Technical Reference

Technical Service Manual 1 Revision Date: August 2004

XPM2Reflow Soldering / Curing Systems

Technical Reference Manual


TABLE OF CONTENTS

TABLE OF CONTENTS _______________________________________________________________ 2

PURPOSE OF THIS MANUAL & WHO SHOULD USE IT ____________________________________ 4

CONTROL PANEL SYMBOLS__________________________________________________________ 5

GLOSSARY OF TERMS GLOSSARY OF TERMS & MEASUREMENT CONVERSIONS ___________ 6MEASUREMENT CONVERSIONS ------------------------------------------------------------------------------------------------------------------8

A - CONTROL SYSTEM OPERATION ____________________________________________________ 9OVEN CONTROL SYSTEM OVERVIEW ----------------------------------------------------------------------------------------------------------9HEAT CONTROL OVERVIEW---------------------------------------------------------------------------------------------------------------------- 10POWER DISTRIBUTION OVERVIEW ------------------------------------------------------------------------------------------------------------ 10COMPUTER AND CONTROLLER OVERVIEW ----------------------------------------------------------------------------------------------- 11CONVEYOR OVERVIEW ---------------------------------------------------------------------------------------------------------------------------- 12FAN CONTROL OVERVIEW------------------------------------------------------------------------------------------------------------------------ 13HEAT CONTROL OVERVIEW---------------------------------------------------------------------------------------------------------------------- 14HEATING CELL DESCRIPTION ------------------------------------------------------------------------------------------------------------------- 16

B - HEATING SYSTEM _____________________________________________________________ 18PROBLEMS AND POSSIBLE SOLUTIONS (The most likely cause is listed first) -------------------------------------------- 18HEATING PROBLEMS ------------------------------------------------------------------------------------------------------------------------------- 18HEATER TESTING PROCEDURE----------------------------------------------------------------------------------------------------------------- 36TEST PROCEDURE FOR HEATER GROUND CONTINUITY ----------------------------------------------------------------------------- 40MAXIMUM HEATERS ON---------------------------------------------------------------------------------------------------------------------------- 40MAXIMUM PHASE IMBALANCE ------------------------------------------------------------------------------------------------------------------ 40THERMOCOUPLES ----------------------------------------------------------------------------------------------------------------------------------- 40TEST PROCEDURE ----------------------------------------------------------------------------------------------------------------------------------- 40HEATER PLATE REPLACEMENT ---------------------------------------------------------------------------------------------------------------- 41TEST PROCEDURE FOR HEATER CONTROL----------------------------------------------------------------------------------------------- 41CELL FAN MOTORS ---------------------------------------------------------------------------------------------------------------------------------- 42TEST PROCEDURE FOR MOTOR RESISTANCE ------------------------------------------------------------------------------------------- 42CELL FAN MOTOR ROTATION CHECK-------------------------------------------------------------------------------------------------------- 42VERIFYING CELL FAN SPEED-------------------------------------------------------------------------------------------------------------------- 42CELL FAN ASSEMBLY REMOVE AND REPLACE PROCEDURES-------------------------------------------------------------------- 43HEATER REMOVE AND REPLACE PROCEDURES---------------------------------------------------------------------------------------- 49

C - CONVEYOR ____________________________________________________________________ 53CONVEYOR TYPES----------------------------------------------------------------------------------------------------------------------------------- 53PROBLEMS AND POSSIBLE SOLUTIONS (The most likely cause is listed first)---------------------------------------------- 56CONVEYOR PROBLEMS---------------------------------------------------------------------------------------------------------------------------- 56CONVEYOR BELT, CHAIN & RAIL SERVICE------------------------------------------------------------------------------------------------- 69REMOVE AND REPLACE CONVEYOR BELT ------------------------------------------------------------------------------------------------ 69REMOVE AND REPLACE CONVEYOR RAILS AND CHAINS---------------------------------------------------------------------------- 74DRIVE MOTOR SERVICE & REPLACEMENT ------------------------------------------------------------------------------------------------ 75ENCODER SERVICE & REPLACEMENT------------------------------------------------------------------------------------------------------- 77

D- ELECTRICAL POWER & COMPUTER _______________________________________________ 78ELECTRO - STATIC DISCHARGE PROCEDURES ( ESD)-------------------------------------------------------------------------------- 78A.C. & D.C. POWER SUPPLIES -------------------------------------------------------------------------------------------------------------- 80

OVEN CONTROLLER _______________________________________________________________ 82ADDRESSING DIP SWITCHES ON DI BOARD----------------------------------------------------------------------------------------------- 83ADDRESSING LINKS ON AI BOARD ------------------------------------------------------------------------------------------------------------ 83CONTROLLER STATUS ----------------------------------------------------------------------------------------------------------------------------- 83RS-232 SERIAL COMMUNICATION CHECK -------------------------------------------------------------------------------------------------- 84COMPUTER SYSTEM -------------------------------------------------------------------------------------------------------------------------------- 86CONTROL CIRCUIT ----------------------------------------------------------------------------------------------------------------------------------- 86ELECTRICAL GROUNDING OF OVEN---------------------------------------------------------------------------------------------------------- 87


E - ASSOCIATED SUBSYSTEMS _____________________________________________________ 88TRUE N2 / AIR SWITCHING ------------------------------------------------------------------------------------------------------------------------ 88BATTERY BACK-UP FOR PC, CONTROLLER, CONVEYOR, AND HOOD LIFTS------------------------------------------------- 89PRODUCT TRACKING AND ALARM------------------------------------------------------------------------------------------------------------- 89COMPUTER CONTROLLED EDGE-RAIL LUBRICATION--------------------------------------------------------------------------------- 90AUTO CHAIN LUBE TANK/PUMP ASSY ------------------------------------------------------------------------------------------------------- 91BOARD SUPPORT------------------------------------------------------------------------------------------------------------------------------------- 93CONTROLLED COOLING --------------------------------------------------------------------------------------------------------------------------- 93CONTROLLED EXHAUST SYSTEM (AIR ONLY OR OVENS EQUIPPED WITH AIR SWITCHING)------------------------- 94INTEGRATED EXHAUST STACK FILTER------------------------------------------------------------------------------------------------------ 95FLUX EVACUATION SYSTEM --------------------------------------------------------------------------------------------------------------------- 96FUNCTION OF THE FLUX EVACUATION SYSTEM----------------------------------------------------------------------------------------- 97HOODLIFTS---------------------------------------------------------------------------------------------------------------------------------------------- 99THREE ACTUATOR SYSTEM ---------------------------------------------------------------------------------------------------------------------105INDEPENDENT ALARM SCANNER OVER-TEMP & ALARM/SHUTDOWN---------------------------------------------------------106INDIVIDUAL CELL SENSING ---------------------------------------------------------------------------------------------------------------------107HEATER CELL OVER-TEMPERATURE SWITCHES --------------------------------------------------------------------------------------110LIGHT TOWER-----------------------------------------------------------------------------------------------------------------------------------------111ON-BOARD OXYGEN (O2) ANALYZER-------------------------------------------------------------------------------------------------------112POLAR COOL™ OPTION --------------------------------------------------------------------------------------------------------------------------114EXTERNAL COOLING LIQUID SUPPLY OPTION ------------------------------------------------------------------------------------------119RAIL ADJUST: -----------------------------------------------------------------------------------------------------------------------------------------121SMEMA INTERFACE---------------------------------------------------------------------------------------------------------------------------------124TEMPERATURE PROFILE PLOTTING (PRECISION PROFILING)--------------------------------------------------------------------132


PURPOSE OF THIS MANUAL & WHO SHOULD USE IT

CAUTIONIMPROPER SAFETY PRECAUTIONS OR UNSAFE WORK METHODS MAY RESULT IN SERIOUS INJURY!

The following conditions may be encounteredwhen working on any reflow oven:

High Temperature areas (up to 350o C) High Voltage areas (up to 480 VAC) High Current areas (up to 200 Amps) Moving Mechanical Parts and Systems Heavy Components Sensitive Electronic Components

This manual is intended to meet the needs of service personnel responsible for the regular service of Vitronics-SoltecReflow Ovens. Vitronics-Soltec does not consider this manual a specification for Vitronics-Soltec products or anycomponents contained in those products and reserves the right to change information contained in this manual withoutnotification. This manual is intended to be a reference. Some of the topics explain manufacturing and assemblymethods and practices; however, many topics deal with specific service information and methods. Hopefully, insight willbe provided about the various sub-systems of the electrical control system to allow quick identification of problems andpossible solutions.

IT IS THE RESPONSIBILITY OF THE END USER TO ENSURE THAT ONLY QUALIFIED PERSONNELSHOULD BE ALLOWED TO WORK ON THE EQUIPMENT. THIS MANUAL IS FOR SERVICE OF VITRONICS-

SOLTEC OVENS BY TRAINED QUALIFIED PERSONNEL. AN APPROPRIATE UNDERSTANDING AND USE OFSAFETY PROCEDURES WHEN WORKING ON AND AROUND THE OVEN IS NECESSARY

Some people who might use this manual are:

• Vitronics-Soltec service technicians• Customer service technicians• Customer facilities maintenance personnel• Technical operators


CONTROL PANEL SYMBOLS

XPM2 OPERATOR CONTROL PANEL

KEY SWITCH RAISESAND LOWERS THE

OVEN HOOD

SELECTOR SWITCHADJUSTS RAIL

IN or OUT


GLOSSARY OF TERMS GLOSSARY OF TERMS & MEASUREMENT CONVERSIONS

999 º C Indicates an open thermocouple or thermocouple connection.

Actuator The lift cylinders used to raise and lower the top section of the oven.

AI Analog Input board. One of the boards in the Oven internal control unit.

Antistatic Device to inhibit the generation and instantaneous dissipation of static electricity.

Control Ladder Oven electrical schematic which show the relationship of all electrical circuits the ovencontroller and to each other

DC Drive An electronic power amplifier used to control the speed of DC motors.

E-stop Emergency stop switch

EPO Emergency Power Off

Encoder The electronic mechanism that supplies feedback information to the oven controller on how fastthe conveyor system is moving.

ESD Electro Static Discharge.

FNPT Female National Pipe Thread.

GPM Gallons Per Minute.

Heat slinger A set of fan blades mounted on the shaft of every cell motor. The function of a heat slinger is topush heated air away from the motor windings and thus prevent premature motor failure.

Heater panel A large aluminum “sandwich” panel on the face of each heater cell in the oven.

Heat sink A piece of metal generally used to dissipate heat from some device.

ICB Inter Cell Baffle. These are pieces of metal used to help increase zone definition within theOven process tunnel.

Interlocks Optional Switches used to ensure that the access panels are closed on the Oven.

Inverter Variable Frequency Drive used to control the speed of the convection fan motors in the Oven.

IR Infrared, refers to a component of the heat which is generated in an oven.


LED Light Emitting Diode.

DI Digital Input Board. One of the boards in the Oven internal control unit.

MNPT Male National Pipe Thread.

Offload The end of the oven where product exits the tunnel.

Ohmmeter A precision instrument used to check and display the value of electrical resistances in Ohms.

Onload The end of the oven onto which product is placed and enters the tunnel

Phase One leg of three-phase power.

Plenum A large (or elongated) cavity or chamber, usually in ductwork.

Preheat A thermal area inside a Vitronics-Soltec Reflow oven.

Recipe A file within of the Vitronics-Soltec software in which heater temperatures and conveyor speedconfigurations can be set.

Reflow A thermal area inside a Vitronics-Soltec Reflow oven.

ROSCO Redundant Over-temperature Sensing and Control Option.

RTV (Room Temperature Vulcanizing) The type of silicone sealing agent used in the Reflow oven.

Set point A number used to define a particular parameter in the oven. For example, the temperaturesthat are defined in a recipe are referred to as the heater set points for each heater.

Slot settings Air passages (slots) on both sides of the heater panel that can be adjusted from fully open tofully closed. Slot settings refers to the actual opening size of these air passages.

SSR Solid State Relay

T/C ThermoCouple

OCP Oven Control Program. The software which controls the operation of the Vitronics SoltecReflow oven.

VCS Vitronics Control System – Oven controller consisting of the card cage / backplate, a DI board,and one or more AI boards

Zone An area of a Vitronics-Soltec Reflow oven that is comprised of an upper and a lower cell withinthe process tunnel. Usually referred to as a “heat zone” or “cooling zone”.


MEASUREMENT CONVERSIONS

Temperature LengthDegrees Celsius (°C) = 5 / 9 x (°F - 32) Centimeters (cm) = 2.54 x inchesDegrees Fahrenheit (°F) = (9 / 5 x °C) + 32 Feet (') = 3.281 x meters

Inches (") = 0.03937 x millimetersInches (") = 0.3937 x centimetersMeters (m) = 0.3048 x feetMillimeters (mm) = 25.4 x inches

Area VolumeCentimeters2 = 6.452 x inches2 Centimeters3 = 1000000 x meters3

Inches2 = 0.155 x centimeters2 Centimeters3 = 16.387 x inches3

Feet2 = 10.76 x meters2 feet3 = 0.161 x Imperial gallonsMeters2 = 0.0929 x feet2 feet3 = 35.31 x meters3

feet3 = 0.134 x US gallonsinches3 = 0.061 x centimeters3

inches3 = 0.061 x milliliters (ml)inches3 = 1728 x feet3Imperial gallons = 0.833 x US gallonsImperial gallons (gal) = 0.22 x liters (l)Liters (l) = 1000 x meters3

Liters (l) = 3.7854 x US gallons (gal)Liters (l) = 4.55 x Imperial gallons (gal)Liters (l) = 0.001 x milliliters (ml)meters3 = 0.00455 x Imperial gallonsmeters3 = 0.02832 x feet3meters3 = 0.00379 x US gallonsUS gallons (gal) = 0.264 x liters (l)US gallons = 1.2012 x Imperial gallons

Pressure Volumetric flow ratesBar = 1.01325 x atmosphere (ATM) Imperial gallons / minute = 0.1035 x feet3 / hourKilograms / meter2 (kg/m2) = 10332.3 x atmosphere(ATM)

Imperial gallons / minute = 220.06 x meters3 / Min

Kilograms / centimeter2 = 0.0703 x pounds / inch2

(psi)liters3 / second = 0.06308 x US gallons / minute

KiloPascals (KPa) = 101325 x atmosphere (ATM) meters3 / minute = 0.00006 x centimeters3 / secondKilograms / meter2 (kg/m2) = 703.07 x pounds / inch2

(psi)meters3 / hour = 0.02832 x feet3 / hour

millimeters mercury (mm Hg) = 1 x Torr = 760 xatmosphere (ATM)

meters3 / hour = 0.22713 x US gallons / minute

Pounds / inch2 (psi) = 14.696 x atmosphere (ATM) US gallons / minute = 264.18 x meters3 / minutePounds per square inch (psi) = 14.504 x Bar US gallons / minute = 0.12468 x feet3 / hour


A - CONTROL SYSTEM OPERATION

OVEN CONTROL SYSTEM OVERVIEW

For discussion here, the Oven Control System will be divided into five parts:

• Power Distribution Overview• Computer and Controller Overview• Conveyor Control Overview• Fan Control Overview


HEAT CONTROL OVERVIEW

POWER DISTRIBUTION OVERVIEW

3-phase power supplied to the High Voltage terminals on the electrical panel is distributed to:1) The primary terminals on the Control Transformer (T1), the secondary side of T1 is connected to the line side

of the E-stop relay (K37). T1 provides 120VAC for ALL control functions throughout the oven.2) The line terminals of the Heater Contactor (K2)3) To either the line terminals of the Fan Contactor (K3), or the primary side of the INVERTER (if the oven has

the Nitrogen Option) or three phase Fan transformer if the three phase supply voltage is higher than 240volts.

CAUTION:

WHEN THE OVEN IS “OFF”, MANY PARTS OF THE OVENMAY BE ELECTRICALLY POWERED AND DANGEROUS

.


COMPUTER AND CONTROLLER OVERVIEW

Control of the oven is accomplished by:

1. An IBM ™ compatible COMPUTER runs the Oven Control Program. The computer has a serial communication linkwith the CONTROLLER on the electrical panel.

2. The CONTROLLER interprets the Computer’s requests to energize, de-energize, or modulate devices or sub-

systems within the oven, then receives or sends the necessary signals. If the required signal (in or out) is 5VDC orless, it is handled directly by the CONTROLLER. If a 120VAC output signal is needed, the CONTROLLERcommunicates with the INPUT / OUTPUT BOARD. The I/O board relays will switch the necessary power foroperation.


CONVEYOR OVERVIEW

The electrical portion of the Conveyor System consists of three major components:

1. The DRIVE MOTOR, which drives the belt and/or chain, shafts, and sprockets through a mechanical clutch.

2. The SPEED CONTROL MODULE, which:A. Receives a 120VAC CONVEYOR RUN SIGNAL from the INPUT/OUTPUT BOARD.B: Receives a modulated analog DC CONVEYOR SPEED SIGNAL from the CONTROLLER.C: Sends a variable voltage output to the MOTOR.

3. The ENCODER, driven by the CONVEYOR, which sends a known number of pulses to the CONTROLLER foreach revolution of the conveyor drive shaft.

(10,000 pulses/rev for Stepper Drive Motors and 1,200pulses/rev for Analog Drive Motors)


FAN CONTROL OVERVIEW

1) POWER SOURCE:3 Phase power is provided to either the line terminals of the Fan Contactor (K13), the primary side of theINVERTER, or 3 phase Fan Transformer, or the 3-phase line filter depending on the Oven options and OperatingVoltage.

2) CONTROL ELEMENTS:Air-Only Ovens:FAN CONTACTOR (K13) coil is energized by I/0 Board Output Relay A1-K2, K13’s contacts close, 3 phasepower is permitted to flow to/through the Fan CIRCUIT BREAKER(s). (F41 for all upper Fans & F42 for all lowerFans) to the Fans for Full-Speed On/Off Control.Nitrogen Option Ovens:FAN CONTACTOR (K13) does not exist. I/0 Board Output Relay A1-K2, in this case, serves as the Enableinput to the INVERTER. An analog (modulated) Low Voltage D.C. output from the CONTROLLER signals theINVERTER to vary it’s output frequency to the Fans, resulting in variable-speed Control of the Fans.

3) FANS:The FAN MOTORS are Open Frame, 3 Phase, 50/60 Hz, 1/6 Hp, 2800-3400 RPM @ rated frequency,continuous duty.


HEAT CONTROL OVERVIEW

The electrical portion of the Heat Control System consists of three major parts:1) POWER SOURCE:

Three Phase power is provided to the line terminals of the Heater Contactor (K2).

2) CONTROL ELEMENTS:

A) POWER DEVICES:HEATER CONTACTOR (K2) coil is energized by I/0 Board Output Relay A1-K5, (see Interlocks, below) it’scontacts close, three phase power is permitted to flow to the Heater CIRCUIT BREAKER(s). (Each Heater hasit’s own Circuit Breaker) and to the SSRs (one Solid State Relay for each Heater) which is the final Heater powercontrol element.


2- B) INTERLOCKS:1. Over Temp Switch (es):

Bi-metallic snap switch (es) mounted on each Cell Assembly, open when the temperature exceeds normal operatingtemperature of the Cell. They are all wired in series and power the coil of K4. (K4 is not shown on this Overview) The coil of K2 is wired through the contacts of K4. When an over temperature switch opens, voltage to the coil of K4is lost. This will cause K2 to de-energize, and ALL power will be removed from ALL heaters.(K4 also signals the Controller to shut the Oven down)

2. Heater Thermocouple (IAS Option)A Heater mounted thermocouple connected to the Independent Alarm Scanner option. The IAS output contacts arewired in series with the cell over temperature switches and power to the coil of K4. (K4 is not shown on this Overview) The coil of K2 is wired through the contacts of K4. When an over temperature condition is sensed, the I.A.S boardcontacts open and voltage to the coil of K4 is lost. This will cause K2 to de-energize, and ALL power will be removedfrom ALL heaters. (K4 also signals the Controller to shut the Oven down)

3) Heater Thermocouple (Standard)A Heater mounted thermocouple(s) to sense the temperature of the Heat Cell and connected to the Controller forheater control.

3) HEATERS:

Each Heater Assembly has two large flat Inconel elements (resistors) mounted between two aluminum plates. Each pair of elements may be wired in series or parallel, depending on the operating voltage of the oven.

Heater Schematic See: “Heater Resistance & Replacement Reference Chart” for resistance values


HEATING CELL DESCRIPTION

HEATING CELL CROSS-SECTION

CONSTRUCTION: The heat Cells are assembled and sealed as self-contained units with the Fan Motor, and OverTemperature Switch mounted and wired to terminals, and the Thermocouples (1 or 2) mounted and wired to connectors.

OPERATION: The relatively thick heater assembly has a series of holes allowing heat transfer to the oven gases passingfrom the Cell Cavity to the process tunnel.Recirculation occurs through the low-pressure intakes at the sides of the Cell. These gasses are drawn into the cellcavity, where they are passed through the heater and back into the process tunnel. Fan Speed controls the velocity of the heated atmosphere, which influences the heat transfer to the PCB.

