed to activate at the start of the COOL period It automatically de activates w...

Page 71: ... the idle state Alarm ON OFF for alarm conditions Auto reset when alarm is cleared Clean Thermode ON OFF when clean thermode counter expires Auto reset when counter is edited Replace Thermode ON OFF when replace thermode counter expires Auto reset when counter is edited End of Reflow ON OFF when reflow process cycle is complete Auto reset at start of the next cycle Head is Up The weld head is in h...

Page 72: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 2 PULSED THERMODE CONTROL 990 228 B 13 Relay State Timing ...

Page 73: ...he foot switch 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 cycl...

Page 74: ...s are inactive 0000 the Profile Number 1 15 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 and SCHED 3 The Profile Number Zero 0 is not a displayable selection Remote Profile Inputs Binary Profile Profile Number SCHED ...

Page 75: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS UNIFLOW 2 PULSED THERMODE CONTROL B 16 990 228 Operator Initiation Switch and Firing Switch Inputs Input Signal Rating 0 or 24 VDC 2 mA maximum ...

Page 76: ...witch Normally 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 Rating 0 to 24 VDC 2 mA maximum Timing By applying a signal at J4A 7 a PLC or external computer can readily reset all alarms before proceeding with the next reflow process ...

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Page 78: ...UNIFLOW 2 PULSED THERMODE CONTROL 990 228 C 1 APPENDIX C SYSTEM TIMING NOTE All inputs are debounced for a fixed 30ms period ...

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Page 80: ...KEYWORDS 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 81: ...nt 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 o...

Page 82: ...the external 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 Fo...

Page 83: ...ket on the back of the unit 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 wo...

Page 84: ...eflowCntrs 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 37 Byte...

Page 85: ... 29 LOGO_SCR 30 LOWER_TEMP 31 MANUAL_TUNING 32 MAX_TEMP 33 PASSWORD 34 PIDPARAMS 35 PIXELONTEST 36 PIXELOFFTEST 37 REFLOW1 38 REFLOW2 39 REFLOW_COUNTERS 40 RELAY 41 RELAY1 42 RELAY2 43 RELAY3 44 RELAY4 45 RELAY1WHENSCR 46 RELAY2WHENSCR 47 RELAY3WHENSCR 48 RELAY4WHENSCR 49 RELEASE_TIMER 50 REPLACE_CNTR 51 REPLACE_CNTR_SETUP 52 SETTODEFAULTS 53 SAFETY_TIMER 54 SETUP 55 SHOWPASSWD 56 SYSTEM_SEC 57 SY...

Page 86: ... Reflow time 000 999 3 Bytes 1 Byte CoarseRate Coarse heating rate 0 3 1 Byte 0 Very Slow 1 Slow 2 Medium 3 Fast 27 Bytes Total RELAY VR Read relay values 0 Bytes VS Relays1 on_off 0 NORMALOPEN 1 NORMALCLOSED 1 Byte 1 Byte Relays1 when 1 Byte REFLOW_TRIG 0 PREHEATON_TRIG 1 ALARM_TRIG 2 CLEANTHERM_TRIG 3 REPLACETHERM_TRIG 4 ENDOFREFLOW_TRIG 5 HEADACTIVE_TRIG 6 SYSTEMREADY_TRIG 7 NOTACTIVE_TRIG 8 1 ...

Page 87: ...YSTEM YR Read Read system values 0 Bytes YS Set HeadCoolValveStatus 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 Contrast 00 99 2 Bytes 1 Byte BuzzerLoudness 00 99 2 Bytes 1 Byte BuzzerAtEnd 0 OFF 1 ON 1 Byte 1 Byte PreheatStatus 0 ON 1 TIMED 1 Byte 1 Byte UpperTempLimit 000 999 3 Bytes 1 Byte LowerTempLimit 0 999 3 Bytes ...

Page 88: ...er 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 39 Bytes Total LOAD LR Read Returns the current...

Page 89: ...ELAY1 42 RELAY2 43 RELAY3 44 RELAY4 45 RELAY1WHENSCR 46 RELAY2WHENSCR 47 RELAY3WHENSCR 48 RELAY4WHENSCR 49 RELEASE_TIMER 50 REPLACE_CNTR 51 REPLACE_CNTR_SETUP 52 SETTODEFAULTS 53 SAFETY_TIMER 54 SETUP 55 SHOWPASSWD 56 SYSTEM_SEC 57 SYSTEMTESTS 58 TESTRELAYS 59 TOTAL_USAGE 60 UPPER_TEMP 61 IDLE_TEMP_SCR 1 Byte CurrStatusMsg 0 39 2 Bytes 0 SYSTEMREADY 1 EMERJMPR 2 PREHEAT_LOWLIMIT 3 PREHEAT_HIGHLIMI...

Page 90: ...E 31 MODIFYPROFILE 32 LASTPROFILE 33 IDEALPROFILE 34 EMERSTOP 35 MAXTEMP 36 NOPWR 37 OVPWR 38 THERMODE 39 ACCESSDENIEDREM 40 FOOTSWOPEN 6 Bytes Total PROFILE DR Read ProfileNum Profile number read 01 15 2 Bytes 1 Byte PreheatTemp Preheat temperature 060 999 3 Bytes 1 Byte ReflowTemp Reflow temperature 060 999 3 Bytes 1 Byte CoolTemp Cool temperature 060 999 3 Bytes 1 Byte PreheatTime Preheat time ...

Page 91: ... when As above 1 Byte 15 Bytes Total REPORT RR Read Reports the results of the last reflow Sent automatically by the Uniflow Unit at the end of the reflow ProfileNum Profile number 01 15 2 Bytes 1 Byte StartTemp Starting Temperature 000 999 3 Bytes 1 Byte PeakTemp Peak Temperature 000 999 3 Bytes 1 Byte FinalTemp Final Temperature 000 999 3 Bytes 1 Byte AverageTemp Average Temperature 000 999 3 By...