INSULATION

EXHAUST

FAN MOTOR

HEATER ASSEMBLY

THERMOCOUPLES

OVER TEMPERATURESWITCH

HEAT SLINGERFAN BLADES

AIR ORNITROGEN IN


OVEN CELL ARRANGEMENT

The cells are mounted both above and below the conveyor, as shown, forming a series of “Heat Zones”.

Each Heat Zone circulates heat primarily within itself, thereby maximizing the thermal isolation between zones.

An insulated exhaust plenum mounted under the Bonnet collects gases from the individual upper heat cell exhausts andconveys the combined flow to the Plant Exhaust System.

An oven contains several heating zones (5,7,8,10, or 12) and 2, 3, or 4 cooling zones. Cooling zones are identical toheating zones except they have no heating elements and no exhausts (only gas intakes).

A properly operating oven is an inter-dependent system. When a heater or fan malfunctions, the balance andperformance of the oven as a system may be affected. Usually, an irregularity in operation could be the result of any one(or more) malfunctions.

INSULATED CONTROLLEDEXHAUST PLENUM

TO PLANTEXHAUST

SYSTEM

CELL 2BCELL 1B CELL 3B

CELL 4TCELL 3TCELL 2TCELL 1T

Zone 1


B - HEATING SYSTEM

In the following “Problems and Possible Solutions”, the most likely cause is listed first...investigate the most likely first,then proceed to the next one in the list.

PROBLEMS AND POSSIBLE SOLUTIONS (The most likely cause is listed first)

HEATING PROBLEMS

OVER TEMPERATURE PROBLEM: Not more than 10o C above set point and stable:

1. Temp drift from adjacent heater See: 1,2 2. Possible cell fan failure: See: 2, 3

Slow rise past set point:

1. Temp drift from adjacent heater See: 1, 2 2. Thermocouple problem in opposite heater See: 5 3. Radical recipe change See: 31 4. Short to ground in heater See: 8

Rapid rise past setpoint.

1. Latched control SSR See: 7, 12 2. Loose thermocouple wire See: 25 3. Controller Failure See: 11 4. Radical recipe change See: 31 5. DC stage of control SSR hot See: 4


UNDER TEMPERATURE PROBLEM.

CELL TEMPERATURE RISES, BUT DOES NOT REACH SET-POINT: 1. No power to heater:

2. Open circuit breaker See: 10

3. Control SSR failure See: 12

4. Loose wire See: 16

5. Open heater element See: 13

6. Shorted thermocouple See: 18

7. Excessive exhaust flow See: 14

8. Excessive air entering oven See: 15

9. Under voltage or Phase failure See: 19

Cell appears to stay cold:

1. Thermocouple short See: 18

2. Controller failure See: 11

3. General oven failure See: 20

Temperature drops down below set point:

1. Power loss to heater. See: 19,21 2. Control SSR failure See: 12 3. Thermocouple short See: 18 4. Controller failure. See: 11 5. Radical recipe change See: 31

RANDOM HIGH TEMPERATURES.

1. Thermocouple connection See: 25

2. Grounding. See: 28

3. Conveyor motor noise. See: 26

4. Failure of control SSR See: 12

5. AC Signal on T/C or T/C Wires See: 27

RANDOM LOW TEMPERATURES.

1. Failure of control See: 11

2. Erratic exhaust. See: 14


3. External air forced into heat tunnel See: 30

COLD SOLDER JOINTS 1. Conveyor speed See: 22

2. Dirty circuit board See: 23

3. Old solder paste See: 24

4. Cell fan motor malfunction See: 3


TEMPERATURE DRIFT FROM A NEARBY HEATER A Cell temperature is higher than set point, not more than 10o C, and stable. POSSIBLE CAUSES

The problem is most likely the result of temperature drift from a nearby Cell. The recommended method to locatethe offending Cell is to turn off the nearby Cell heaters one at a time, and look for a change in the symptom when eachone is off.

Refer to the “HEAT CELL ARRANGEMENT” illustration, and consider the following possibilities on all sizes of ovens: *

If Cell 3T temperature is higher than set point, then Cell 3B, 2T, 2B, 4T, or 4B could be at fault.If Cell 4T temperature is higher than set point, then Cell 3T, 3B, or 4B could be at fault.

The Cell slot settings can cause thermal drift: Cell 4T’s left slot open and right slot closed could cause thermal drift fromCell 4T to Cell 3T.

CELL FAN MOTOR MALFUNCTION IN AN NEARBY CELL A Cell indicates an over- temperature condition of not more than 10o C above set point and is stable. This is may be the result of a Cell Fan Motor malfunction in a nearby cell.

POSSIBLE CAUSESThe TC senses a combination air/IR temperature. When the fan fails, the controller will try to heat the metal heater platehot enough to read normal set point. The heat that is radiated is then absorbed into the air of an adjacent cell, causingthe adjacent cell to go above set point.

HINT: If a stopped motor is suspected, visually check the heat slinger fan blades. The heat slinger is a set of fan bladesmounted directly on the motor shaft between the motor and the outside of the cell. If the heat slinger is turning, the motoris turning. The motor should be turning in a counter clockwise direction as viewed from the outside of the cell. If the ovenhas the Individual Cell Fan Sensing Option check for an LED that is lit, indicating a cell motor that is not turning.

See Heat Cell cross-sectional Diagram in “A-HEATING CELL DESCRIPTION”

2

1


CELL FAN MOTOR MALFUNCTION

A Cell Fan Motor malfunction can produce the following symptoms:1) A Cell slowly reaches setpoint.2) Cold solder joints on the product.

CHECK: Rotation of the Motor can be confirmed by a visual check of the heat slinger fan mounted on the motor shaftbetween the Motor and the Cell. During normal operation, the heat slinger fan turns counter clockwise as viewed fromthe outside of the cell.

SYMPTOM # 1A cell over temperature approximately 10o C during startup,POSSIBLE CAUSESWith this symptom, some careful investigating is necessary to find the problem. If the blower motor malfunctions, theheat at the T/C will not change much. There will not be any convection in that zone, creating the possibility of temperaturedrift from an adjacent heat zone.

SYMPTOM # 2A Cell slowly reaches setpoint.POSSIBLE CAUSESThis condition may occur when the motor is non-functional and the oven is just starting up. If the motor is not blowing air,the Zone will take longer to heat up and the temperature at the faulty Cell will not reach set point. The T/C in the faulty cellwill sense the Infrared radiation from the Heater Panel

SYMPTOM # 3Cold solder joints on the product.POSSIBLE CAUSESCheck for a group of fans not operating because of a tripped circuit breaker or because of an Inverter malfunction.If cold solder joints on the product may be an indication of a faulty fan in just about any location in the oven. The heattransfer in the oven works by air volume and velocity. If a fan is not operating, the T/C for that cell could still register theapproximate correct temperature because the heater panel has reached the temperature setpoint. The amount ofconvection in that zone will be significantly lower than normal. Since the heat is transferred by air moving over thecomponents and joints of the product, smaller airflow produces less heat transfer. The faulty fan could be anywhere in the oven because if the product is not up to the required temperature upon enteringthe reflow zone, it will probably not be at the “reflow temperature” for the required time. (Cold solder joints can beproduced if the preheat is incorrect, the preflow temp is low, or the reflow temp is low)

3


DC STAGE OF CONTROL SSR IS HOT A Cell is indicating an over temperature condition with the temperature slowly (or rapidly) risingpast the set point. This may be caused by the DC stage of the control SSR getting hot.

POSSIBLE CAUSESThe control SSR is mounted on a heat sink (the electrical back-panel) because the normal operation generates heat inthe SSR. If the SSR is not making a good thermal connection with the electrical back panel, it may get excessively hotduring normal operation. When the SSR gets too hot, the control side can "conduct" for as many as three extra ACcycles. This little bit of additional power to the heater will cause a slow temperature rise. If the SSR is "conducting" morethan three cycles, the additional power will cause a more rapid temperature rise.The solution is to replace the faulty SSR when it is located. Use an adequate amount of heat sink compound whenreplacing the SSR.

HINT: Cool the SSRs in the electrical enclosure by blowing cool air on them with a fan.If the cooling of the fan causes the symptom to go away, replace the bad SSR.

THERMOCOUPLE PROBLEM IN OPPOSITE CELL HEATER Cell temperature slowly rises past the set point.

POSSIBLE CAUSESThis problem may be caused by a T/C (thermocouple) problem in the opposite Cell heater.Visually monitor the power supplied to the “problem” Cell heater: This can be done by viewing the Percent Output line onthe oven monitor screen. This option must be enabled in Setup, Display Layout, for it to function. Another method it tolook at the appropriate LED on the SSR relay board and/or check the Percent Power Indicators in the Control ProgramOperating Screen on the Oven Computer. If the SSR LED is not on, (indicating little or no power applied) then the T/C onthe opposite Cell heater may be defective. Shut down the oven and open the Circuit Breaker to the opposite Cell heater. Restart the oven and watch for the ”problem” Cell temperature to stabilize at set point. If it does stabilize properly, thenthe T/C in the opposite Cell heater is probably defective or has a loose connection. (Refer to the “HEAT CELL ARRANGEMENT” illustration.)EXAMPLE: If Cell 1T is over temperature, open the Circuit Breaker for Cell 1B heater. After restarting, if Cell 1Tstabilizes at set point, the problem may be the Cell 1B T/C.EXPLANATION: If a T/C is defective, then the Controller interprets the low of T/C signal as a “cold Cell” and continues toheat the Cell beyond set-point. The resulting excess heat is transferred to the opposite Cell and sensed by the T/C there,causing a reduction of applied power to the opposite Cell heater. (The oven controller is “fooled” by the low t/c signal)

4

5


(FOR FUTURE USE)

LATCHED CONTROL SSR A Cell has an over- temperature condition with a rapid rise past set point. The cause may be a latched (failed in the “ON” condition) control SSR.POSSIBLE CAUSESIf the LED on the SSR controller board is NOT on, but the heater is getting hotter, a failed SSR could be the cause. TheSSRs provide AC power (200 to 480V) to the heaters for short periods of time (cycles) determined by the Program andthe temperature sensed by the thermocouple.When an SSR latches “ON”, the heater is turned on without any limiting control.If this is the case, the SSR has failed and must be replaced. Remember to use enough heat sink compound whenreplacing the SSR.

SHORT TO GROUND IN HEATER A short in the heater should produce a slow temperature rise past set point. The temperature increase is aresult of the power leg that goes straight to the heater making a circuit to ground.

POSSIBLE CAUSESThe “short to ground” could be in the wires, heater’s ceramic blocks or the heater itself. The “short to ground” will have tobe isolated and repaired.

(If the short is in the heater or the terminal blocks, the heater panel will require replacement.)

7

8

6


(FOR FUTURE USE)

OPEN CIRCUIT BREAKERA Cell is indicating an under temperature condition where the temperature rises but does not reachset point. The cause may be an open circuit breaker or conductor in the heater power circuit.POSSIBLE CAUSESWhen a circuit breaker opens, power is not supplied to the heater. The Cell temperature rise is probably thermal drift fromnearby cells caused by the Cell Fan motor recirculating air in the tunnel between the Top and Bottom Cells in the zone.Check the Operating Screen for a heater receiving power at a high percentage rate. The opposite heater in the sameZone probably is receiving extra power to compensate for the nonfunctioning heater. The nonfunctioning heater shouldindicate almost 100% power and the opposite heater in the same Zone should indicate about 50% power (normal is 10%to 30%).Circuit breakers are identified as F1-B, F1-T to F12-B, F12-T. (-B = bottom, -T = top)Reset the circuit breaker. Then, if:1) The circuit breaker trips again, very likely there is a short to ground in the heater conductors or the heater.2) The circuit breaker does not trip again, but Cell temperature does not return to normal. Very likely there isan “open” in the heater circuit or heater.3) The circuit breaker does not trip, and Cell temperature returns to normal. Should the Circuit Breaker trip again later, it might indicate an intermittent problem with the Circuit Breaker or the heater circuit.

10

9


CONTROLLER FAILURE

SYMPTOM # 1A Cell indicates an over temperature condition with the temperature rapidly rising past set point. The failure of a singleoutput on the controller is a possibility.POSSIBLE CAUSESIf a single output on the controller fails with a short to ground, the heater will receive full power continuously. Duringnormal operation, the SSR receives a ground signal from the controller output, and it turns on the AC power to the heater. Therefore, when the output shorts to ground, the heater is “ON” all of the time. If this condition occurs, the controller mayor may not be aware of the fault condition, but, could not do anything about it because the failed output was the only wayfor the controller to control the heater. These symptoms indicate the need to replace a faulty controller.HINT: To help isolate this problem, disable the suspect heater in the software and then watch the SSR board LED forthat heater. If the LED is on after the heater has been disabled, then the controller output may be faulty.

SYMPTOM # 2A Cell indicates an under temperature problem in which the cell appears to stay cold.This condition can be caused by a controller failure.POSSIBLE CAUSESThis condition will only occur when starting the oven from a cold state. When/if a single output of the controller fails, it ismost likely to fail “open”. If this happens, the SSR (and its heater) will never be turned “ON”. The SSR requires a groundsignal to turn “ON” to supply AC power to the heater. Should there be a general controller failure, all outputs (and SSRs)should be “OFF” and all the heaters should be cold. These symptoms indicate the need to replace a faulty controller.HINT: To help isolate this problem, enable the suspect heater in the software and then watch the SSR board LED for thatheater. If the LED is never on after the heater has been enabled, then the controller may be faulty.

SYMPTOM # 3A Cell indicates an under temperature condition where the temperature falls from set point.POSSIBLE CAUSESThis condition can be a result of 1) a controller failure, 2) or loose SSR screws, 3) loose power wires to heater.

HINT: To help isolate this problem, enable the suspect heater in the software and then watch the SSR board LED for thatheater. If the LED is never on after the heater has been enabled, then the controller output is faulty.NOTE: If the oven is operating and up to temperature, it may take some time for the cell to cool down enough to verifythe state of the output, SSR, and heater.

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FAILED CONTROL SSR SYMPTOM # 1A Cell indicates an under temperature condition where the temperature rises but does not reach set point.The Cell may not be heating because the control SSR has failed or is failing.POSSIBLE CAUSESWhen an SSR fails open, power is not supplied to the heater. The Cell temperature rise is probably thermal drift fromnearby cells caused by the Cell Fan motor recirculating air in the tunnel between the Top and Bottom Cells in the zone.Check the Operating Screen for a heater receiving power at a high percentage rate. The opposite heater in the sameZone probably is receiving extra power to compensate for the nonfunctioning heater.

If the control SSR fails to operate for ANY reason, the default is to not conduct.If the SSR fails internally, it could fail in the open state it will not conduct AC power to the heater. Replace the faulty SSR. When replacing an SSR, use adequate amounts of heat sink compound on the back of the new SSR when mounting it tothe electrical panel.

SYMPTOM # 2A Cell indicates random high temperatures. The Cell can no longer hold set point because the control SSR has failed or isfailing. This condition may occur during normal operation.POSSIBLE CAUSESAn over-heated SSR can fail in the “ON” (conducting) condition after receiving an “ON” signal from the controller output.The failed SSR will have to be replaced. Use adequate amounts of heat sink compound on the back of the new SSRwhen mounting it to the electrical panel.

SYMPTOM # 3A Cell indicates random low temperatures. The Cell can no longer hold set point because the control SSR has failed or isfailing. This condition may occur during normal operation.POSSIBLE CAUSESThe SSR may be over-heated. Replace the SSR with adequate heat sink compound on the replacement SSR whenmounting it.

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OPEN HEATER ELEMENT A Cell indicates an under temperature condition where the temperature rises but does not reach Set point. This condition may be caused by an open heater element.POSSIBLE CAUSESThe heater is physically broken (open) and is an interrupted electrical circuit. A complete (uninterrupted) path for theapplied electricity is necessary to generate heat.The Cell temperature rise is probably thermal drift from the opposite cell caused by the Cell Fan motor recirculating air inthe tunnel between the Top and Bottom Cells in that zone. Check the Numeric Screen for a heater receiving power at ahigh percentage rate. The opposite heater in the same Zone probably is receiving extra power to compensate for thenonfunctioning heater.HINT: Perform a continuity test on the suspect heater. Turn off power, disconnect the power leads at the Cell terminals toelectrically isolate the heater, then check the resistance of the heater elements.

Refer to the HEATER RESISTANCE AND REPLACEMENT REFERENCE CHART in the HEATER TESTINGPROCEDURE.

(See Table of Contents in this manual)

SPECIAL NOTE: if the oven operates on 200V, 208V, 220V, or 240V, and the resistance measures 18 Ohms or more,then, one (1) of the parallel heaters is “open”.

The diagram below represents a heater assembly within a Cell.

If the heater assembly does not resistance check close to the listed values, (or, if any measurement shows “open”), theheater assembly must be replaced. Resistance values vary slightly between heaters in Air and Nitrogen Ovens.

To replace a heater assembly, refer to “Heater Remove / Replace Procedures”.

EXCESSIVE EXHAUST FLOW

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One (or more) Cells is indicating an under temperature condition where the temperature rises, but doesnot reach set point. Excessive factory exhaust flow is a possibility.POSSIBLE CAUSESIf the factory exhaust flow is much too high, then the oven will lose large amounts of heated gas while trying to heat up to“Process Ready”. Because of this, the oven can only raise the internal temperature to some level lower than the setpoint. Throttling the factory exhaust flow will reduce the cooling effect of cold air infiltration to the oven and allow it tocome up to setpoint temperature.HINT: Check actual exhaust rate and compare it to the recommended exhaust rate in the Site Preparation Manual.

EXCESSIVE AIR ENTERING THE OVEN One (or more) Cells is indicating an under-temperature condition in which the temperature risesbut does not reach set point. Too much cool air entering the oven is a possibility.POSSIBLE CAUSESThis condition may be caused two different ways:1) Incorrect ICB settings. The ICBs must be properly adjusted to bias the airflow correctly on both ends of the oven.

This may mean air coming slightly into the oven at the ends, but not an excessive amount (ICBs can be adjusted toexpel a small amount of air). Whichever setup is selected, it must be correct for the oven and application.

2) Other external sources of cool air are always a possibility. For example, a large fan or room air conditioning blowingcool air towards the oven opening.

(ICB = Inter Cell Baffle)

LOOSE WIRE A Cell indicates an under temperature condition where the temperature rises but does not reach set point.A loose or open conductor supplying electrical power to the heater may cause this condition.POSSIBLE CAUSESThe heaters all have four connections for AC voltage and ground INSIDE the cell. Any of the four could be loose. Theconductors supplying the heaters run from the circuit breakers to the SSRs, out of the electrical panel, across the 'tops' ofthe cells to terminal blocks on the Cells.If this condition occurred after changing a component, check for captured insulation on wires and terminals. Tighten anyloose connection(s) found, then check the operation of the oven

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(FOR FUTURE USE)

SHORTED THERMOCOUPLE

SYMPTOMS:1) A Cell indicates an under temperature condition in which the temperature rises but does not reach set point.2) A Cell indicates an under temperature condition in which the cell appears to stay cold. (The actual temperature

could be very high.)3) A Cell indicates an under temperature condition. (The Cell temperature was operating at setpoint, but now has

dropped from setpoint.)

POSSIBLE CAUSESA shorted Thermocouple is a possibility. When a T/C is shorted, the two T/C conductors touch each other (notintentionally) somewhere between the controller and the T/C sensing tip. The temperature “sensing” occurs at the locationof the “short”, instead of the tip.The thermocouple is intended to “sense” the temperature at the cell face, so when a T/C shorts, the “indicatedtemperature” will be lower than the “actual temperature” at the cell face.HINT: Check the percent power indicators.One Cell in the Zone with the shorted T/C should be at 100% power and the opposite Cell should be at 0% power.One cell will shut off (0%) because the shorted Cell (100%) is causing a high tunnel temperature because ofmisinformation received from the shorted T/C.HINT: When this under temperature condition exists, check all T/C terminations and connectors. A simple check for ashort: remove the T/C connector from the cell and check the percent power indicators to see if the Cell stops overdriving. (An open T/C should read as 999o C.)

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PHASE FAILURE A Cell is indicating an under-temperature condition in which the temperature rises but does not reachset-point. An under voltage condition is a possibility. The under voltage condition can occur when one phase of the power drops out.POSSIBLE CAUSESAt lower voltage, the heater will produce less heat. Check the voltage at the Circuit Breakers first. If supply power is O.K.,then the problem is with the heater or heater conductors. On reduced voltage, the heater may not produce enough heatto reach set point during start-up. (Each heater is connected to two phases of the three-phase power)HINT: Check the heater conductors where they pass through the metal tube on the top of the cell. Remove the heaterplate and check the conductors and connections inside the Cell at the heater’s terminal blocks. Missing a leg could meanthat the circuit breaker for the heater tripped, or it could be a bad connection on the heater panel itself at the terminalblocks. It could also be a bad connection anywhere in the wiring from the relay board to the heater.

* This could cause both legs to be without power.

GENERAL OVEN FAILURE There is an under temperature condition where the entire oven appears to stay cold. This conditionis probably the result of a major oven control failure.POSSIBLE CAUSESSome reasons for this type of failure might be:1) The controller fails to activate any heaters. (The AI board may have failed)2) The 3-phase power turns into single-phase power (loss of 1 power leg) and some heaters will not operate properly.

(Heaters are single phase and with the loss of one phase, depending on which phases supply power to them,some would operate properly.)

3) The control transformer circuit breaker tripped producing a power loss to all 120 VAC devices (K2 will de-energize and remove power from the heaters)

POWER LOSS TO HEATER A Cell indicates an under temperature condition following a drop from set point. This might be a resultof power loss to a heater.POSSIBLE CAUSESWhen the power to a heater is taken away, the heater cannot maintain the heat level that it has attained. The result is theheat level in that cell dropping from the set point to some lower value. This may also be the result of thermal drift to alower temperature section of the oven. If the temperature drop is showing up in a cell which is a boundary cell for atemperature change, and the heater in one of the lower temperature cells stops working, the thermal drift from high to lowmay show up as a drop from set-point in the (normally) higher temperature cell. One possible way to find this failurewould be to disable power to the suspect heater in the software and watch for no change in the symptom. If there is achange in the symptom, then the heater in question may not be the one that failed.

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CONVEYOR SPEED Cold solder joints on the product may be caused by a problem with the conveyor speed.POSSIBLE CAUSESConveyor Calibration: The conveyor speed must be set correctly to allow the optimum time for the product to stay in thevarious heat zones. If the conveyor calibration is not correct, the product may be traveling faster than the indicated speedand not be getting enough heat to reflow properly before leaving the oven.Encoder Error: If the encoder assembly were returning incorrect values to the controller, the results would be the same asthe above “Conveyor Calibration” description.Controller: If the controller is having a problem, it could be causing a conveyor problem.

If a conveyor speed problem is suspected as the reason for cold solder joints, refer to the conveyor system overview atthe beginning of this troubleshooting manual for other information and troubleshooting tips.

DIRTY CIRCUIT BOARD The product has cold solder joints due to dirty circuit boards.POSSIBLE CAUSESThe heat and flux in solder paste in the oven can overcome a limited amount of oxidation and contaminants.If cold solder joints are being produced due to impurities on the boards and components, check the stock going into theoven. The stock may need to be rotated sooner or pre-cleaned before soldering. If the boards are not clean, raising the heat in the oven will probably not do much to resolve the problem.

OLD SOLDER PASTE The product has cold solder joints due to old solder paste.POSSIBLE CAUSESThis condition can not be "fixed" by raising the heat. Check and/or change the solder paste currently in use. Check the date(s) on the solder paste to be certain that it has not passed the expiration date. Keep the supply of solderpaste rotated so that the oldest paste gets used first. USE FRESH SOLDER PASTE FOR BEST RESULTS

NOTE: the paste being on the board for too much time before the reflow process occurs can also cause this condition.

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THERMOCOUPLE CONNECTION The oven is indicating what appears to be a random high temperature due to a bad thermocoupleconnection.POSSIBLE CAUSESThis condition is an indicator error, because the actual temperature is probably acceptable. When a thermocouple getsopen in its conductor(s), it indicates the maximum possible temperature. It produces a higher indicated temperature thanexpected. It is also possible to have the open exist for one sample time and not for the next sample time, therebyproducing a short indication of maximum temperature and then normal temperature immediately after. If the connectionis not open but simply high resistance, then the temperature indication could be higher than the actual temperature.HINT: Check the connector(s) where the T/C plugs into the conductors on top of the cell and the terminations at thecontroller.

CONVEYOR MOTOR NOISEThe oven is indicating random high temperatures due to conveyor motor noise.POSSIBLE CAUSESThe conveyor motor is a DC motor with a set of brushes, which may emit a high, pitched audible noise. When thebrushes make this noise, they are also generating electrical noise, which can be transmitted to various parts of the oventhrough the wiring. The T/C conductors are not shielded, so it is possible for the T/C conductors to pick up electricalnoise from nearby wires. The electrical noise on the T/C conductors can cause the system to indicate random hightemperatures.If the conveyor motor is noisy, try replacing the motor brushes, the motor or shielding the T/C wire for its entire length inthe oven.

AC ON T/C or T/C WIRES The oven is indicating random high temperatures due to an AC signal on the thermocouple or thethermocouple wires.POSSIBLE CAUSESThis is very similar to the conveyor motor noise problem.THERMOCOUPLE / CONDUCTORS: The AC on the T/C or T/C wires is interpreted by the controller as a highertemperature. Since the AC is not the normal signal, it is intermittent and random. The AC is closer to the controller thanthe T/C so it shows up as a higher temperature than normal.HINT: Disconnect the T/C at the controller (Jumper T/C terminals on controller) and check for the AC with anoscilloscope. If it is still on the T/C wires, disconnect the T/C at the top of the cell to isolate the problem from the inside ofthe cell or the wiring in the oven.FRAME: Make sure that the AC is not on the oven frame. (Since the T/Cs are grounded, AC on the oven frame canshow up on the T/Cs.)

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GROUNDING PROBLEMS The oven is indicating what appear to be random high temperatures due to a grounding problem.POSSIBLE CAUSESEach T/C is grounded at the controller when it is properly connected. If there is a poor connection to ground at this point,the T/C reading will be unreliable and will indicate random high temperatures.Check the ground connection AT THE CONTROLLER. Make sure that it is correct.Use an Ohmmeter to check the connections and refer to the oven prints to make sure that the connections are correct.(The grounding problem is usually electrical noise on the ground or a faulty facility ground with high resistance. This canresult in the noise affecting the T/C reliability.

(FOR FUTURE USE)

EXTERNAL AIR FORCED INTO HEAT TUNNEL The oven is exhibiting random low temperatures due to external air entering the oven tunnel.POSSIBLE CAUSESICBs (inter cell baffles): If the ICBs are improperly adjusted, it allows air from outside to enter the oven tunnel, resulting inrandom low temperatures (Refer to the chart of initial slot settings for the oven.)EXTERNAL DISTURBANCES: The reflow process is also susceptible to external cold air and large airflow events outsidethe oven. For instance, locating the oven next to a large loading dock area could cause this problem. The XPM Seriesovens are not very susceptible to external influences, but under the right circumstances, this is a possibility.AIR LEAKS: Check for air leaks in the oven tunnel.

(External air forced into the Oven tunnel usually affects only the first 1 or 2 zones)

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RADICAL RECIPE CHANGE

SYMPTOMS 1 through 6For all of the following symptoms:

1. Temperature =< 10 degrees above setpoint and stable2. Temperature slow rise past set point3. Temperature rapid rise past set point4. Temperature rises but doesn’t reach set point5. Temperature appears to stay cold6. Temperature drops from set point

POSSIBLE CAUSESA radical change in the running recipe can cause these symptoms. An example of a radical change would be switchingfrom a reflow recipe to a curing recipe or vice versa. If you are experiencing this problem and cannot work around it, callthe Vitronics-Soltec Field Service or Applications Support departments for assistance.

(FOR FUTURE USE)

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HEATER TESTING PROCEDURE

When a heating problem is suspected, applying this procedure should reduce the time required to eliminate a number ofitems that may NOT be responsible for the problem. This will leave a much smaller number of possibilities forconsideration.

To be effective and efficient, the trouble-shooting process does not jump directly to the “answer”, but rather, eliminates allof the possibilities one-at-time with a systematic approach, until only the “answer” remains.

SIMPLIFIED HEATER CONTROL CIRCUIT

EXPLANATION:

Each heater has a Circuit Breaker and SSR. K2 supplies two hot, high voltage conductors to the Line Side of the HeaterCircuit Breaker(s). Both of the current paths are interrupted by the Circuit Breaker when it is open or tripped.

A) On the Load Side of the Circuit Breaker, one of the conductors goes directly to the heater terminals (HT-A,HT-B, HT-C) on the outside of the Heater Cell.

B) The other conductor is interrupted by the SSR. When the SSR operates, it conducts power from the CircuitBreaker to the heater terminals (1, 1A, and 2) on top of the Heater Cell.

O.K. TEST: Check the heater(s) for agreement with the “HEATER RESISTANCE REFERENCE CHART” afterdisconnecting the supply conductors at the heater terminals (HT-A, HT-B, HT-C) on top of the Heater Cell. (This does work, however, it is time consuming, and does not check theconductors between the Circuit Breaker / SSR and the Heater Cell.)BEST TEST: The heater(s) and conductors can be checked at the Circuit Breakers/SSRs. Reference the “ HEATERRESISTANCE CHECK LOCATIONS” diagram.


PROCEDURE:

1) Disconnect ALL POWER to the Oven. 2) Check for Tripped Heater Circuit Breakers, (F8 & F11 are not heater circuit breakers) If a circuit breaker is tripped

(open), (See 10, and 17 in the Heating System Diagnostic tree) 3) Open ALL Heater Circuit Breakers: F1-B to F12-B and F1-T to F12-T (Depending on Oven size, the highest CB No.

may not be 12 as shown in the illustration on the next page) 4) Perform Resistance Checks. See “HEATER RESISTANCE REFERENCE CHART” (Oven Type & Voltage must be

known) See “ HEATER RESISTANCE CHECK LOCATIONS” and connect Meter (M) on CBs and SSRs as shown.A) If the resistance is “infinite” (open), the Heater may have a broken/disconnected wire or the heater element

may have an “open” in it.B) If the resistance on Parallel wired Heaters - (see “CHART”, Fig A)- is twice what it should be:

1. One Heater element may be “open”2. One conductor from the Heater may be disconnected. 3. The jumper from term (1) to term (1A) may be missing or loose.

C) If the resistance is in agreement with the “HEATER RESISTANCE REFERENCE CHART”, then it isreasonable to expect that the Heater and its conductors are in proper operating condition.

5) Close ALL Heater Circuit Breakers.

6) Refer to “HEATING - Problems and Possible Solutions” for other possibilities.


CAUTION:

DISCONNECT ALL POWER BEFORE TESTING

Heater Resistance Check Locations

Read resistance with Ohmmeter acrossthese two terminals to check the heater

resistance for Heater No. 1-B.(Heaters 2B thru 12B are similar)

Read resistance with Ohmmeter across thesetwo terminals to check the heater resistance

for Heater No. 12-T.(Heaters 2T thru 12T are similar)

Top Heater Circuit Breakers

Bottom Heater Circuit Breakers


Fig. A Fig. B (Parallel) (Series)

XPM2 Release Date: February 25, 2004

Heater Element Resistance Reference Chart

VOLTAGE RESISTANCE HOLE SIZE HEATER ASSY #(stamped on face plate)

ELEMENT #(2 ELEMENTS PER

HEATER)

.136” 3085401200 - 208 Volts

(LOW RANGE)

Test: 8.55 Ω - 9.45 Ω9.0 Ω nominal

18.0 Ω = 1 open element

.170” 3160501

0866601

.136” 3085401380 - 415 Volts

(LOW RANGE)Test: 34.20 Ω - 37.80 Ω

36.0 Ω nominal.170” 3160501

0866601

.136” 3085402220 - 240 Volts

(HIGH RANGE)

Test: 11.40 Ω - 12.60Ω12.0 Ω nominal

24.0 Ω = 1 open element

.170” 3160502

0904001

440 – 480 Volts

(HIGH RANGE)

Test: 45.60 Ω - 50.40 Ω48.0 Ω nominal

.136” 30854020904001


TEST PROCEDURE FOR HEATER GROUND CONTINUITY

1) Disconnect the main power connection to the oven and disable all heater circuit breakers.

2) Check each line to the respective heater element for a short to ground using an Ohmmeter.

3) The heater element conductors should be completely isolated from ground (i.e. open circuit with reference to ground).

MAXIMUM HEATERS ON

The Oven Control Program limits the maximum number of heaters to be energized at the same time to seven.

MAXIMUM PHASE IMBALANCE

The difference between the maximum loaded phase and the minimum loaded phase is limited to two heaters by the OvenControl Program. The Oven Control Program limits the number of heaters “ON” at the same time for each phase.

THERMOCOUPLES

All thermocouples in the oven are type 'K', and identified by a red (-) and a yellow (+) wire. Connectors, wires andterminals must be designated for use with type “K” thermocouples.

TEST PROCEDURE

1) Remove the thermocouple connection block from the front of the AI board in the Oven controller.

2) Measure the resistance of each thermocouple using an Ohmmeter. (All T/Cs have one side connected to ground.For

best results, isolate the T/C being tested)

3) The resistance of a thermocouple wire should be approximately 5 ohms.

4) Test for shorts between the thermocouple wires by disconnecting the thermocouple cable from the plug on the

outside of the cell.

5) Measure the resistance between the two thermocouple wires; it should be open circuit with the connector removed

from the front of the controller.

6) Check for short circuit to ground on both thermocouple wires.

7) Wiring connections must be tight. Verify that all negative thermocouple connections are grounded, along with all

unused thermocouple ports on the front of the controller.

8) Check to determine that one side of the TC probe is NOT common to ground.


HEATER PLATE REPLACEMENT

CAUTION:

BEFORE STARTING ANY MAINTENANCE, DISCONNECT THEOVEN FROM ALL POWER SOURCES.

TOP HEATER REPLACEMENT

1. Locate the defective heater.2. From inside the tunnel, remove the ICB (inter-cell baffles) from either side of the heater cell.

NOTE: DO NOT REMOVE THE BACK ANGLE BRACKET.

3. Note the location of the thermocouple(s) and circle the hole(s) with a permanent marker. Unscrew the bracket holdingthe thermocouple in place and gently straighten the thermocouple.

NOTE: DO NOT USE PLIERS TO STRAIGHTEN THE THERMOCOUPLE(S).

4. Remove the angle bracket (at front of top heater plate) ( at front and back on bottom heater plates)5. Carefully ease the heater plate away from the cell body to expose the wire connections.6. The terminal blocks are fragile, CAREFULLY disconnect the wires from these blocks. (Using two wrenches (11/32"

open end wrenches 1/8" thick or less), 1 to hold the nut and 1 to turn the screw- (Air Oven Panels only)7. Disconnect the ground wire.8. Install the new heater plate following the removal sequence in reverse. Be sure that the thermocouple(s) goes

through the correct hole in the heater plate.

BOTTOM HEATER REPLACEMENT

1. Locate the defective heater. 2. For edge rail systems: remove the top mounting screws from the rails. Remove the chain from the sprockets and

prop the rails out of the way of the heater plate. 3. For mesh conveyor systems: prop the conveyor out of the way of the heater plate and remove the wear rods. 4. Follow instructions 2 to 8 in the TOP HEATER REPLACEMENT instructions above.

TEST PROCEDURE FOR HEATER CONTROL

NOTE: DISABLE ALL HEATER CIRCUIT BREAKERS BEFORE PROCEEDING WITH THE TESTS INTHIS SECTION.

Ensure that the screws clamping the PCB to the SSRs are all tight. Do not over-tighten as this strips the thread in theSSR.Manually activate the heater outputs within the Oven Control Program. NOTE: This operation may require a password.Check all SSRs by activating them one at a time, and viewing the respective LED.If an LED does not light, there could be a cable problem, the LED might be faulty or the AI's driver circuits could be faulty.


CELL FAN MOTORS

Each cell is fitted with a convection motor and fan assembly. The motor is a three-phase, 1/6-hp unit. The motor and fanassemblies are dynamically balanced to reduce vibration. On some ovens, an inverter is used to control the operatingspeed of the motors.

The convection cell motors have a thermal cutout switch installed internally. If the motor exceeds its maximum operatingtemperature (155° C), the cutout switch will “open” and the motor will not run. If the cutout is “open”, it will be necessaryto let the motor cool down before attempting to restart it. During normal operations, the motor should not reachtemperatures that cause the cutout to “open”. The upper and lower banks of cell fans are protected by circuit breakers.

The motor supply voltage may be derived from a three Phase step-down transformer. The inputs and outputs of thistransformer are protected by circuit breakers.

TEST PROCEDURE FOR MOTOR RESISTANCE

With power off to the oven, disable the circuit breakers to the motors (top and bottom). Using an Ohmmeter on its lowest scale, measure the resistance between each phase leg of the motor loads.

Using an Ohm meter check for short to ground (between each phase leg and the motor housing)

The resistance measured between each pair of phase legs should be approximately the same. If the resistance of onephase leg is significantly different from the other two, either there is a defective motor (short in the windings) or one of themotors is incorrectly connected.

CELL FAN MOTOR ROTATION CHECK

Create a recipe to activate the cell fans only. Start the recipe and observe the rotation of each motor. During normaloperation, the heat slinger fan turns counter clockwise as viewed from the outside of the cell. If a group of motors (top orbottom) is not turning in the correct direction, de-activate the cell fan motors via the computer (stop recipe). Shut offmotor circuit breaker (F8) and swap two phase leads at one of the following locations:

- The Load side of K13. (to change rotation of ALL fans), or the load side of F41, F42, F43, F44. (to change rotation of allUpper or Lower fans), or for an individual Fan Motor rotating backwards, swap any 2 power leads to the Fan Motor at theCell terminal Block. (Do NOT move the Green Wire)

VERIFYING CELL FAN SPEED

The system will run the fans at full speed (approx. 3500 RPM). The Output from the controller to the Inverter is +10VDC. The cell fans will slowly accelerate to full speed.After the cell fans reach full speed, the true speed of the fans can be measured with a stroboscope. If one or more fansare NOT between 3400-3600 RPM, then it is likely that either a fan motor or the fan motor wiring is faulty.


CELL FAN ASSEMBLY REMOVE AND REPLACE PROCEDURES

CAUTION:

BEFORE STARTING ANY MAINTENANCE, DISCONNECT THEOVEN FROM ALL POWER SOURCES.

TOOLS AND MATERIALS REQUIRED:

RTV SS986 silicone sealer.Cleaning solvent or Isopropyl alcohol.Clean rags.Putty knifes 3" wide & 1" wide.Razor scrapers.1/8" tip, 4" long, flat bladed screwdriver.#2 cross head, 8-10" long, screwdriver.1/8" hex key T-handle or 1/8" hex key bit for impact wrench.5/32" hex key T-handle or 5/32" hex key bit for impact wrench.Impact wrench.Torque wrench calibrated in inch pounds with a range exceeding 50 inch pounds (click type).(2) 11/32" open end wrenches 1/8" or less in thickness..090" Fan mounting gauge.A 10" 4x4 block of wood1/8” tubing Paper and pencil.

Make a clear sketch of the Inter Cell Baffle (ICB) settings for all cells. The ICBs will be removed and replacedduring this procedure.

1 Remove the oven sheet metal skin(s) to gain access to the cell fans.

2 At the front of the Oven open the Hood with the hood up switch. Make sure that the 'hood' is in thefully open position. NOTE: watch the overhead clearance and exhaust duct movement while raisingthe Hood.

Motors and Fans MUST NOT be separated or mixed up, be sure to match up the serial numbers on bothcomponents. The motor/ fan units are dynamically balanced and MUST remain together.


BOTTOM CELL MOTOR REMOVAL

1. If the Oven is belt-only, disconnect the belt at the master link and unthread the belt from the tunnel.See the procedure for disconnecting the conveyor belt.

2. If the Oven is rail-only, disconnect the conveyor chains at the master links and unthread them from thetunnel. See the procedure for disconnecting rails and chains.

3. If the Oven has a combination rail/belt conveyor, disconnect and unthread the chains first and then thebelt from the tunnel. See the procedures for disconnecting rails and chains and disconnecting theconveyor belt.

4. Remove all outer panels to allow access to the underside of the Oven. Remove power from the Oven. 5. Remove the screw(s) holding the thermocouple(s) in place on the cell face. Using a permanent black

marker, circle the hole the thermocouple(s) pass through on the heater face. Carefully straighten thethermocouple wire and cover it with a piece of 1/8" vinyl tubing. This is to aid relocating thethermocouple when reassembling the cell.

6. Remove the four Philips style screws holding each ICB in place on the sides of the heater panel.Remove the ICBs.

7. Remove the three Philips style screws holding the front heater panel bracket. Remove the bracket. 8. Using a hex head wrench, carefully insert the short end into a hole in the heater panel and gently pull

up on the heater panel. Use the 3" putty knife to push the insulation guard clear of the heater panel. 9. Tip the heater panel on its side to gain access to the heater wires on the inside of the cell. Block the

panel in place to remove the heater wires. 10. SKETCH the wire placement on the connections on the heater panel. They will have to be replaced in

the same order. 11. Remove the four wires by using two 11/32" wrenches. Uses one to hold the bottom nut (closest to the

panel) steady, while the other unscrews the top nut to free the wire.

IT IS VERY IMPORTANT TO USE TWO WRENCHES AND HOLD THE BOTTOM NUT STEADY BECAUSE THEHEATER FOIL IS DIRECTLY ATTACHED TO THE STUD AT THIS LOCATION. THE CERAMIC BLOCKS AREFRAGILE AND EASILY BROKEN. IF THE HEATER FOIL TEARS, IT CANNOT BE REPAIRED, AND THE HEATERPANEL ASSEMBLY MUST BE REPLACED.