Page 92: ...OFILE 33 IDEALPROFILE 34 EMERSTOP 35 MAXTEMP 36 NOPWR 37 OVPWR 38 THERMODE 39 ACCESSDENIEDREM 40 FOOTSWOPEN 25 Bytes Total SECURITY SR Read ProfileLock Profile Lock 0 OFF 1 ON 1 Byte 1 Byte SystemLock System Lock 0 OFF 1 ON 1 Byte 1 Byte ProfileTuneLock Profile Tuning Lock 0 OFF 1 ON 1 Byte 5 Bytes Total SYSTEM YR Read HeadCoolValveStatus 0 OFF 1 ON 1 Byte 1 Byte SolderCoolValveStatus 0 OFF 1 ON 1...

Page 93: ...yte AutoscalingEnabled 0 OFF 1 ON 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 MaxIdleTemp 0 NONE 1 500 2 700 3 900 1 Byte 37 Bytes Total TEMP TR Read CurrTemp Current temperature of the thermode TYPE TY Read Uniflow2 Release Revision 17 Bytes Example Uniflow2 1 00 AxP ...

Page 94: ...The 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...

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Page 96: ...ts 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 ...

Page 97: ... Heat 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 260qC burning of the surface and thermode contamination can result This des...

Page 98: ...es 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 ...

Page 99: ...ea 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...

Page 100: ... 0 012 x 0 039 0 30 x 1 2 0 012 x 0 047 Pad size 0 4 x 3 2mm 0 016 x 0 126 Pitch 0 8 mm 0 031 0 02 0 03mm 0 00079 0 0012 175 micron 0 007 0 26 x 1 0 010 x 0 039 0 26 x 1 2 0 010 x 0 047 100 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 micron 0 007 0 5 x 1 6 0 020 x 0 063 0 5 x 2 3 0 020 x 0 091 Pad size 0 8 x 5 ...

Page 101: ...x 0 083 Pad size 1 5 x 5 5 mm 0 059 x 0 216 Pitch 3 0 0 118 0 13 0 19 mm 0 0051 0 0075 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 ther...

Page 102: ... 0 079 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 ...

Page 103: ...ing 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 ...

Page 104: ... 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 soldering control footswitch input 4 The soldering control then actuates the bonding head and thermode module to the parts 5 At a pre...

Page 105: ...ols the flow of air at the end of the reflow period and cool the joint and thermode rapidly Because most connections have a relatively high heat sink the temperature in the solder is lower than the measured thermode temperature even when using cooling air Therefore the release temperature can be set to 180º C in most cases without the chance of encountering a dry joint Force Control And Simple Sys...

Page 106: ...fer to the parts Care must be taken so as not to round the edges of the thermode or spoil the flatness There is a distinct difference between the pollution of the thermode for soldering processes where the thermode is positioned directly on the leads in contact with the solder and those where the thermode is in contact with a Kapton surface In the first case the pollution and thermode wear is much...

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Page 108: ...Cool 3 3 COPY PROFILE 3 15 COUNTERS Key 1 5 COUNTERS Key 3 4 Cursor Keys 1 4 D DATA EDIT Keys 1 6 3 5 DATA Key 1 5 3 3 Definition of Command Elements D 2 Description 1 1 Controls and Indicators 1 3 COUNTERS Key 1 5 Cursor Keys 1 4 DATA EDIT Keys 1 6 DATA Key 1 5 Display LCD 1 3 Front Panel 1 3 Graph Key 1 4 HEAT NO HEAT Switch 1 7 HEATING RATE Key 1 6 Keypad 1 4 PROFILE NUMBER Keys 1 5 SETUP Key 1...

Page 109: ...NO HEAT Switch 1 7 HEATING RATE Key 1 6 HEATING RATE Key 3 6 Host Originated Command Set D 4 I I D NUMBER 3 11 Index Index 1 Input Power Connections 2 3 Installation and Setup 2 1 Connections To External Equipment 2 2 Control to Head Connections 2 3 Input Power Connections 2 3 Overview 2 2 Equipment Setup 2 5 Force Fired Air Actuated Head 2 6 Force Fired Mechanically Actuated Head 2 5 Planning for...

Page 110: ...LDER COOL VALVE IS Page 1 3 8 Space Requirements 2 1 STATUS Messages 5 1 Switch Contact Input External Power B 5 Switch Contact Input Internal Power B 4 Switched Input Electrical Requirements A 2 SYSTEM SECURITY 3 14 System Timing C 1 T Technical Specifications A 1 Electrical Mains A 1 Environment A 1 Dimensions A 1 Performance A 1 Temperature Control A 2 Switched Input Electrical Requirements A 2...

Page 111: ... HEAD COOL VALVE IS Page 1 3 8 HEATING RATE Key 3 6 LIST OF HARDWARE Page 1 3 9 MAX IDLE TEMP LIMIT 3 14 MAX TEMPERATURE LIMIT 3 14 Overview 3 1 PROFILE NUMBER Keys 3 4 REFLOW TEMPERATURE SETUP Page 2 3 13 Saving Changed Values 3 5 SET OUTPUT RELAYS Page 2 3 10 SET RELEASE TIMER 3 14 SET SAFETY TIMER 3 13 SETUP Key 1 6 3 7 SOLDER COOL VALVE IS Page 1 3 8 SYSTEM SECURITY 3 14 Utilities 2 1 V Valve ...

Page 112: ...l service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE INSPECTION Remotely inspect equipment before purchasing with our interactive website at www instraview com LOOKING FOR MORE INFORMATION Visit us on the web at www artisantg com for more information on ...

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