12. Disconnect the thermal switch, then remove the heater panel and set it aside. 13. Remove the blower from the motor shaft. Using a 1/8" hex head wrench, loosen the two setscrews on

the blower enough to remove the blower from the motor shaft. Save the blower to return with themotor.

14. Go to the rear of the oven and go in under the cell that has the motor to be removed. Document thelocations of the wires in the terminal block. Using a 5/32" hex head wrench or T-handle, carefullyremove the three screws holding the motor in place on the cell.

CAUTION: Hold the motor with one hand while you remove the last screw as the weight of the motormay cause it to fall on top of you.

15. Remove the Cell Fan motor. You may have to tap on the motor to break it loose from its mount on thecell.

16. Scrape all RTV off the cell in the motor area. Clean all grease, dirt and RTV from the shaft hole areaand the motor support areas.


BOTTOM CELL MOTOR REPLACEMENT

1. Under the rear of the oven, locate the cell where the motor is to be installed.

2. Assemble three screw assemblies. A screw assembly consists of one 5/32" hex head screw, one flat washer, andone rubber washer in that order. The rubber washers are to aid in vibration isolation.

3. Using RTV, put a very small dab on each support leg of the motor. Place one rubber washer (not the rubberwasher from the screw assembly in Item 2 above) on the bottom of each motor leg and position them so they arecentered on the screw holes.

4. Put a small amount of RTV into each of the fan mounting holes on the cell plate.

5. Insert one screw assembly into a hole on the motor base and place the motor up against the cell face. CAUTION:Orient the motor so the wires will reach the terminal block. Center the holes and hand-start the screw.Tighten it until it is snug.

6. Insert the second screw into a hole on the motor base and hand start it. Tighten it until it is snug.

7. Finally, insert the last motor mounting screw into the last hole and hand start it. Tighten it until it is snug.

8. Using the 5/32" T-handle, tighten all three screws until they are tight and the motor is securely fastened onto thecell plate.

9. Properly connect the motor wires to the connector block. (Red=L2, Yellow=L3, Blue=L1)

10. Place the fan mounting gauge on the cell on the cell face with the opening of the V facing the rear of the oven andsurrounding the motor shaft. Make sure that the sides of the gauge are between the screws in the cell plate. Seedrawing of the fan gauge.

11. Place the matching fan blade onto the motor shaft of the motor just installed. Note that the fan has two setscrewsand the motor shaft has two flats on it.

12. With the fan blade resting on the gauge, tighten the setscrews with a 1/8" hex head bit on a torque wrench set to50 inch pounds. Remove the gauge by sliding it forward and lifting it out of the cell.

13. Retrieve the heater panel for this cell and lay it into place in the cell. Be careful not to bend the thermocouple wire.Prop the heater panel up from the front so the heater wires can be reconnected.

14. Reconnect the wires to the panel referring to the SKETCH made when the panel and wires were removed. Usetwo 11/32" wrenches to prevent breaking the ceramic block or tear the foil connected to the lower (closest to thepanel) nut on the stud. Reconnect the thermal switch.

15. Carefully place the thermocouple wire in its protective 1/8" vinyl tubing through the correct hole in the panel. If thethermocouple(s) was NOT marked (circled) before removing the panel, then count three rows from the right andseven holes from the front to locate the correct hole. If the Oven has the Independent Alarm Scanner (IAS) over-temperature sensing option, refer to the SKETCH to locate the second thermocouple.

16. After the thermocouples are located in their proper holes, lower the heater panel in place. Remove the vinyl tubingfrom the thermocouple(s).

17. Replace the front panel bracket and fasten it down with two Philips type screws. Replace the rear heater panelbracket and fasten it down with two screws.

18. Replace the left and right ICBs and fasten them down with two Philips type screws each. Refer to your drawing ofICB placement to adjust them.

19. Carefully bend the thermocouple probes into the proper position under the hold down clamps, and tighten theclamps screws.(Do NOT use longer screws, they will damage the heater panel)

20. Reconnect the conveyor system. See the procedures for reconnecting rails and chains and reconnecting the belt.


TOP CELL MOTOR REMOVAL

1. Remove power from the oven. 2. Remove the screw holding the thermocouple in place on the cell face. Using a permanent black marker, circle the

thermocouple on the heater face. Carefully straighten the thermocouple wire and cover it with a piece of 1/8" vinyltubing. This will aid in relocating the thermocouple when reassembling the cell later.

3. Remove the four crosshead style screws holding each ICB in place on the sides of the heater panel. Remove theICBs.

4. Remove the three crosshead style screws holding the front heater panel bracket. Remove the bracket. 5. If the heater panel does not fall down by itself, using a hex key wrench, carefully insert the short end into a hole in

the heater panel and gently tug down on the heater panel. You may need to use the 3" putty knife to push theinsulation guard clear of the heater panel.

6. Lower the heater panel far enough to gain access to the heater wires on the inside of the cell. Block the panel upwith a 10" 4x4 block of wood to relieve the strain on the wires.

7. Document the wire placement on the connections on top of the heater panel as you will have to replace them laterin the exact same order.

8. Remove the four wires by using two 11/32" wrenches. Use one to hold the bottom nut (closest to the panel)steady while the other unscrews the top nut to free the wire.

IT IS VERY IMPORTANT TO USE TWO WRENCHES AND HOLD THE BOTTOM NUT STEADY BECAUSE THEHEATER FOIL IS DIRECTLY ATTACHED TO THE STUD HERE. IF IT TEARS, YOU WILL HAVE TO REPLACE THEENTIRE HEATER PANEL. IT CANNOT BE REPAIRED. IN ADDITION, THE CERAMIC BLOCKS ARE FRAGILE ANDEASILY BROKEN.

9. Disconnect the two wires on the thermal switch. 10. Remove the heater panel and set it aside. 11. Remove the fan assembly from the motor shaft. Using a 1/8" hex head wrench, loosen the two setscrews on the

fan blade enough to remove the fan blade from the motor shaft. Save the fan blade to return to Vitronics-Soltecwith the motor.

12. At the rear of the oven, SKETCH the locations of the wires in the terminal block and then remove the wires. Usinga 5/32" hex head wrench or T-handle, remove the three screws holding the motor in place on top of the cell.

13. Remove the fan motor. Tap on the motor to break it loose from the cell.

14. Scrape all RTV off the cell in the motor area. Clean all grease, dirt and RTV from the shaft hole area and themotor support areas.


TOP CELL MOTOR REPLACEMENT

1. If they are not already marked with serial numbers, mark the fans and motors so they will not be mixed up.

2. At the rear of the oven, assemble three screw assemblies. A screw assembly consists of one 5/32" hex headscrew, one flat washer, and one rubber washer in that order. The rubber washers are to aid in vibration isolation.

3. Using RTV, put a very small dab of RTV on each support leg of the motor. Place rubber washer (not the rubberwasher from the screw assembly in Item 2 above) on each leg and position them so that they are centered on thescrew holes.

4. Put a small amount of RTV into each of the fan mounting holes on the cell plate.

5. Insert one screw assembly into a hole on the motor base and place the motor up against the cell face. Center theholes and hand-tighten the screw.

6. CAUTION: Orient the motor so that the wires will reach the terminal block. 7. Insert the second screw into a hole on the motor base and hand-tighten it.

8. Finally, insert the last motor mounting screw into the last hole and hand-tighten it.

9. Using the 1/8" T-handle, tighten all three screws until they are tight and the motor is securely fastened onto thecell plate.

10. Properly connect the motor wires to the connector block. (Red=L2, Yellow=L3, Blue=L1).

11. At the oven, place the fan mounting gauge in the cell up against the cell face with the opening of the V facing therear of the oven and surrounding the motor shaft. Make sure that the sides of the gauge are between the screwsin the cell plate. Hold the gauge in place. See drawing for the fan gauge.

12. Place the matching fan blade onto the motor shaft of the motor that you just installed. Note that the fan has twosetscrews and the motor shaft has two flats on it.

13. With the fan blade resting against the gauge, tighten the setscrews with a 1/8" hex key bit on a torque wrench setto 50 inch pounds. Remove the gauge by sliding it forward and down out of the cell.

14. Retrieve the heater panel for this cell and set the rear of it into place in the cell between the bracket and the cell. Be careful not to bend the thermocouple wire. Prop the heater panel up from the front so that you can reconnectthe heater wires.

15. Reconnect the wires to the panel referring to the SKETCH made when the panel and wires were removed. Usetwo 11/32" wrenches so NOT break the ceramic block or tear the foil connected to the lower (closest to the panel)nut on the stud. Reconnect the wires to the over-temperature switch.

16. Carefully place the thermocouple wire in its protective 1/8" vinyl tubing through the correct hole in the panel. If thethermocouple(s) location was NOT marked (circle) prior to removing the panel, then count four rows from the leftand seven holes (6 visible) from the front to locate the correct hole.

17. Once the thermocouple is located in its proper hole, raise the heater panel in place.

18. Replace the front panel bracket and fasten it with two Philips head screws. Remove the vinyl tubing protecting thethermocouple(s).

19. Replace the left and right ICBs and fasten them in place with two Philips head screws each. Refer to the sketch ofICB placement to adjust them.

20. Carefully bend the thermocouple into its correct place and replace the clamp and screw. Tighten the screw.


5 INCHES

2.5 INCHES

2.75 IN

6 IN

FAN MOTOR GAUGE-Make from 3/32” alum sheet

3/4 IN

Hole is to facilitate removal ofgauge from under blowerwheel. ¼ inch drill bit, ¼ inchfrom out outside edges.


HEATER REMOVE AND REPLACE PROCEDURES

Make a clear sketch of the Inter Cell Baffle (ICB) settings for all cells. The ICBs will be removed and replacedduring this procedure.

TOP HEATER REMOVAL

1. Remove power from the oven.

2. Loosen the screw holding the thermocouple in place on the cell face. Using a permanent black marker, circle thethermocouple on the heater face. (This will help relocate the thermocouple when reassembling the cell).

3. Carefully straighten the thermocouple wire and cover it with a piece of 1/8" vinyl tubing.

4. Remove the two Philips head screws holding each ICB in place on the sides of the heater panel. Remove theICBs.

5. Remove the two Philips head screws holding the front heater panel bracket. Remove the bracket.

6. Remove the two Philips head screws holding the rear heater panel bracket. Remove the bracket. CAUTION: Theheater panel may drop down.

7. If the heater panel does not drop down by itself, using a hex head wrench, carefully insert the short end into a holein the heater panel and gently tug down on the heater panel. Use the 3" putty knife to push the insulation guardclear of the heater panel.

8. Lower the heater panel enough to gain access to the heater wires on the inside of the cell. Block the panel up witha 10" 4x4 block of wood to relieve the strain on the wires.

9. Document the wire placement on the connections on the heater panel. They will need to be replaced later in thesame positions.

IT IS VERY IMPORTANT TO USE TWO WRENCHES AND HOLD THE BOTTOM NUT STEADY BECAUSE THEHEATER FOIL IS DIRECTLY ATTACHED TO THE STUD AT THIS LOCATION. THE CERAMIC BLOCKS AREFRAGILE AND EASILY BROKEN. IF THE HEATER FOIL TEARS, IT CANNOT BE REPAIRED AND THE HEATERPANEL ASSEMBLY MUST BE REPLACED.

10. Remove the four wires by using two 11/32" wrenches. Use one to hold the bottom nut (closest to the panel)steady while the other unscrews the top nut to free the wire.

11. Disconnect the two wires on the thermal switch.

12. Remove the heater panel and set it aside.


TOP HEATER REPLACEMENT

1. Retrieve the heater panel for this cell and set the rear of the heater panel into place in the cell between the bracketand the cell. Be careful not to bend the thermocouple wire. Prop the heater panel up from the front so the heaterwires can be reconnected.

2. Reconnect the wires to the panel referring to the SKETCH made when the panel and wires were removed. Usetwo 11/32" wrenches so as NOT break the ceramic block or tear the foil connected to the lower (closest to thepanel) nut on the stud. Do not forget to connect the thermal switch wires.

3. Carefully place the thermocouple wire in its protective 1/8" vinyl tubing through the correct hole in the panel. If youdid NOT circle the thermocouple(s) before removing the panel, then count four rows from the left and six holesfrom the front to locate the correct hole.

4. Once the thermocouple is located in its proper hole, raise the heater panel into place.

5. Replace the front panel bracket and fasten it with two Philips head screws. Remove the vinyl tubing protecting thethermocouple.

6. Replace the left and right ICBs and fasten them in place with two Philips head screws each. Refer to the sketch ofICB placement to locate and adjust them.

7. Carefully bend the thermocouples into the correct places and replace the clamps and screws. Tighten the screws.


BOTTOM HEATER REMOVAL

1. If the Oven is belt-only, disconnect the belt at the master link and unthread the belt from the tunnel. See theprocedure for disconnecting the conveyor belt.

2. If the Oven is rail-only, disconnect the conveyor chains at the master links and unthread them from the tunnel. Seethe procedure for disconnecting rails and chains.

3. If the Oven has a combination rail/belt conveyor, disconnect and unthread the chains first and then the belt fromthe tunnel. See the procedures for disconnecting rails and chains and disconnecting the conveyor belt.

4. Remove the screw(s) holding the thermocouple(s) in place on the cell face. Using a permanent black marker,circle the hole that the thermocouple(s) pass through on the heater face. Carefully straighten the thermocouplewire and cover it with a piece of 1/8" vinyl tubing. This will aid in relocating the thermocouple when reassemblingthe cell later.

5. Remove the two Philips head screws holding each ICB in place on the sides of the heater panel. Remove theICBs.

6. Remove the two Philips style screws holding the rear heater panel bracket. Remove the two Philips head screwsholding the front heater panel bracket. Remove the brackets.

7. Using a hex head wrench, carefully insert the short end into a hole in the heater panel and gently pull up on theheater panel. Use the 3" putty knife to push the insulation guard clear of the heater panel.

8. Tip the heater panel on its side far enough to expose the heater wires on the inside of the cell. Block the panelin place to remove the heater wires.

9. SKETCH the wire placement on the connections on the inside of the heater panel. They will be replaced in thesame order.

10. Remove the four wires by using two 11/32" wrenches. Use one to hold the bottom nut (closest to the panel) steadywhile the other unscrews the top nut to free the wire.

IT IS VERY IMPORTANT TO USE TWO WRENCHES AND HOLD THE BOTTOM NUT STEADY BECAUSE THEHEATER FOIL IS DIRECTLY ATTACHED TO THE STUD AT THIS LOCATION. THE CERAMIC BLOCKS AREFRAGILE AND EASILY BROKEN. IF THE HEATER FOIL TEARS, IT CANNOT BE REPAIRED AND THE HEATERPANEL ASSEMBLY MUST BE REPLACED.


BOTTOM HEATER REPLACEMENT

1. Retrieve the heater panel for this cell and lay it into place in the cell. Be careful not to bend the thermocouple wire.Prop the heater panel up from the front to reconnect the heater wires.

2. Reconnect the wires to the panel referring to the SKETCH made when the panel and wires were removed. Usetwo 11/32" wrenches to NOT break the ceramic block or tear the foil connected to the lower (closest to the panel)nut on the stud.

3. Carefully place the thermocouple wire in its protective 1/8" vinyl tubing through the correct hole in the panel. If thethermocouple(s) was not marked (circled) before removing the panel, then count three rows from the right andseven holes from the front to locate the correct hole. If the Oven has the Redundant Over-temperature SensingOption (ROSCO), refer to the SKETCH to locate the second thermocouple.

4. Once the thermocouples are located in their proper holes, lower the heater panel in place. Remove the vinyl tubingfrom the thermocouple(s).

5. Replace the front panel bracket and fasten it down with two Philips head screws. Replace the rear heater panelbracket and fasten it down with two Philips head screws.

6. Replace the left and right ICBs and fasten them down with two Philips head screws each. Refer to the sketch ofICB placement to adjust them.

7. Carefully bend the thermocouples into the correct places and replace the clamps and screws. Tighten the screws.

8. Reconnect the conveyor system. See the procedures for reconnecting rails and chains and reconnecting the belt.


C - CONVEYOR

CONVEYOR TYPES

This Section describes the three types of conveyor transport systems available on the Vitronics-Soltec Reflow Ovens. They are:

1) Edge Rail Conveyor System,2) Mesh Belt Conveyor System,3) Combination Conveyor System.

The Mesh Belt conveyor system is standard on most Vitronics-Soltec Reflow Ovens. By special order, Ovens may haveonly the Edge/Rail or Combination Edge Rail / Belt Conveyor System’

The description of all three follow:

EDGE / RAIL CONVEYOR SYSTEM

The edge / rail conveyor system (shown below) permits single or double sided surface mount printed circuit boards to beprocessed through the oven. The standard chain conveyor carries circuit boards on 0.185 inch (4.75mm) long pinsextending from the chains. This conveyor system provides a convenient interface to other equipment in the productionline. Some Ovens have two sets of rails and chains (Dual Rail) for the processing of two PCBs at the same time.

ADJUSTMENT LEAD SCREWS

PROCESS TUNNEL

Edge Conveyor Rails

Edge / rail conveyor system.


MESH BELT CONVEYOR SYSTEM

The mesh belt conveyor system is used to process single sided surface mount printed circuit boards.

Mesh Belt Conveyor

COMBINATION CONVEYOR SYSTEM

The combination belt/rail conveyor has both the edge rail and the mesh belt. The mesh belt is below the edge railconveyors, and both conveyors are driven together. The belt conveyor is shorter than the outside edge of the machinewith the sheet metal covers on, and shorter than the end of the rails with chain guards installed.

Approximately 3 inches between end ofbelt and end of rail conveyor (bothends).


PRINTED CIRCUIT BOARD DESIGN CONSIDERATIONS

Printed circuit board (PCB) design is an important factor in the selection of the oven conveyor system. The meshbelt conveyor system limits PCB processing to single sided PCBs without projecting leads or traces on the bottom of thePCB. The edge/rail conveyor system allows double-sided PCBs to be processed with few restrictions. Major factors tobe considered in processing PCBs on the edge/rail conveyor system are described below.

PCBs processed on the edge/rail conveyor system are supported by pins projecting from the chains on each side of thePCB. These pins can act as heat sinks drawing heat away from the PCB. This heat sink effect can result in unevenheating of the PCB if the artwork (circuit traces, contact pads, etc.) contacts the pins supporting the PCB. To avoiduneven heating problems, allow at least 0.20 inches (5mm) of clearance from the artwork to the edge of the PCB restingon the pins.

The rail can be adjusted for different PCB widths. However, there are limits to the rail width adjustment. Minimum PCBwidth is 2.0 inches (50.8 mm) and the maximum is 18 inches (450mm). For wide tunnel conveyors the maximum width is22 inches.

The edge/rail conveyor is positioned at the factory to allow the minimum (2.0 inches) and maximum (18 inches) PCBwidths to be processed without moving the fixed rail.

Moving the fixed rail is not recommended unless it is necessary to accommodate other equipment in the production line.

PCB

Extended Pins

Chain Links

Rail Width Measurement Illustration


PROBLEMS AND POSSIBLE SOLUTIONS (The most likely cause is listed first)

CONVEYOR PROBLEMS

CONVEYOR WILL NOT RUN.

1. Conveyor drive clutch needs adjustment See: 12 2. Check the on/off/stop circuit (Emergency Stops) See: 2 3. K37 & K38 do not operate See: 4 4. Conveyor has no power See: 3 5. I/O relay has failed or is off See: 66. Controller to I/O board signal problem See: 87. No signal to DC drive module from I/O Board See: 98. Unreliable output from the DC drive module See: 79. Conveyor motor does not operate See: 1110. The conveyor is jammed See: 1011. ( Reserved for future use )

CONVEYOR STOPS RUNNING.

1. There is a board jammed on the conveyor See: 10 2. There is a conveyor jam See: 10 3. The drive clutch needs adjustment See: 12 4. There is an AC circuit failure See: 13 5. An alarm condition has occurred See: 14 6. The E-stop circuit is causing the stop See: 2 7. Unreliable output from the DC drive module See: 7 8. The conveyor motor has stopped running See:11 9. The controller has had a failure. See: 15

CONVEYOR SPEED IS UNSTABLE. 1. Check the conveyor drive clutch See: 12 2. Check the encoder See: 20 3. Check the drive chain tension See: 21 4. Check sprocket shaft alignment See: 18 5. Check the transfer gear assembly See: 16 6. Check the voltage to the encoder See: 22 7. Check the controller See: 15 8. Unreliable output from the DC drive module See: 7 9. Check the Conveyor motor See: 11 10. Check the encoder drive linkage See: 19 11. Chain may need lubrication See: 10


CONVEYOR "JERKS" (MOTION IS NOT SMOOTH).

1. The chains are dirty and/or dry See: 24 2. Check the drive clutch See: 12 3. Check the excess belt / chain under the oven See: 23 4. Check the lube / operation of transfer gear See: 16 5. Unreliable output from the DC drive module See: 7

MEASURED SPEED IS NOT EQUAL TO DISPLAYED SPEED. 1. Run the conveyor calibration procedure See: 25 2. Check the encoder voltage See: 22 3. Check the encoder See: 20 4. Check the controller See: 15


FOR FUTURE USE

CHECK THE “ON - OFF - STOP” CIRCUIT The conveyor will not run. Check the On/Off/Stop circuits on the oven.

POSSIBLE CAUSESThe on/off/stop circuit consists of the E-STOP switches, K37 & K38 relays, electrical enclosure interlock switches(optional), F50, F52, F55, and the wiring and terminal strip connections.HINT: First check the devices physically: the E-STOP switches should be “up”, The electrical enclosure interlock switchesshould be depressed, K37 & K38 should be energized, and F50, F52 and F55 should “closed”. (not tripped).After a physical check, check the connections of the conductors, look for them to be tight and correctly connected. If anyrepairs were recently been performed in this area, look for a device that may have been improperly connected when thework was done.

Finally, check all components' electrical integrity with a volt-ohm meter for correct voltage and internal resistance:1 E-STOP switches.2 Electrical enclosure interlock switches (optional).3. K 37 & K384. F50, F52, F55

NOTE: If F50 or F52 trips (opens), the entire oven will lose control power.

2

1


CONVEYOR HAS NO POWER The conveyor will not runPOSSIBLE CAUSESSince the conveyor subsystem is an Electro-mechanical system, check the mechanical components before replacingelectrical parts. Ensure that the belt is not hung up below the oven, or that a board is not jammed somewhere on theconveyor. After confirming that the mechanical elements of the conveyor are in operating order, start troubleshooting theelectrical components

The transformer secondary (F52) supplies power to ALL control circuits including the DC drive module.One of the following is likely to be responsible:

1) F50, F52.2) DC drive module.3) Conveyor motor.4) RT1 (motor inrush current limiter)5) A1 I/O board (conveyor relay A1-K12).6) Short in the wiring.7) F67

K37 & K38 DOES NOT OPERATE The conveyor will not run because K37 & K38 will not energize.POSSIBLE CAUSESIf K37 & K38 will not energize, the conveyor will not operate.

Check the following components.1) E-STOP switches.2) G2 24vdc Power Supply.3) Electrical enclosure interlock switches4) K37 & K38.5) F50, F52.6) F55

The on/off/stop circuit consists of the E-STOP switches, K37 & K38, F50, F52, and F55 as well as the wiring and terminalstrips connecting the components.HINT: First check the devices physically: the E-STOP switches should be “up”. K37 & K38 should be energized, and F50,F52 and F55 should be “closed”. (not tripped).After a physical check, check the wire connections... look for them to be tight and correctly connected. If any repairs wererecently been performed in this area, look for a device that may have been improperly connected when the work wasdone.Finally, check all components electrically with a volt-ohm meter for correct voltage and internal resistance. NOTE: If F50,F52 or F55 open (trips), the entire oven will lose power.

3

4


FOR FUTURE USE

I/O RELAY HAS FAILED OR IS OFFThe conveyor will not run because the I/O relay has failed or is off.POSSIBLE CAUSESIf the I/O relay has failed or is turned off, two items can be checked without a meter: 1. Is the relay properly seated in the I/O board?2. Are both ends of the cable from the controller Interface board connected?

Refer to the schematics. The conveyor relay is number A1-K12 and connects to pins PX5-14 & Px5-15 on the I/O board. Also, check the connections from the encoder and the DC drive. These are on A1, PX9 pins 1,2, & 3 on the controllerinterface board.

The oven will “alarm” and shut down if the conveyor does not run, therefore it will be necessary to enable“Conveyor Calibration” in Oven Operation Program for trouble-shooting to take place.

5

6


UNRELIABLE OUTPUT FROM DC DRIVE MODULE The DC drive module may be causing one of the following:

1) (No Output) The conveyor will not run2) (No Output) The conveyor stops running3) (Intermittent Output) The conveyor speed is unstable4) (Intermittent Output) The conveyor “jerks” (motion is not smooth)

POSSIBLE CAUSESThe DC drive module is an electronic assembly that receives a control signal from the controller on pins +SIG and -SIGand AC voltage on L1 and L2. This produces DC voltage on pins A1 and A2 at a level sufficient to power the Conveyormotor at various speeds.HINT: Check the following items when troubleshooting a faulty DC drive circuit.The most likely are listed first:

1) DC drive module.2) Conveyor motor.3) I/O relay.4) E-STOP switches.5) K37 & K38.6) F50, F52 or F55 (This will cause complete system failure).7) Controller.8) Speed – (If the conveyor is set less than 8”/min, the conveyor will become unstable

(DC motor, NOT stepper motor)

In addition to the items listed above, check the signals from the oven controller to help determine why there is no signalfrom the DC DRIVE MODULE. The signals in question are listed on the Control ladder print as follows:

Analog Out Common (A1 Board PX9-18) (-SIG drive V1)Analog Out 1 (A1 Board PX9-17) (+SIG drive V1)(A voltage level between 0v and +10v should be found when checking these two signals with a voltmeter. Place

the negative lead on Analog Out Common and the positive lead on Analog Out 1)

Check the switches, circuit breakers and relays, to be securely mounted and that the wires are connected correctly* andtightly.

When checking the drive motor, refer to the section on motor troubleshooting if the fault is not obvious.The final test will be to replace the DC Drive Module after all other possibilities have been eliminated.

* Use the oven schematics to verify correctly connected wires.

7


PROBLEM WITH THE SIGNAL FROM THE CONTROLLER TO I/O BOARDThe conveyor will not run because there is a problem with the signal from the controller to the I/O board.

POSSIBLE CAUSES

Check the following in the order given for the source of the problem.1 Check the Alarm Conditions displayed on the computer screen.2 I/O relay board (Check for the led lit on A1-K12).3 Connections from the controller to the I/O relay board A14 Controller board.5 Encoder (check the signal levels)

NO SIGNAL TO DC DRIVE MODULE FROM THE I/O BOARDThe conveyor will not run because there is no signal from the I/O Board to the DC drive module.

POSSIBLE CAUSES

Check the following for a solution: the most likely is listed first; 1 An alarm condition.2 The connections or cables from the I/O Board to the DC drive module.3 The controller.4 The software in the computer or controller.

See the Control ladder print for the circuit details.

THE CONVEYOR IS JAMMED

The conveyor is jammed. This is causing the conveyor either to not run or to stop running.

POSSIBLE CAUSESIf the conveyor is jammed, there is a mechanical reason for it. The most common reasons for conveyor jams are:

1 Lubrication problems on a chain or combo conveyor. If the chain is not lubricated at the appropriateintervals, the conveyor may jam and stop.

2 Mechanical jam in the tunnel. 3 Misalignment of the sprockets or idlers.)4 Conveyor clutch5 Conveyor motor.6 Excess belt or chain catching and hanging up on something under the oven.

* See the Preventive Maintenance Manual for recommended lubrication intervals.

CONVEYOR MOTOR DOES NOT OPERATE

8

9

10

11


The conveyor motor has illustrated one of the following symptoms.1) The conveyor will not run2) The conveyor stops running3) The conveyor speed is unstable

POSSIBLE CAUSESSince the conveyor subsystem is an Electro-mechanical system, check the mechanical components before replacingelectrical parts. Ensure that the belt is not hung up below the oven, or that a board is not jammed somewhere on theconveyor. After confirming that the mechanical elements of the conveyor are in operating order, start troubleshooting theelectrical componentsThe most likely are listed first:

1) Conveyor motor.2) DC drive module.3) I/O Interface board.4) E-STOP switches.5) Electrical enclosure interlock switches.6) K37, K38.7) F50, F52, F55 (When tripped, causes complete power loss to oven).8) Controller signal).9) Controller.).

CONVEYOR DRIVE CLUTCH NEEDS ADJUSTMENTThe conveyor drive clutch needs adjustment and this is causing one of the following symptoms.

1) The conveyor will not run2) The conveyor stops running3) The conveyor speed is unstable4) The conveyor “jerks” (motion is not smooth)

POSSIBLE CAUSES The conveyor clutch is mechanically connected to the end of the conveyor motor shaft and serves as protection for themotor if there is a jam that actually stops the conveyor belt/chains from moving. Exercise extreme caution when working near the conveyor drive system.The clutch is set at the factory to slip at 35 + 5 foot pounds as measured with a linear scale. With time, the torque settingmay change. The adjustment mechanism is a large nut that presses against the clutch disc to create tension. Toincrease the tension, turn the nut clockwise, the opposite will decrease tension. Use a linear scale and a hook on a chainpin or a conveyor belt loop to pull until the conveyor stops moving. Read the measurement on the scale. The scale shouldindicate 35 + 5 foot-pounds. If the tension cannot be adjusted between 30-40 foot pounds, the clutch may need to bereplaced. Other possible causes for improper clutch operation are:

1) Mechanical or lubrication problems with conveyor shafts.2) Conveyor belt or chains catching and/or dragging3) Conveyor sprockets slipping

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THERE IS AN AC CIRCUIT FAILURE IN THE CONVEYOR CONTROLSThere is an AC circuit failure in the conveyor controls, causing the conveyor to stop running.POSSIBLE CAUSESThe electrical components, which could affect the conveyor system, are mostly switches and are in the circuits thatdirectly affect the conveyor operation.

1) I/O relay – (A! – K12)2) A!-K13) E-STOP switches (4).4) Electrical enclosure interlock switches.5) F50, F52 or F55 (This will cause a complete system failure).6) A1-K3.7) DC drive module.

All of these components can be found on the Oven Schematic.

AN ALARM CONDITION HAS OCCURREDAn alarm condition has occurred and has stopped the conveyor.

POSSIBLE CAUSES

This may or may not indicate an actual component failure. The operator must look at the computer screen to see whatalarm message is displayed and take the appropriate action from there.The conveyor stops on a critical alarm condition. The alarms that can be set to critical are listed below.

1) One or more E-STOP switches are pressed.2) The computer is unable to communicate with the controller.3) The bonnet is open while the oven is operating.4) A cell heater is not reacting correctly to the power being applied to it.5) The safety over-temperature unit has detected the temperature of a cell

exceeding a predefined level.6) The temperature of a cell has exceeded a predefined safety level.7) The conveyor has stopped.8) A circuit breaker has tripped (opened).

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THE CONTROLLER HAS HAD A FAILURE The controller has had a failure causing one or more of the following symptoms.

1) The conveyor stops running2) The conveyor speed is unstable3) The conveyor measured speed is not same as actual speed

POSSIBLE CAUSESIf the controller fails, there are other symptoms to help isolate the problem.It is possible to isolate a controller failure by monitoring the signals from the controller at the I/O board HINT: There is an Amber LED indicator on the front of the controller that which flashes on and off at a regular intervalwhile the controller is functioning properly. There also is a Green LED which is on steady when the unit is powered.The items to check in the event of a suspected controller failure:

1) Controller.2) Controller cables and connectors.3) Power supply for the controller (see Oven Schematics).

PROBLEM WITH OPERATION OF TRANSFER GEAR ASSEMBLYThere is a problem with the transfer gear assembly causing either unstable conveyor speed or ajerky motion of the conveyor. This applies only to a combination conveyor system.POSSIBLE CAUSESUnstable conveyor speed and/or jerky motion of the conveyor can usually be attributed an improperly lubricated orimproperly adjusted chains or rails.Check the following for tightness and adjustment:

1) Transfer gear assembly (sprocket and shaft).2) Transfer gear chains.3) Sprockets for transfer gear chains on the conveyor shafts.

THERE IS A BOARD JAMMED SOMEWHERE ON THE CONVEYORThere is a board jammed somewhere on the conveyor and this is causing the conveyor to stop running POSSIBLE CAUSESThere is a printed circuit board assembly somewhere in the oven that is keeping the conveyor from running. Someplaces to look are:

1) The chain guards on the ends of the chains on rail and combination ovens2) The small gap between rails and chains on combination ovens3) Between belt and rails on combination ovens.4) Improper boards placement onto conveyor.

If this type of problem is a regular occurrence in the oven and it happens in approximately the same place or with thesame product, then perhaps the areas in question should be realigned/readjusted. This could be a warning sign for otherproblems in the mechanics of the conveyor system such as improper leveling or lack of rail parallelism.

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PROBLEM WITH SPROCKET ALIGNMENT ON DRIVE/DRIVEN SHAFTSThere is a condition with the sprocket alignment on either the drive or the driven shafts causingthe conveyor speed to be unstable. POSSIBLE CAUSESWhen the sprockets on a belt conveyor are not lined up properly, the belt can sometimes jump, jerk or "pop" as it goesaround the shaft producing a jerky belt movement and can affect belt tracking. The side of a belt loop catching on thesprocket teeth as the belt goes around the sprocket causes the “pop”. The proper way to align the belt sprockets is tocenter the belt on the shafts and line up the sprockets with the belt.

1) Adjust the outer sprockets to less 1/8" from the sides of the belt.2) Center the belt on the shafts by lining up the belt with the wear rod carriers.3) Align every sprocket within 1/8" of the outside edge of its belt loop. This means that half of

the sprockets must be aligned on the left side of the belt and the other half on the right side of the belt.If the oven has a rail or combination conveyor, the problem could be with the chain idler followers. (They are locatedbelow the surface of the belt where the chains go down to/come up from the under side of the oven). The sprockets areadjusted with precision shims to locate them in reference to the drive sprockets. Confirm that the extension arm thatholds the idlers is straight, and that the chains track correctly. Too much bend in the extension arm can cause the chainto jump or bind.

The assemblies to check are:1) Sprockets/idlers2) Drive/driven shafts3) Belt/chains4) Idler brackets/shims

PROBLEM WITH THE ENCODER DRIVE LINKAGE There is a problem with the encoder drive linkage causing the conveyor speed to be unstable.

POSSIBLE CAUSES On ALL conveyors, there are a couple of pulleys and a toothed belt driving the encoder from the conveyor assembly.If the encoder drive is loose, then check the clamps for tightness. Check the belt for proper tension (1/4" to 1/2" fulldeflection when squeezed) and missing or damaged teeth. Check the pulleys for wear and tightness of the setscrews onthe shafts.

Areas to check are:1) Encoder pulleys and belt.2) Encoder alignment.

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PROBLEM WITH THE ENCODERThere is a problem with the encoder causing the conveyor speed to be unstable or causing theconveyor measured speed to be different from the displayed speed.POSSIBLE CAUSESThe encoder is mounted next to the conveyor drive motor inside the outer sheet metal.Check the following items for problems:

1) Encoder assembly. If it seems to be turning, check the output at the controller with a oscilloscope. Refer to the oven schematics for pin numbers and locations.

2) Encoder data cable. Check for kinks, cuts etc, in wiring3) Encoder drive assembly (pulley & belt or coupling).4) Controller power supply. See schematics.5) Encoder mounting hardware and brackets. Check alignment and tightness.

DRIVE CHAIN TENSION IS INCORRECTThe conveyor motor drive chain tension is incorrect causing the conveyor speed to be unstable.POSSIBLE CAUSESIf tensioning of this chain is too tight, the motor will be side-loaded excessively and the motor will fail prematurely. Iftension is too loose, the conveyor could "jerk" or vary its speed.The chain should be adjusted with approximately 1/4" of deflection in the chain when it is pressed down from above. (This adjustment is not an easy to see or make)Checking and adjustment of this chain can only be done from under the off-load end of the oven.

VOLTAGE TO THE ENCODER IS INCORRECT OR MISSING The voltage to the encoder is incorrect or missing causing the conveyor speed to be unstable.POSSIBLE CAUSESIf you suspect the voltage to the encoder, check in the following places.

1) Power supply for the controller (+5V). See schematics2) Encoder cables/connections.3) Encoder voltage (No voltage will cause the conveyor to stop)3) Controller.

The controller could be over-loading the signal from the encoder. The cables could also be distorting or reducing theencoder signal. If the power supply has failed, the encoder may not work at all. Refer to the schematics for the oven.

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EXCESS BELT/CHAIN UNDER OVEN IS BOUNCINGThe excess belt or chain under the oven is bouncing and causing a “jerky” conveyor motion.POSSIBLE CAUSESIf the conveyor has a "jerky" motion, look under the oven at the excess belt or chain. Sometimes, the excess belt canstart to bounce underneath. A "standing wave" can be seen on the conveyor. This can be caused by the under ovenidlers and followers sticking. Clean the "bearing surfaces" of the idlers to allow a smooth rotation and linear movement.Another possibility is that the drive sprockets are holding the conveyor belt/chain too long on the off-load, causing theconveyor to wrap around the sprocket and then drop quickly, instead of rolling off the sprocket smoothly. This can becaused by excessive wear between the teeth.

1 Sticky chain/belt idlers under the oven.2 Chain/belt drive sprockets holding conveyor too long.3 The Chain may “catch” on the Belt at the ends of the Oven.

THE CHAINS ARE DIRTY (EDGE RAIL CONVEYOR ONLY) The chains are dirty and/or dry (edge rail conveyor system only) causing the conveyor to “jerk”as it goes around.POSSIBLE CAUSESIf the chains are dirty, they will not flow smoothly around the sprockets and the idlers. The links can stick and kink upholding an angled position instead of laying flat. Clean the chain links if they appear to have an excessive amount of buildup residue. The chains may need to be removed and soaked in a cleaning solvent to completely clean them.If they look "dry", oil the chains, however, refer to the Preventive Maintenance Manual for lubrication recommendations.Do not over-oil the chain. Too much oil will cause smoke when the oven heats up.

Also since the opening in the rails is very small, any chain links with any dirt could get stuck in the rails and cause a"jerky" motion of the conveyor.

RUN “CONVEYOR SPEED CALIBRATION” PROCEDUREThe conveyor is in need of calibration if the measured speed of the conveyor to be different from the displayed speed of the conveyor.POSSIBLE CAUSESPerform the conveyor calibration. Refer to the Oven Operations Manual for details on this procedure.If after calibration, the conveyor measured speed is not equal to the displayed speed, then the electrical wiring andcomponents should be checked, especially the encoder output.

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CONVEYOR BELT, CHAIN & RAIL SERVICE

REMOVE AND REPLACE CONVEYOR BELT

DISCONNECTING THE CONVEYOR BELT

1. Locate the master link in the belt. The master link can be identified by the double size 'holes' in the belt. There will betwo double size holes located at the fourth link in from each end. There are five master links in the belt. The single lanemaster link is the center link on the belt. The conveyor will have a belt with five single master links. (instead of two triplesand one single master link).

2. At the right side of the belt, locate the master link. Using screwdriver or chain nose pliers, unhook the left hook of thismaster link from the belt. Then, using the same tool, unhook the right hook of the master link from the belt.

3. Using a screwdriver, lift the left side of the master link out of its position in the fourth link from the end on the oven sideof the belt. Using a screwdriver, unhook the right side of the master link from the belt.

4. Locate the triple master link on the left side of the belt. Using screwdriver or chain nose pliers, unhook the right hookof this master link from the belt. Now using the same tool, unhook the left hook of the master link from belt.

5. Using a screwdriver, lift the right side of the master link out. Using a screwdriver, unhook the left side of the masterlink from belt.

6. Squeeze the ends of the triple master link together and slide the master link ends out of the oven side of the secondlink in from the end.

7. At the right side of the belt, squeeze the ends of the triple master link together and slide the master link ends out of theoven side of the second link in from the end.

8. The triple master links will stay in this position to reassemble the conveyor belt. Carefully lower the bottom end of theconveyor belt taking care not to let it get caught anywhere

9. At the center of the belt, using a screwdriver, unhook the right side of the single link. Lift the unhooked side up andremove the single master link from the belt. The belt will now separate. Unhook the bottom edge of the belt from thedriven shaft and lay it on the floor under the oven.

NOTE: Use only single links for replacement.


RECONNECTING THE CONVEYOR BELT

1 Retrieve the single master link previously removed. Hold the master link so that the opening faces youand the curve in the link matches the curve in the belt. Insert the link into the belt so the hooks go into thetwo links surrounding the center link.

2 Hook the right hook into the center link of the bottom belt edge. Push the link back into place and using ascrewdriver, connect the left hook to the center link of the bottom belt edge.

3 Grasp a triple link and squeeze it into a U shape. While holding this shape, slide the ends of the triplemaster link into the belt. Release the ends of the master link.

4 Grasp the other triple master link and squeeze it into a U shape. While holding the U shape, slide theends of the master link into the belt. The master links should now be connecting the two belt ends.

5 At the right side of the belt, using a screwdriver, hook the master link right hook into the last hook of thebelt (insert the master link hook from the top). Then using a screwdriver connect the master link righthook into the first link on the bottom edge of the belt.

6 Using a screwdriver slide the left side of the same master link into the belt. Then, using the screwdriver,connect the left master link hook to the belt, inserting the hook from the underside of the belt.

7 At the left side of the belt, using a screwdriver, hook the master link left hook into the last hook on the belt(insert the master link hook from the top). Then using a screwdriver connect the master link left hook tothe belt.

8 Using a screwdriver, slide the right side of the same master link into the belt. Then, using thescrewdriver, connect the right master link hook to the belt, inserting the hook from the underside of thebelt.

End of procedure.


DC DRIVE CALIBRATION

1. Definitions-

A DC drive is actually a DC voltage amplifier. A small signal is sent to the drive and a large voltage is sent to themotor. The typical DC drive uses an AC power source of 120 or 240 volts.

The set of controls found on a DC drive is:

A. Minimum speed adjustB. Maximum speed adjustC. IR compD. TorqueE. Signal

2. What do the controls do?

A. Minimum speed adjust -- adjusts the minimum voltage output of the DC drive at the minimum-input value. This value is typically 0 - 10% of the maximum input voltage.

B. Maximum speed adjust -- adjusts the maximum voltage output of the DC drive at the maximum inputvalue. An experienced individual might set the input voltage to 100% of range and set the output to 80 -90 volts. When in doubt, set the maximum output of the DC drive to 100 - 130 volts.

C. IR comp -- this adjusts the feedback circuit from the output of the DC drive. If the output voltage drops,the IR comp circuit senses the drop, and more power is fed to the motor. This function is preset to avalue that covers 90% of all applications.

D. Torque -- this limits output current, and should only be adjusted by experienced people.

G. Signal -- signal adjust is found on DC drives which provide an option of being controlled by a computer. Ifthe DC drive is adjusted by a speed control potentiometer, signal or signal adjust has no function.

A DC drive with computer control will have a signal/manual selector switch or jumper. If the input doesnot match the input selected, the DC drive will not operate correctly.If a computer controls the DC drive, the maximum adjustment potentiometer will have no function.

3. How to make adjustments

The output of a DC drive is linear. The speed of rotation of a permanent magnet DC motor of less than one halfhorsepower is not. Install the new DC drive and operate the conveyor for one half-hour. This warms up the components on the DCdrive and the motor. Calibrating before a one half-hour warm up period will require a second calibration.

A. Set the input of the DC drive to 0%. Use the minimum speed adjustment to establish the minimumspeed at 1 to 2 inches per minute. Most systems will require a minimum of 5 to 7 inches per minute.

B. Set the input of the DC drive to 100%. Set the output voltage to the motor to 90 volts. Experiencedpeople may set the output to a higher or lower value.Initially set the “IR comp” at 12 O’clock, “Torque” at 10 O’clock, “Min Speed” at 10 O’clock, “MaxSpeed” = Off, and “Signal Adj.” at 12 O’clock to begin.

4. Additional useful information

A. Always recalibrate when any component of a control system is changed.


B. Conveyor speed can be calibrated to specific requirements. This takes practice, but can yield greaterspeed accuracy.

C. The conveyor speed should be measured with a stopwatch every sixty days.

D. Motor brushes wear out.

E. Calibration values may change with the age of the system.

F. Always record the adjusting potentiometer settings before replacing or calibrating a DC drive.

G. When replacing a DC drive, record the potentiometer settings; draw a sketch of the wire hookups; makesure all wires have labels.


5. CALIBRATION PROCEDURE FOR MINARIK CONTROLS

Tools required: Multimeter (auto-ranging)

Small non-metallic screwdriverSpeed indicator

Before connecting the power supply:1. Set the two ‘Jumper’ to ‘signal’.2. Set the MAX SPEED pot to full clockwise.3. Set the MIN SPEED pot to full counter clockwise.4. Set the IR COMP pot to the setting shown below.5. Set the TORQUE pot to the setting shown below.

6. Set the signal Pot to full clockwise

With the power supply connected:1. Set the multimeter to VOLTS AC and measure the input voltage to the control. If the voltage is less than

108V or greater than 132V disconnect the power supply and correct the supply voltage problem.2. Disconnect the multimeter and set to measure VOLTS DC. Attach leads to the motor side of the control.

- In the Program Diagnostics, set the conveyor speed to 0%.- Set the MIN speed pot so the conveyor is just barely moving.

3. Set the speed indicator on the front panel to 100 or full speed.4. Adjust the MAX SPEED pot until the VOLTS DC equals the armature voltage listed on the motor nameplate.

5. Check the speed of the conveyor.6. Calibration is complete.

TORQUE IR COMP

MINARIK DRIVE POTENTIOMETER SETTINGS


REMOVE AND REPLACE CONVEYOR RAILS AND CHAINS

DISCONNECTING RAILS AND CHAINS

1. At the off-load end of the oven, remove the chain guard from each chain by removing the 1/8" hex key head screws.

2. Run the conveyor until the master link for one or both chains comes up just under the rail. Remove the master link(s)from the chain(s). Unthread the chain from all of the pulleys that it wraps around on its way under the oven. Make surethat the chain is off the drive sprocket and tie wrap it to the idler shaft just below the end of the oven. Be sure to note theposition of the chain around all pulleys. Go to the on-load end of the oven and remove the chain guards. Pull the chainsout of the rails in the direction of the on-load end of the oven. Let the chains drop down and tie wrap them to the idlershaft below the end of the oven.

3. If only one master link came into position, run the conveyor until the second chain master link shows up. When itdoes, remove it as you did on the other chain.

4. Remove the 5/32" hex head screws holding each rail onto the conveyor assemblies.

5. Remove the rails. DO NOT to let them bend or they may be permanently deformed.

RECONNECTING RAILS AND CHAINS

1. Reconnect each rail to its end assembly using the 5/32" hex head screw.

3. Install the chains in the rails making sure the long pins face in toward the center of the oven. Be careful not to twistthe chains.

4. Slide the chains through the rails until they reach the off-load end of the oven.

5. Rethread the chains on the sprockets and idler pulleys at the on-load end of the oven. Reinstall the chain guards withthe 1/8" hex key head screws.

6. At the off-load end of the Oven, rethread the chains through the sprockets and idler pulleys. Reconnect the masterlinks in both chains. Make sure the closed end of the keeper clip is facing the direction of conveyor travel (off-load end). Reinstall the chain guards on the rails with the 1/8" hex key head screws.

7. Make sure the chains are not hung up or twisted anywhere on top or underneath the Oven.


DRIVE MOTOR SERVICE & REPLACEMENT

CONVEYOR DRIVE MOTOR REPLACEMENTMOTOR LOCATION

There are only two locations for the conveyor motor on all Vitronics-Soltec Reflow Ovens. On an oven with a left to right conveyor, the motor assembly is in the front right corner of the oven. On an oven with a right to left conveyorsystem, the motor assembly is on the front left corner of the oven.

CONVEYOR MOTOR

To remove/replace the Conveyor Drive Motor:

1. Open the Hood 2. Turn off the U.P.S. and disconnect all power from the oven. 3. Remove the long sheet metal piece around the Operator’s Control Panel on the end the oven. 4. The Motor is mounted with four bolts on the Oven Frame “C” Channel. Loosening the four bolts will allow the

Chain to be removed from the Clutch Drive Sprocket without removing the Master Link from the Chain. 5. Unplug the Motor power leads.

6. While supporting the Motor, remove the four bolts. Remove the motor, mounting plate and clutch sprockets fromthe Oven.

7. Rotate the Motor to permit access to the setscrews that secure the Clutch Assembly to the Motor Drive Shaft.Loosen the setscrews and remove the Clutch Assembly, then remove the Motor from the mounting plate.

8. Reverse steps 7 through 1 to replace the Conveyor Drive Motor

THE “MOTOR REPLACEMENT” IS NOT COMPLETE UNTIL YOU:

Check the tension of the Drive Chain as well as the alignment between the Clutch Drive Sprocket and the End AssemblyDrive Sprocket. The chain should have some slack, but not enough to remove the chain from the sprocket(s).

The alignment of the two (2) sprockets should be as exact as possible.

1. Run the oven to verify that the MIN/MAX speed settings with the new motor are similar to the speed settings with theold motor.

Left To Right Conveyor


2. Do the “conveyor calibration” described in the Oven Operation Program Manual after the clutch assembly is properlyadjusted.

CONVEYOR DRIVE SYSTEM

The controller supplies an analog signal corresponding to the desired conveyor speed. The DC drive card sends anamplified signal to the conveyor drive motor.(The motor has a slip clutch connected to the conveyor shaft that drives the encoder.) The encoder generates +5 VDC pulses as the motor drive system operates. The pulses go to the controller, whichmodifies the analog signal to the DC drive card to compensate for any conveyor speed.

Set up the Conveyor Drive within the Oven Operation Program.NOTE: This operation may require a password.

If the conveyor motor does not turn, check the following:

1 - Determine that K37 & K38 are energized

2 - Check for 120 VAC at the DC drive board (between terminals L1 and L2). If there is no 120VAC there, make sure thatA1-K12 is energized at the I/O board. Next, check the signal to the DC drive board. The signal should be +10 VDCbetween DC drive terminals + and – signal input. If there is no signal at those terminals, make sure the ovencontroller card cage is receiving +/– 15 VDC. If the cage is receiving +/– 15 VDC, but the drive is not receiving +10VDC, there is either a wiring error or the DI board is faulty, or a poor wire connection.

3 - After all electrical signals are present and correct, adjust the IR COMP potentiometer to it's mid-point and adjust theSIGNAL ADJUST potentiometer on the DC drive board to a level which produces a +90 VDC armature voltagewhile under manual computer control. The armature voltage is measured between terminals A1 and A2 on the DCdrive board using a DC Voltmeter.

4 - At this point the MIN SPEED potentiometer should be adjusted to generate an armature voltage of approximately +12VDC between terminals A1 and A2. This should keep the conveyor running slowly at a 0 VDC signal level.

5 - After the conveyor system has been tested, run the conveyor calibration routine in the Oven Control Program.

The conveyor system should be adjusted for the following speeds:

Conveyor Speed Table

MOTOR TYPE MINIMUM SPEED MAXIMUM SPEED

Analog Drivemotor

10.0 inch/min( 25.4 cm/min)

75.0 inch/min(178 - 203 cm/min)

MIOP Oven I/O Board DC DriveRibbon Cable Round Cable


Stepper Drivemotor

0.8 inch/min( 2.0 cm/min)

45.0 inch/min(114.3 cm/min)

If the conveyor speed is not consistent after running the conveyor calibration routine, adjust the IR COMP potentiometerof the conveyor drive up or down to compensate for the fluctuations.

ENCODER SERVICE & REPLACEMENT

Test procedure for encoder signal

To verify that the controller is receiving conveyor encoder pulses, run the conveyor at maximum speed. Monitor thevariable conveyor pulses. This should indicate the number of pulses received by the controller during the last scaninterval.

If the controller is not receiving pulses from the encoder, ensure that the encoder is receiving +5VDC (red wire atencoder,) and that the wiring is correct. If all is correct, but the conveyor is still not functioning, next: monitor the encoderpulses using an oscilloscope (wire #1016). If encoder pulses are present, the connection at the front of the DI boardcould be faulty or the DI board could be faulty. Use of an oscilloscope should show a ‘square wave’.

A quick check to test for pulses from the encoder is to connect a DC Voltmeter between wires 1007 and 1016 and run theconveyor. If a voltage level of approximately +1.2 VDC is measured, then pulses are probably being generated. Avoltage level of +5 VDC or 0 VDC indicate a possible fault with the encoder.

Oven I/O BoardRibbon Cable

Oven I/O Board1016 PX9-3 PX2-8 J4-6

TB1-15 Test Point


D- ELECTRICAL POWER & COMPUTER

CAUTION:

WHEN THE OVEN IS “OFF”, MANY PARTS OF THE OVENMAY BE ELECTRICALLY POWERED AND DANGEROUS

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ELECTRO - STATIC DISCHARGE PROCEDURES ( ESD)

When any electronic PC board or any semiconductor device is to be handled, an antistatic wrist strap and an antistaticwork surface or mat must be used to reduce the possibility of causing damage to electronic components on the PCboard.

Semiconductor devices are sensitive to static electricity which can reach potentials of 20,000 volts or more. Staticelectricity may reach 3000 volts before it can be felt ! If the discharge (spark) is visible, it is probably in excess of 5000volts!

The current in static electricity is low. The component is usually weakened by the static damage, but does not failimmediately. This causes intermittent problems, which can be very difficult to isolate. Static electricity can also causeimmediate failures on boards and components. Static failures from improper handling and packing can mask the originalproblem from a repair person so that when you receive a board back from a repair facility, you end up with the sameproblem you had before the repair.

Any clothing made with synthetic fibers is capable of generating static electricity. Any clothing can insulate a wriststrap from your skin. The purpose of the strap is to discharge static electricity that has been built up on your body in acontrolled manner to prevent personal injury and damage to the equipment involved.

As long as you are properly connected to the oven ground by the antistatic wrist strap, you will be at the samepotential, as the oven and the risk of damaging the components with static electricity will be reduced.

When a board with electronic components on it is removed, it is important to remain connected to the oven. When the board has been completely removed from the oven, it may be placed on top of the antistatic mat (connected tothe oven).

The board should be put into an antistatic bag while you are still connected to the oven. The bag should be 'sealed'before disconnecting yourself from the oven ground.

Some antistatic bags are made of plastic that is coated on the inside with a thin conducting metallic film. This film turnsthe bag into a “Protective Shield” surrounding its contents with a path for electricity to follow, thus preventing damage tothe contents when it is completely closed. (Torn bags should be discarded.).

The bags can hold a static charge on their outside surfaces. Always properly ground yourself and have aproperly connected antistatic work surface to rest the bag and contents on before opening an antistatic bag.

When replacing a PC board or electronic component, always be properly grounded until finished with the repair orreplacement procedure. Always be properly grounded to the oven that is being worked on. Not all ovens are at the sameground potentials.

All electronic boards and components must always be properly protected from static electricity and properlystored.


Every Field Service Technician should be issued an antistatic kit consisting of a static dissipative portable work surfaceand a combined wrist strap and grounding strap to connect to the work surface. The proper way to use the kit follows.

NOTE: Vitronics-Soltec strongly recommends the use of a similar antistatic kit for all customers who do any self-maintenance on an Oven involving PC assemblies or semiconductor components.

1. Unfold the antistatic work surface and place it near the section of the oven where work will take place. Set it downwith the pocket side up. In addition, the surface under the mat must be clean and dry.

2. Remove the wrist strap and grounding cord from one of the pockets in the mat. Snap the round black connector inthe middle of the cord to the snap connector that is at one corner of the mat.

3. You might want to rotate the mat at this time so that the cord connector is closest to the oven where it will begrounded.

4. Slide the alligator clip onto the banana jack which is on one end of the cord. Use the alligator clip to connect the cordto an appropriate ground on the oven. Usually a piece of frame that is not painted works well.

5. Connect the wrist strap to the snap connector on the other end of the cord. The strap should 'snap' onto theconnector for a positive connection.

6. Put the wrist strap onto your wrist, making sure that the strap is in contact with your skin all the way around your wrist. Make sure that the strap is facing in the correct direction. The 'inside' of the strap will have metallic strands woveninto the material on the inside. You may not be able to see the strands but you will see the wrong color of thesestrands, typically off-white or gray.

7. Make sure that the wrist strap is tight on your wrist. If it needs to be adjusted, then 'pop' open the small plastic clipand pull the strap until it is tight around your wrist. When it is tight, hold the strap and close the clip so that it 'snaps'in place. This clip can be re-opened and the strap resized at anytime.

You are now ready to work on the static sensitive portions of the oven.

Remember; always put the wrist strap on before working on PC boards or semiconductors and leave it on until finishedwith the task. Always remain connected until all PC assemblies are re-installed on the oven or protected by antistaticbags.

When working on any electronic component, ALWAYS observe proper ESD handling procedures.

TAKE THE WRIST STRAP OFF before working on AC power!


A.C. & D.C. POWER SUPPLIES

CONTROL CIRCUIT TRANSFORMER

The control circuit transformer is a multi-tapped transformer. Determine that the primary conductors to this transformerare connected in agreement with the supply voltage at the Oven Installation site.

Refer to the table below for transformer tap settings.

SPLIT PRIMARY T1 CONNECTIONS

INPUTVAC

CONNECT F50 TO1L1 1L2

INSTALLJUMPER

190V H1A & H1B H2A & H2B200V H1A & H1B H3A & H3B208V H1A & H1B H4A & H4B220V H1A & H1B H5A & H5B240V H1A & H1B H6A & H6B380V H1A H2B H2A & H1B400V H1A H3B H3A & H1B415V H1A H4B H4A & H1B440V H1A H5B H5A & H1B480V H1A H6B H6A & H1B

Test procedure for control transformer voltage

With main power to the oven off, close the circuit breaker on the line side of the transformer. Open the circuit breakeron the secondary side of the transformer. Verify that the secondary side of the transformer's neutral leg is grounded.

Re-apply oven power. Using a Voltmeter set the proper range, measure the output voltage of the single phasecontrol transformer.(X1 – X4)

The output voltage of the transformer should be within +/-10% of the nominal transformer voltage (i.e. 108 VAC to 132VAC). If the output voltage of the transformer is outside these values, the primary taps of the transformer should beadjusted accordingly.

120 VAC PERIPHERAL SUPPLY (Option)

Two double way AC convenience outlets are located on the oven. The 120 volt convenience outlets have their hot terminals connected to wire #5, neutral to wire #2, ground to any groundterminal on the main electrical back panel. These outlets are protected by circuit breaker F54, located on the mainelectrical back panel.


Test procedure for AC Convenience Outlets

Disconnect power to the system. Using an Ohmmeter on its lowest scale, measure the resistance between theground terminal on the socket and the ground block on the main electrical back panel. This value should typically beless than 1 ohm.

With power applied to the system, use a Voltmeter set on the proper scale, measure the voltage between the live and

neutral terminals on the socket, this value should be to either 120 VAC.

D.C. POWER SUPPLY

Two DC Power Supplies provide the controller and various transducers with the required DC voltage. These suppliesare configured for 120 VAC input.For Power Supply Wiring Connections, refer to the Oven Schematics

Minimum load:

A minimum load is required by the +5 VDC output to maintain proper operation of the other outputs. A load pulling0.6 Amp is required. If the load is insufficient, a 10 ohm (5 Watt) resistor should be connected between the +5 VDCoutput (wire number 1001) and the DC ground output (wire number 1007).

Test procedure for D.C. power supply voltage:

Verify that all single pole circuit breakers on the secondary side of the transformer are off except F52 & F55. Applyoven power. If 120 VAC is present, measure the output voltages of the DC power supply.

D.C. power supply voltage adjustment:

Adjustments should be made to correct the voltage at the power supply output terminals. Voltage drops occurringover lengths of cable should have larger cables installed to reduce voltage losses.

Voltage Checks

When troubleshooting an electrical or electronic problem, always verify the basic AC and DC voltagessupplied for operation.


OVEN CONTROLLER

The Vitronics Control System is comprised of one DI (Digital Input /Output) board, a back-plane board, and one or moreAI (Analog Input) boards. One AI board controls up to 32 process loops. Each additional AI board increases the numberof control loops by 32. The Vitronics Control System controls the temperature of the cells, drives the conveyor and raildrive motors, and drives various logic signals through the I/O board.The Vitronics Control System receives all of its instructions from the computer by a serial interface.

NOTE: DI OR AI BOARDS SHOULD NEVER BE INSERTED OR REMOVED WITH POWER APPLIED TO THEVITRONICS CONTROL SYSTEM!

Test procedure for D.C. input voltage:

The power requirements for the Vitronics Control System, with one AI board, is:

+5.0 - +5.07 VDC @ 2 Amps max+15 VDC @ 0.1 Amps max (+12 to +15 VDC)-15 VDC @ 0.1 Amps max (+15 to -15 VDC)

Shut off circuit breaker F55 supplying 120 VAC power to DC power supply. Remove DI and AI boards from Vitronics Control System.

Reactivate 120 VAC power to DC power supply. Using a DC Voltmeter, measure the DC voltages at the backplaneconnector:

Oven Controller

Circuit Board

Common+5V

-15V+15V

1007100110021003


ADDRESSING DIP SWITCHES ON DI BOARD

The following shows the DI board DIP switches and meanings:

The status of the switches can be viewed in the Oven Control Program by selecting “DEBUG”, then “I/O”, then AnafazeDipswitch Setting.(It is not necessary to physically remove the electrical enclosure doors and actually view the actual switches on the OvenController)

ADDRESSING LINKS ON AI BOARD

The AI board contains two series of jumpers, combinations of which dictate the address of the AI board. The followingtable identifies the required jumper settings for the first two AI boards in a system:

Board number Channels Jumpers set

1 1 to 32 JU1 and JU11

2 33 to 64 JU2 and JU10

CONTROLLER STATUS

Upon power up the AI board's status lights should be in the following states:

Green light: On, steady. Orange light: On, flashing at approximately once per second. If the status lights are not in the above states check the +5 VDC at the terminal block mounted on the motherboard.

If the voltage at this point reads less than +5.00 VDC, check that the minimum load of the power supply is sufficient. If minimum load conditions are being met, then adjustment of the power supply output voltage may be attempted.

If no problems are detected with the power supply, then replace the EPROM on the DI board.

NOTE: WHEN REPLACING AN EPROM WEAR A STATIC GUARD WRIST STRAP (GROUNDED APPROPRIATELY)AND USE AN EXTRACTION / INSERTION TOOL TO REMOVE AND REPLACE THE EPROM. ENSURE THAT THE


EPROM IS CORRECTLY ORIENTED.

If the status lights are still not in the correct state then replace the controller boards, one at a time, in the following order:AI, DI, Mother board.

RS-232 SERIAL COMMUNICATION CHECKMake sure the connections on the Oven controller are correct. Check that jumper E20 on the DI board is in place.Using an Ohm meter check the continuity of the communications cable. The pin assignments should be as follows:• DB-9 Pin #2 (RX of computer) to I/O Board PX11-17 (TX of VCS)• DB-9 Pin #3 (TX of computer) to I/O Board PX11-18 (RX of VCS)• DB-9 Pin #5 (SG) to I/O Board PX11-19 (SG)

The direction of communication failure may be determined by connecting an LED and 470 ohm resistor in series betweenPX11-17 and PX11-19 on the Oven I/O board, and a similar LED and resistor network between PX11-18 and PX11-19 onthe Oven I/O board. If both LED's flash and there is no communications, and the computer is not receiving any data, thiscould indicate a fault with the cable or the computer serial port. If the LED connected to PX11-18 flashes, then data isbeing transmitted to the controller, but the controller is not responding. This could indicate a faulty DI board, EPROM inthe controller, or possibly, the TX and RX cables are reversed. If neither LED flashes then the computer is nottransmitting any data. This could indicate a fault with the cable or the computer serial port (check that thecommunications cable is connected into the correct serial port (COM1) on the computer).A further test is to use an oscilloscope to look at the voltages at PX11-17 (TX) and PX11-18 (RX). The signal shouldswitch between a positive value (+12 VDC to +16 VDC) and a negative value (-12 VDC to -16 VDC). The signal shouldbe free from noise greater than +/- 0.2 VDC.Noisy communication lines can be corrected by grounding the shield of the communication line, as well as moving thecommunication link away from any high voltage sources (especially running parallel to the communications lines).


CONTROLLER OUTPUTS (Input/Output board)

The Input/Output board provides the ability to switch 120 VAC power through interposing relays. The Oven controllercontrols the output status of the Input/Output board. Current limiters are installed on all conductors that supply power tomotors. As a diagnostic tool, the Input/Output board outputs may be manually activated one at a time.

See: “Checking Digital Output Status” in the Oven Operation Program.

NOTE: OPEN HEATER CIRCUIT BREAKERS BEFORE TESTING “Heater Power Enable”


COMPUTER SYSTEM

The computer system must be set up and connected to the Vitronics-Soltec Oven. The monitor and keyboard are placedon the swing arm / light tower. The keyboard, monitor, and computer connect together. The connections on the back ofthe computer are color coded, and they are different sizes/shapes to help connect them properly. (If the keyboard/mousedoes not function, swap the two connectors on the back of the Computer.)One data cable must be connected from the computer to the oven.Two 120VAC power cables (they are identical) are factory-wired for the Computer and Monitor. Plug the power cablesinto the receptacles on the rear of the Computer and Monitor.

CONTROL CIRCUIT

Test procedure for safety interlock circuit

Activate all circuit breakers. Ensure all E-stop switches are pulled out. Log into the Oven control Program and reset the E-Stop Alarm The E-stop relays K37 & K38 should be energized. If not, check the output of the control transformer using a

Voltmeter at wires #3 and #2. If voltage is present, but K37 & K38 are not energized, there is a break in the seriesconnection of safety interlocks.

Check that each E-stop and safety interlock switch de-energizes K37 & K38.

Note: The enclosure safety interlock switches mentioned above are optional and do not exist on all ovens.


ELECTRICAL GROUNDING OF OVEN

GENERAL:1) All ground wires have green or green/yellow insulation. Ground wires without green or green/yellow insulation

are identified using green or green/yellow tape.2) The main electrical panel has a single ground terminal. All grounds must be connected to the ground

terminal.3) Bare copper grounding wire inserted into an aluminum grounding block should be coated with an oxidation

inhibitor. Copper to aluminum has a natural galvanic reaction, which will degrade the electrical connection ina short time. Inhibitor is not required when ferrules are used.

4) Use long nose pliers when inserting a ground wire into a double layered ground block. Insert the wirecompletely into the block for a proper ground bond.

5) Ground blocks should be mounted on a clean and paint free surface. Use a star washer under the mountingscrews.

Test procedure for system ground continuity

1) Check continuity between the main ground terminal of the oven and the ground terminal on the mainsconnecting plug or distribution board using an Ohmmeter.

2) Check continuity from the mains ground terminal of the oven to each individual component using anOhmmeter.

3) The resistance values should not exceed one Ohm.

Test procedure for insulation leakage (MEGGER [or Resistance] TEST)

1) Disconnect the system from the mains supply2) Connect the three phases together at the mains supply connection point on the oven.3) Disconnect the Circuit Breakers supplying the control circuit transformer and the circuit breaker supplying

the inverter.4) Disconnect the computer and all peripheral equipment from the oven.5) Connect an insulation test meter between one of the three phases and the ground connection point.6) Turn on the Main Disconnect and test the system insulation for leakage at twice the single-phase voltage.

For example, for 240 VAC phase to neutral, check insulation at 500 Volts.7) The resistance should be at least 1 MegOhm.


E - ASSOCIATED SUBSYSTEMS

TRUE N2 / AIR SWITCHING

TRUE N2 / AIR Switching is: Standard on all NITROGEN ovens An option (NOT installed on all ovens)

On Nitrogen (N2) Reflow Ovens, the N2 / Air Automatic Switching Option permits switching from a Nitrogen to an AmbientAir (room air, not compressed air) atmosphere.

DESCRIPTION

This configuration is for customers who want a nitrogen oven, but intend to run both air and nitrogen atmospheres. Themachine is set up to optimize nitrogen performance, minimize 02 levels, minimize N2 consumption, and minimize tunnelmaintenance.

APPLICATION

The True N2 / Air switching provides automated switching from the N2 Mode to Air Mode with all of the benefits of a trueair machine. Any application considering air operation to any extent should incorporate this option.

BENEFITS

In addition to the benefits of Nitrogen, this option offers the ability to run a true air process, with the benefits longassociated with air machines (economical gas flow, and continuously flushing cleanliness). Both modes are controlledautomatically by the selection in the recipe file.

FUNCTION

A series of valves are added to the individual cell intakes, the Controlled Exhaust, and the FFC manifold to allowautomatic control of gas flows in the machine.

N2 MODE-Nitrogen flow to the machine automatically closes individual cell intake valves, closes the Air Controlled Exhaustvalve, and opens the Flux Flow Control manifold valve. In this configuration the machine functions as thestandard N2 FFC machine.

AIR MODE-Upon closing the N2 solenoid, individual cell intake valves automatically open, the Controlled Exhaust valveopens, and the FFC manifold valve closes (stopping gas recirculation). A valve on the far end of the FFCmanifold opens to allow air intake into the manifold. In this configuration the machine functions as an Air machine

MAINTENANCE:The True N2 / Air switching system requires minimal maintenance if operating properly, using recommended flowssettings, and periodic checks, as outlined in the operator manual. Periodic (every six months) inspection of the valvecylinders and valve seats is recommended to insure proper operation. Nitrogen lines to the valves should be checked forleaks.


BATTERY BACK-UP FOR PC, CONTROLLER, CONVEYOR, AND HOOD LIFTS

The UPS Battery Back-up is:

Standard, (installed on all ovens) An option, (NOT installed on all ovens)

DESCRIPTION:

In case of a power failure, the UPS, (uninterruptable power supply) battery provides power to the PC, oven controller,conveyor, and hood lift system. This provides a sufficient amount of time to completely empty out the Reflow Oven of anyproduct that may have been in process when the power failure occurred. The oven controller will provide an audiblealarm, and the PC will provide a message indicating the operation of the UPS system. The Battery Back-up Option willalso allow the Reflow Oven operator to open the Hoodlift should there be a need to remove product from the oven due tothe power failure.

NOTE: The length of time the UPS will operate is dependent on oven size, not time. The UPS will operate for a period oftime equal to the amount of time it will take a PCB to travel the full length of the oven at the speed contained in therunning recipe at the time of the power failure. After this period, the UPS will turn off, shutting down the PC, ovencontroller, conveyor, and hoodlift system.

(If the operator wishes to prevent the conveyor from running, the UPS backup battery should be disabled through theOven Control Program before a power failure.)

“POWER ON” DEFAULT FOR THE UPS BACKUP BATTERY:

Each time the oven’s PC is turned on or resets the UPS backup battery unit is reset to the previous status (on or off). The oven software remembers the last configuration, even after being ‘reset'.

PLEASE READ THE UPS MANUFACTURERS MANUAL DELIVERED WITH THE OVEN

PRODUCT TRACKING AND ALARM

Product Tracking and Alarm is:


The product tracking option has two photo-sensors. One mounted at the Onload end and one at the Offload endof the oven. Boards loading onto the conveyor are detected by the sensor and counted. The program calculates boardtravel through the oven, and each board is expected to pass under the Offload sensor within a time period based on theconveyor speed (as measured in PPI) and the oven length.

If a board does not pass under the Offload sensor within the calculated time, the "Board Dropped Alarm" is activated. The product length specified in the Product Definition determines the board length displayed on the screen.Additional information about Product Tracking is available in the XPM2 User Manual.


COMPUTER CONTROLLED EDGE-RAIL LUBRICATION

Computer Controlled Edge-Rail Lubrication is:


DESCRIPTION:

The edge-rail lubrication system is designed to improve the lifetime of the rail chain conveyor by periodically applyinglubrication to the chain during oven operation.

Two modes of lubrication are available, automatic and manual. Systems with automatic chain lubrication are alsocapable of performing manual chain lubrication, initiated by the operator, through the Oven Operation Program.

OPERATION: Following the enabling of an output from the controller, the system pumps oil from the reservoir, through tubing, to

stainless steel brush/wheels which are touching the chain and the oil is applied to the chain. It is the user’s responsibility to ensure that this reservoir is always filled with the required lubricant. The system

generates a warning message when it calculates that the oil in the reservoir is getting low. The lubricant type is DARMEX OIL # 773ND

During the lubrication process, the oil is applied for two complete cycles of the chain at the minimum calibrated conveyorspeed. The user may determine the number of chain cycles between automatic lubrications. 275 is the default number.

The number of complete lubrications held within one reservoir is set to the factory default of 50. The system will display awarning whenever it calculates that the reservoir level is getting low when the number of lubrication cycles that haveoccurred reaches the tank count number in the lubrication setup screen. Since the amount of oil dispensed in oneapplication is system dependent, the number of complete lubrications is best found by trial and error.

Construction:

The Auto Chain Lube Systemconsists of a 1liter polypropyleneoil reservoir, drain plug,electrically powered pump, tubingfor oil distribution, and twostainless steel brushes for theapplication of lubricating oildirectly to both oven conveyorchains.

Auto Chain Lube System Schematic


AUTO CHAIN LUBE TANK/PUMP ASSY

Operation:

The lubrication pump motor speed is 1 rpm with a displacement of .06cc per stroke (rev). The pump will supply 1 drop ofoil to the chain for each minute of conveyor chain travel. Therefore: if the conveyor is traveling at 14 in/min, 1 drop will beplaced on the chain every 14 inches. (A lube is done at whatever speed the conveyor is running at that time). A “LubeCycle” duration is (manual or automatic) is two complete chain cycles.

Priming:

Priming the system through the software can be very time consuming because of the low displacement of the pump... itis best to use an oil can (not supplied with oven) to do most of the priming.

Priming should only be necessary after:1. Servicing the autolube system2. The reservoir has been allowed to run dry and air has been pumped into the lube lines

Location:The Lubrication Tank-Pump Assembly is mounted to the frame at the front of the oven, inside the utility cabinet, at theexit end of the oven. Opening the cabinet will expose the Lubrication Tank-Pump Assembly mounted on the OvenFrame:

CHAIN LUBE RESERVOIR


INITIAL SETUP

The following process is done at the time the oven is built. It should be required only after repair or service of theAutolube System.

1. Locate the lubrication reservoir. ( see illustration above )2. Fill the reservoir with the lubricant, Darmex (Vitronics-Soltec P/N 1227204). (Remove the cap and pour the lubrication

into the top of the reservoir.3. Prime the lube system. Refer to the User Manual (Chain lubrication system setup) for details on how to prime the

system.4. Priming the autolube system can take as much 6 hours depending on the size of the oven. The priming operation will not

shut-off automatically, therefore it MUST be monitored to prevent excess oil from dripping on the floor.(During normal “Manual” & “Auto” Lube operations, the system does stop automatically)

NORMAL OPERATION

First, refer to Rail Chain Lubrication in the User Manual.

To perform a single manual lubrication of the conveyor chain:

1. Select manual lubrication in the Oven Control Software by clicking on the Oil cans Icon. The conveyor chain will run, andlube oil will be applied at the rate of 1 drop per 3 feet of chain, for two complete cycles of the chain(s).

For automatic lubrication of the conveyor chain on a regular basis:

1. Select automatic lubrication in the Oven Control Software. Enter the desired lube frequency. (The default is 275.) This isthe number of chain cycles between lubes.

2. Enter the lubrication alarm count. (The default is 50.) This is an estimate of the number of lubrications contained in theoil reservoir. Observe the amount of oil used for 50 oiling cycles and then adjust the number up or down depending onthe amount of oil remaining in the reservoir only after refilling the reservoir

In automatic mode, the lubrication process does not interrupt oven processing. The chain will be lubed while there is product in the oven.

Avoid “over oiling” and getting lubricant on the conveyor chain transport pins. Apply the lubricant sparingly, do not soakthe chain or apply so much that the lubricant drips off. Make sure the factory exhaust system is on and operatingproperly because some fumes may be created once the heaters are turned on

ALARMS:

When the alarm count for lubrications has been reached a “Low Oil Message” will be displayed at the bottom of theOperating Screen. Automatic or manual lubrication will not be permitted until the reservoir has been filled, and thealarm reset.

This is the best time to adjust the cycles between lubes and/or the number of lubes before “Low Oil Message alarm.


BOARD SUPPORT

Board Support is:


The Board Support is a precision flexible metal belt carrying vertical pins positioned under the Printed Circuit Board duringthe process through the oven. The adjustment of the location of the belt under the product is driven by an electric motor. A selector switch on the operator’s panel operates the motor. If the Board Support is not required for a particular product,it can be positioned between the fixed rail pin chain. The free space required is 8 mm on one side of the Printed CircuitBoard, facing the Operator.

There must be a clear space of 3mm (1/8 inch) on the bottom side of the PCB for the pins of the CBS.

CONTROLLED COOLING

Controlled Cooling is:


DESCRIPTION:The Controlled Cooling System consists of two independent cooling circuits on the oven. The cooling circuits operate byrecirculating a cooling fluid through gas-to-liquid heat exchangers in the cooling cells of the oven and through liquid-to-airheat exchangers external to the process tunnel of the oven. By adjusting the liquid temperature of the coolant with acirculation heater and by controlling the external cooling fan, the gas temperature in the cooling cells of the oven can becontrolled.

CONTROL:The operator interface for adjusting controlled cooling zone setpoints is the same as for the heated zones of the oven. Acontrolled cooling equipped oven has two cooling cell setpoints, which can be changed by the operator within the OvenControl Program. An oven with two cooling zones has a set point for each. An oven with three cooling zones has a setpoint for the first and second cooling zones (the first cooling zone being the one closest to the heated section of theoven). An oven with four cooling zones has a set point for the first and third zones.

OPERATION & PROCESS:Controlled Cooling provides the ability to stabilize the temperatures in the cooling zones of the oven. It providescompensation for factors such as changes in ambient temperature and product loading. It also allows the cooling zonesto reach a stable temperature much sooner than is possible with uncontrolled cooling, and ties the cooling zonetemperatures to the process ready condition of the oven.The temperature range which is attainable for Controlled Cooling zones is influenced by many factors, including, but notlimited to, the following: heated zone set-points, conveyor type, conveyor speed, product loading, nitrogen flow settings,machine exhaust, controlled exhaust setting, etc.


CONTROLLED EXHAUST SYSTEM (AIR ONLY OR OVENS EQUIPPED WITH AIR SWITCHING)

CONTROLLED EXHAUST SYSTEM (CES) (Air Mode)

This exhaust subsystem extracts heated gas directly from the oven chamber between the last heating zone and the firstcooling zone, minimizing the amount of heat and flux entering the cooling section of the oven. The result is productcooling improvement and maintenance reduction in the Air Mode. It generates a controllable, positive exhaust flow anddoes not depend on the facility exhaust for its operation.A small amount of compressed air flows through a Venturi (mounted inside the Controlled Exhaust Tube) and creates anegative pressure at the CES slot in the oven chamber. This draws gas out of the Oven Chamber. The oven chamberexhaust flow rate is controlled by the amount of air supplied to the oven. The cooling effect of the incoming compressed air causes an accumulation of flux condensate in the exhaust nozzle. The nozzle requires periodic cleaning.

INDIVIDUAL CELL INLETS

The “makeup” gas to replace the exhaust flow is supplied by the gas intakes of the individual Zones (cells). Additional “makeup” enters the oven chambers at the “onload” and “offload” openings.CES system is not used with N2 to minimize nitrogen consumption.


INTEGRATED EXHAUST STACK FILTER

The Integrated Exhaust Stack Filter is:


PURPOSE:

To capture and dispose of the byproducts of SMT reflow by condensing and filtering the oven exhaust.

APPLICATIONThe Integrated Exhaust Stack Filter option is a simple filtering method for capturing and disposing of many of the by-products of the Surface Mount Reflow Process. The Integrated Exhaust Stack filter consists of two filters in metalenclosure. The enclosure has an inlet and a connection point for a factory exhaust duct. There is an access door forchanging the disposable filters.The introduction ambient room air powered by the facility exhaust accomplishes condensation. The hot gas exhauststream from the FFC system is routed to the intake tube of the filter enclosure where it is mixed with several streams ofambient air. The cooling effect of the room air streams causes flux and other outgassed contaminants to condense inthe exhaust stream as it enters the box, but prior to passing through the filter. Contaminants are trapped in the filter, andthe cleaned gas continues out the exhaust duct.

BENEFITS• Flux and other out-gassed contaminants are captured in an easily changed, disposable filter.• Provides increased protection of the facility exhaust system from contaminants.• Totally within the overall footprint of the Reflow Oven.• Inexpensive locally available filter

MAINTENANCE:

Filter change interval is approximately every 2 weeks, but is throughput and paste dependent.Filter change requires 1 minute or lessFilter Enclosure cleaning interval is approximately every two months, but is throughput and paste dependent.

Note: The contaminants caught by the filters are hazardous waste. Proper disposal techniques should befollowed. The filter contaminants are paste and product dependent. Refer to the paste specification for moreinformation.

Wear latex gloves, eye protection and breathing protection when changing filter.

Filters:

1 – 1x10x20 Polyester Smith 5003, part number #12486011 – 1x10x20 SEP Pleated Smith Special, part number #1248701


FLUX EVACUATION SYSTEM

The Flux Evacuation System is:


NOTE: The Flux Evacuation System is STANDARD on all N2 Ovens

PURPOSE

The Vitronics-Soltec Flux Evacuation System is designed to reduce the flow of flux fumes into the cool zones of thetunnel, resulting in longer maintenance intervals.

APPLICATION

The Flux Evacuation System is the standard gas management system on Vitronics-Soltec ovens equipped with theNitrogen option. This configuration is best suited for applications running nearly exclusively nitrogen recipes. The oven issetup to minimize tunnel maintenance, optimize nitrogen performance, minimize O2 levels, and minimize N2consumption.

BENEFITS

The XPM2 series Flux Evacuation System is designed to inhibit the flow of hot flux fumes into the cool zones of the tunnel(where they can cause maintenance problems), while still optimizing nitrogen performance. This control of gas flowinsures a cleaner cooling zone with maintenance intervals significantly increased. Although widely varying processparameters will cause individual maintenance intervals to differ, an average expectation should be up to 8 times lessfrequent.

The Flux Evacuation System has secondary benefits. In all applications, there should be a noticeable reduction in coolingzone temperatures. Actual reductions will, of course, be dependent on individual process parameters. The FluxEvacuation System will not adversely effect nitrogen consumption or 02-PPM levels, as specified by Vitronics Soltec forXPM2 series ovens.It is important to be aware that fan speed settings lower than 2500 RPM will disable the Flux Evacuation Systemand will increase flux contamination in the oven

MAINTENANCE

The Flux Evacuation System is virtually maintenance free if operating properly. To ensure this, it is recommended that theinlet tube from the Flux Flow Control manifold into zone 2 be checked periodically (every three months) for flux residue. Ifa flux accumulation is noticed, the flux evacuation manifold may need to be cleaned.


FUNCTION OF THE FLUX EVACUATION SYSTEM

N2 Mode -The Flux Flow Control Manifold creates a recirculation loop by drawing gas from the tunnel into the controlled exhaustplenum between the last heat and first cool zones, and returning it to the preheat and soak zones through several of thepatented individual cell inlets. The force powering this recirculation loop is low pressure at the cell inlet, created by the cellfan. There are no moving parts to this system.

Flow into the controlled exhaust plenum is biased in favor of drawing from the cool zone side. This is accomplished byraising the pressure in the cool zone (by inputting a high percentage of the total oven nitrogen consumption into thatarea), and by reducing the pressure in the last heated zone (by fully opening the individual cell outlet.) The total ovenexhaust is taken from this one port.

The recirculation loop carries low O2 PPM gas from the first cool zone, into the preheat and soak sections of the heatedzone, maintaining low O2 PPMs throughout the tunnel. The recirculation loop carries out flux contaminants trying to enterthe cooling zones. The higher pressure in the cooling zones inhibits the migration of flux contaminants from the heatedzones. The amount of flow into the controlled exhaust from the last heated zone is at a rate that will maintain the totalrecirculation loop gas temperature above 120°C, which prevents condensation.

Exhaust flow out of the oven is maximized in volume, and also positioned in the tunnel at the point of highest fluxconcentration (the last heated zone), to maximize the amount of flux contaminant per cubic foot of exhaust.


AIR MODE-

The N2 solenoid and the Compressed Air Solenoid will toggle, following the selection of an Air profile by the operator. Allgas flows in the oven remain identical to the N2 Mode, except that Nitrogen is replaced with compressed Air. Flow ratiosand all other process parameters remain identical.

MAINTENANCE

The Flux Flow Control system is virtually maintenance free if operating properly. To ensure this, it is recommended thatthe inlet tube from the Flux Flow Control manifold into zone 1 be checked periodically (every six months) for flux residue.

The Flux-Flow Control System is located under the sheet metal skins at the top of the Oven:

Individual Zone Exhaust Duct

Flux Flow Control Duct


HOODLIFTS


Operation;

The electromechanical actuators raise and lower the Hood (including the upper heat zones of the oven). All models ofVitronics-Soltec Reflow Ovens have 2 or 3 (depending on oven size) LINAK hoodlift Actuators with a LINAK control boxdirectly wired to the HOOD UP and HOOD DOWN selector switch on the oven operator control panel. The generalarrangement of the LINAK Actuators is shown here. A UPS option is available to permit opening the Oven Hood in theevent of a power failure.


ACTUATOR REMOVE AND REPLACE PROCEDURES

Removing the actuator assembly when the actuator has failed in the open position:

Stack wooden blocks/boards under the hood (where the actuator is connected to the hood), to keep the hood open whenthe actuator is removed. Be careful to make the stack of wood stable.

Remove the bonnet bridge sheet metal piece on the end of the oven where the actuator will be changed.

Remove the two safety clips from the pin holding the actuator piston to the bracket. Remove the piston pin holding theactuator piston to the bracket. You may need to exert some pressure on the inner hood assembly to remove the pin.

The body of the actuator is accessed through the equipment cabinets on each end of the oven.

Unplug the actuator from the control box and remove the actuatorcable with the actuator.


Remove the two safety clips from the pin holding the actuator piston to the bracket. Remove the piston pin holding theactuator piston to the bracket.

The installation procedure is the reverse if the removal procedure.


REPLACING THE ACTUATOR ASSEMBLY WITH THE BONNET IN THE CLOSED POSITION:

Remove the bonnet bridge sheet metal piece on the end of the oven where the actuator will be changed.

The body of the actuator is accessed through the equipment cabinets on each end of the oven.

Carefully raise the actuator and position it in its frame location. Use the mounting pin to lock the piston in place in thebracket. As you are pushing the mounting pin into place, install the locking shaft collars on each side of the piston. Replace the two safety clips on the mounting pin. Let the actuator hang from the mounting pin.

Carefully position the actuator so that the holes for the actuator pivot pin are aligned with the holes in the side of theactuator sheet metal. Insert the actuator pivot pin. As you are pushing the mounting pin into place, install the lockingshaft collars on each side of the piston. Replace the two safety clips on the mounting pin. Let the actuator hang from the


mounting pin.

Plug the control cable of the new actuator to the control box. Turn power on to the oven so the actuator can be operated. Perform the actuator set-up and synchronization at this time.

The installation procedure is the reverse of the removal procedure.

SET-UP AND SYNCHRONIZATION OF THE LINAK ACTUATORS:

The actuators are installed and synchronized on the oven when it is built.

Caution Notes:The following process is used for two or three actuators on the same oven, and is required only after replacement of anactuator or control box, or if an actuator is out of adjustment.

1. Do not turn the spindle while the actuator is plugged into the actuator control box. This will senderroneous pulses to the control box causing misalignment and possible damage to the system. For initial factoryset-up or field replacement, the spindle may be turned no more than three revolutions to align the clevis pin holeto the bracket. This must only be done when the actuator is unplugged from the control box.

2. Do not unplug the actuator from the control box during operation or in an attempt to adjust or synchronize theactuators. This will cause misalignment resulting in possible damage to the system.

3. Raising or lowering one side of the heat zone more than the prescribed distance may cause structural damage tothe system.


TWO ACTUATOR SYSTEM

The following initialization procedure applies to a two actuator system and requires two people to complete it:

1. With the bonnet in the down position and the actuators properly connected mechanically and electrically, raise theheat zone no more than 1".

2. Disconnect the power to the control box by shutting off the circuit breaker (F52) for at least 5 seconds.

3. On the operator control panel, turn the Hood selector switch to the DOWN position and hold while reconnectingthe main power to the actuator control box. Listen for a buzzing sound coming from the control box. At this pointthe hood selector switch will activate the LEFT actuator and lower the heat zone on that side.

4. Keep the hood selector switch engaged making sure the left actuator pulls the main heat zone down tightlyagainst the lower channel, then release the hood selector switch.

5. Disconnect the power to the control box again by shutting off circuit breaker (F52) for at least 5 seconds

6. On the operator control panel, and turn the hood selector switch to the UP position and hold while reconnectingthe main power to the actuator control box. Listen for a buzzing sound coming from the control box. At this point,the hood selector switch has been used to activate the RIGHT actuator causing it to raise the heat zone on thatside. Once you notice the right side rising slightly, immediately turn the selector switch to the DOWN position andlower the heat zone completely. Caution: Moving the heat zone any more than the prescribed distance maycause structural damage to the system.

7. Keep the hood selector switch engaged making sure the right actuator pulls the main heat zone down tightagainst the lower channel, and then release the hood selector switch.

8. Disconnect the power to the actuator control box again by shutting off circuit breaker (F52) for at least 5 seconds.The initialization process is now complete.


THREE ACTUATOR SYSTEM

The following initialization procedure applies to a three actuator system and requires two people to complete it:

1. With the bonnet in the down position and the actuators properly connected mechanically and electrically, raise theheat zone no more than 1”.

2. Disconnect the power to the control box by shutting off the F52 circuit breaker for at least 5 seconds

3. On the operator control panel, turn the hood selector switch to the UP position while reconnecting the main powerto the actuator control box. Listen for the buzzing sound coming from the control box. At this point turn the hoodselector switch to the DOWN position; this will activate all three actuators to the DOWN position.

4. Keep the hood selector switch engaged making sure that each actuator pulls the main heat zone down tightlyagainst the lower channel, then release the hood selector switch.

5. Disconnect the power to the control box again by shutting off the F52 circuit breaker for at least 5 seconds. Theinitialization process is now complete.

Periodic Inspection and Maintenance:

Clean the piston rod in the fully extended position and inspect for mechanical wear or damage. Inspect the attachmentpoints, wiring, plugs, and control box. The LINAK actuator is an enclosed unit and does not require any internalmaintenance or lubrication.

Troubleshooting:------------------------------------------------------------------------------------------------------------------Symptom: No motor sound or movement of piston rod.Possible Causes:

1. The actuator is not plugged securely into the control box.2. Blown fuse in the control box.3. Cable damage.

------------------------------------------------------------------------------------------------------------------Symptom: Movement of actuators not synchronized.Possible Cause: Control box out of initialization.


INDEPENDENT ALARM SCANNER OVER-TEMP & ALARM/SHUTDOWN

The Independent Alarm Scanner is:


DESCRIPTION:

The Independent Alarm Scanner & Alarm/Shutdown (IAS) system provides a redundant temperature backup system inthe event that a heating cell exceeds the critical temperature safety limit. The hardware consists of one (1) additionalthermocouple per heat cell, and the Independent Alarm Scanner (IAS) instrument, which can monitor as many as 32thermocouples.A second type K thermocouple is clamped on the face of every addition to the standard T/CThe Independent Alarm Scanner (IAS) receives each of these thermocouple signals as separate inputs and scans themfor an over-temperature indication.

The control circuit inter-action is:

In the event that an alarm condition (generated from the Redundant T/Cs) occurs, the IAS' alarm contact interrupts the 24VAC to relay K4. This in interrupts the 120 VAC to the coil of heater contactor K2, and supplies an alarm signal to thecontroller. The IAS unit scans all redundant thermocouples wired to it for an “Over-temperature” condition.

Notes:

All unused T/C terminals MUST be jumpered. In case of a nuisance trip, the defective T/C can be found by

placing a jumper on the T/Cs one-at-a-time until the “alarm” iseliminated.

The setpoint should be set slightly higher than the temperatureexpected during “normal oven operation”.

The IAS will go into an alarm state in case of an IAS failure orloss of power. A jumper on the output contacts will allow theoven to be operated without the IAS until a replacement can beinstalled.

Alarm setpoint adjustment

Thermocouple conductors


INDIVIDUAL CELL SENSING

Individual Cell Sensing and Alarm is:


DESCRIPTION:

The Individual Cell Sensing Option monitors for a cell fan motor failure or a heating cell over-temperature switch failure.

Each Cell Fan Motor has a speed sensor mounted on the end of the motor shaft. When a motor slows to less than 500RPM, the sensor sends a signal to produce the Fan Low Alarm. . When a low fan speed warning exists, an alarmmessage indicating the specific failed fan motor is displayed in the oven software. (Check the heat slinger on the suspectmotor to determine actual fan operation.)

Each heating cell is equipped with a bimetallic over-temperature switch mounted on the backside of the heater panel. When the cell temperature exceeds the switch temperature, the internal contacts open. This will interrupt the 3- phasepower to the heaters, and a signal is sent to the Oven Controller to indicate an "over-temperature" condition. This willgenerate an IAS alert alarm message along with an alarm message that corresponds to the cell location that generatedthe alarm.

General

Cell sensor monitoring only takes place when the cell fans are running to avoid nuisance alarms due to the limitations ofthe existing controller. The IAS alarm level setting must be set for an alarm level other then critical in order to sense andreport individual temperature switch alarms. This is because a critical alarm level setting will cause the cell fans to shut offimmediately when an alarm occurs with a critical alarm level setting.

Cell Motor sensors

Disconnect the following cell motor sensors one at time by unplugging connector P2 (1479503 3 position connector) onthe corresponding 3152701 cell interface board with the cell fans running above 100 rpm.Install a 3-pin connector (1479503) with a jumper installed between pin 2 and pin 3 of the connector in place of the cellmotor sensor to force a cell fan alarm.Verify that each alarm message is displayed on the PC and that the alarm message text corresponds to the cell locationwith the alarm. It takes up to 68 seconds for an alarm condition to be detected and reported on the PC.

This test verifies that each 3152202 board is configured correctly and is communicating correctly with the DI board.

3152202Board#

Model 520 Model 730/820 Model940/1030

Model 1240

Master Zone 1 Top Zone 1 Top Zone 1 Top Zone 1 TopBoard 2 Zone 1 Bottom Zone 1 Bottom Zone 1 Bottom Zone 1 BottomBoard 3 Zone 10 Top Zone 13 Top Zone 16 TopBoard 4 Zone 10

BottomZone 13Bottom

Zone 16Bottom


CELL OVER TEMPERATURE SWITCHES

Preliminary Testing

Verify continuity of the heater over temperature switch circuit from wire number 2400 on zone 1 top to the coil of K4 onthe back panel.Verify that the harness wiring is correct on connector P3 (1479508 8 position connector) of each 3152701 cell interfaceboard by unplugging the heater over temperature switch connector P1 (1479502 2 position connector) on each cellinterface board.The red led on each cell interface board will light when the heater over temperature switch connector is unplugged to theboard. If the red led fails to light and continuity is OK in the heater over temperature switch circuit then the wires arereversed in position 1 and 2 of connector P3.

Alarm Testing

Disconnect the following heater over temperature switches one at time by unplugging connector P1 (1479502 2 positionconnector) on the corresponding 3152701 cell interface board.Verify that each alarm message is displayed on the PC and that the alarm message text corresponds to the cell locationthat has the alarm. It takes up to 68 seconds for an alarm condition to be detected and reported on the PC.Verify that an IAS alert alarm message is present, which indicates that K4 on the back panel is shutting off when a heaterover temperature switch is opened.

This test verifies that each 3152202 board is configured correctly and is also communicating correctly with the DI boardand that relay K4 on the back panel shuts off when a heater over temperature switch is opened.

3152202Board#

Model 520 Model 730/820 Model940/1030

Model 1240

Master Zone 1 Top Zone 1 Top Zone 1 Top Zone 1 TopBoard 2 Zone 1 Bottom Zone 1 Bottom Zone 1 Bottom Zone 1 BottomBoard 3 Zone 7 Top Zone 9 Top Zone 12 TopBoard 4 Zone 7 Bottom Zone 9 Bottom Zone 12

Bottom

3152202 Assembly 16 Channel Input Board Theory of Operation

The Atmel Atmega8 micro-controller is the main component on the board. The Atmega8 has one built in UART. TheUART is used to communicate to an RS485 connection on a multi-drop network through MODBUS protocol.

The RS485 port is not used directly with the existing controller since the existing controller does not have additional serialports available. Instead a frequency generator output from the micro-controller is used on the controller that is set as theMaster through switch 4 of dip switch S1 to communicate digital input status data to the existing controller through using acounter input on the existing controller. The frequency generator output is derived by using the timer/counter compareoutput of timer 1 of the Atmega8 micro-controller.


The master controller initiates MODBUS commands to up to three other 3152202 boards connected on a RS485 networkto gather digital input status information from each board. The master controller transfers digital input status informationfor itself and for up to three other 3152202 boards using a digital input handshake with the existing controller. Thefrequency generator output transfers digital input status data as one nibble at a time (4 bits) to a counter input on theexisting controller. There is a special frequency output setting that serves as an identity stamp to mark the very first nibbleof the possible 16 nibbles that are sent. The existing controller momentarily sets a digital output that is connected to adigital input on the 3152202 board serving as a Master. This is to signal that a frequency has been read correctly and toprompt the Master to send the data for the next nibble or the identity stamp depending on where the Master controller is inthe send sequence. The existing controller checks the counter input once a second and signals the Master to send datafor the next nibble when the past and current counter values are equal, which is typically 4 seconds. It takes 68 secondsto transfer all of the digital input status information for four 3152202 boards.

Table 1.0

S1 Dip Switch SettingsBoardSwitch 1 Switch 2 Switch 3 Switch 4

Description

Master OFF OFF OFF ON

Board address offset 0, board functions as amaster on a MODBUS network and initiatesMODBUS commands to other boards on thenetwork

Board 2 ON OFF OFF OFF Board address offset 1, board functions as a slaveon a MODBUS network

Board 3 OFF ON OFF OFF Board address offset 2, board functions as a slaveon a MODBUS network

Board 4 ON ON OFF OFF Board address offset 3, board functions as a slaveon a MODBUS network


HEATER CELL OVER-TEMPERATURE SWITCHES

Heater cell over-temperature switches are:


DESECRIPTION:

Each heating cell is equipped with a bimetallic over-temperature switch mounted on the backside of the heater panel. When the cell temperature exceeds the switch temperature, the internal contacts open. This will interrupt the 3- phasepower to the heaters, and a signal is sent to the Oven Controller indicating an "over-temperature" condition. This willgenerate an IAS alert alarm message.This system generates only an IAS alert alarm message and will not indicate the cell location that generated the alarm. The faulty cell must be found by diagnostically testing the functions of the cell over-temperature switches, looking foreither continuity (machine power removed) or voltage loss across the switch.

On the back (top / bottom side) of each heater cell is a terminal block assembly.Check for either continuity or +24 VDC between terminals 24-1 and 24-2. To read continuity machine power must becompletely disconnected.To read voltage place the positive lead in terminal 24-1 and the negative lead in ground to verify input voltage to theswitch. If input voltage is present, then move the positive lead to terminal 24-2. If there is no voltage present, the switchis open. If the switch continuity or voltage checks are good, then move on to the next switch. Is it easiest to start at thelast heat zone on the top and then divide the machine in half for each subsequent check. If the last top heat zone switchchecks good, move directly to the bottom heat cells.


LIGHT TOWER

The Light Tower is:


DESCRIPTION:

The Light Tower assembly is a mast with four indicating lights mounted on the on-load end of the Reflow Oven. Thelights indicate the status of Oven operation and are duplicates of functions and colors displayed by the Oven ControlSoftware on the computer screen.

The standard color arrangement is shown below.(Other configurations are available by special order)

.

LIGHT TOWER LENS COLOR MEANINGCOLOR DESCRIPTIONRED Alarm and ShutdownWHITE Power “On” / Applied to ovenAMBER Process WarningGREEN Process Operation Ready (O.K.)

(Refer to Oven schematics for Light Tower and Alarm wiring)


ON-BOARD OXYGEN (O2) ANALYZER

THE ON-BOARD OXYGEN ANALYZER IS:


DESCRIPTION:

The On-Board O2 Analyzer is a self-contained unit consisting of an oxygen sensor, pump, and power supply, completelyintegrated with the Reflow Oven. The Analyzer is mounted at the rear of the oven behind the lower skins and near the N2flow meters. The Neutronics model 3100 oxygen analyzer is a 2-piece design. The controller box mounts in a cutout onthe front of the pneumatics panel and the sensor and pump assembly mounts on a bracket on the rear of the pneumaticspanel.The oxygen sensor consists of a solid state ion conductor of stabilized zirconiumoxide, which is heated to a constanttemperature of 1000 K (727°C). The measured oxygen content is displayed on the face of the Analyzer and on thecomputer monitor through the Oven Control Program.

PURPOSE:

XPM2 Nitrogen ovens are equipped with a single sampling port located in the peak zone (standard) or a 4 port system(optional) with probes located in the Preheat, Soak, and Reflow zones and Source Gas).The 4-port option has a rotary 5-way valve located next to the Analyzer. The 5-way valve is used to select the locationfrom which the Analyzer sample is taken. These sampling ports are used to determine the oxygen content inside theoven.

APPLICATION:

The Analyzer has controls on its front panel for the operation of the unit. The Analyzer settings should not be changedduring normal oven operation while using nitrogen as an atmosphere. The Analyzer will continuously sample to provide areal-time measurement of the tunnel atmosphere.

ANALYZER OPERATION

Switching On the Neutronics Model 3100 O2 Analyzer

Configure the O2 analyzer option for the Neutronics Model 3100 on the atmosphere tab.The 115VAC supply power to the Analyzer is controlled by relay K8 on the A1 board through wire number 52.The analyzer is switched on whenever the oven is operating in a nitrogen mode.

Entering Neutronics Model 3100 Setup Mode

Press and hold the Mode key for 10 seconds, “CAL” will display on the analyzer while the mode key is held in followed by“----“ after 10 seconds.Press the mode key to step through the selections below until the display indicates “4 0”.Use the up and down arrow keys to change the display to “4 3”.Press the mode key until the display shows “- “to exit the setup mode and return to the run mode.


Display Mode Description Setting

A 8 Configuration A:set range Display range setting 8 =Auto Range (default)

1 0 Configuration 1:Alarm 1 Trip

Alarm 1descending/ascending 0 =ascending alarm1 (default)

2 0 Configuration 2:Alarm 2 Trip

Alarm 2descending/ascending 0 =ascending alarm1 (default)

3 1 Configuration 3:Analog output Analog voltage output 1=0-10vdc (default)

4 0Configuration 4:Set SerialOutput

Serial output format0=none (default), Must changeto 3=machine with checksum

7 9 Configuration 7:Set Zero Range Set zero calibration range 9=18%-24% (default)

F 0 Configuration F:Set Fail Safe Alarms 1 & 2 fail safe

0=not failsafe, relays areenergized in an alarm condition(default)

b 5 Configuration b:Serial baud rate

RS-232 port baud rate 5=9600 (default)

C 0Configuration C:Initiate cleanmode

0=normal sensor operation(default)

E 0Configuration E:Set voltage to110 or 220 VAC

Remote Sensor Modulesupply voltage

0=110 VAC (default) do notchange without changing theswitch setting on the remotesensor module, otherwise theremote sensor module will bepermanently damaged

8 0Configuration 8:Reset to factorydefaults

Restore factory defaults 0=normal operation (default), 888restores factory defaults

-

3152502 ASSEMBLY O2 ANALYZER INTERFACE BOARD THEORY OF OPERATION

The Atmel Atmega161 micro-controller is the main component on the board. The Atmega161 has two built in UARTS.The first UART is used to communicate to an RS485 connection on a multi-drop network through MODBUS protocol. Thesecond UART is used to communicate directly to an O2 analyzer through an RS232 connection.

The RS485 port is not used with the existing controller since the existing controller does not have additional serial portsavailable. Instead, two frequency generator outputs from the micro-controller are used to communicate O2 analyzer datato the existing controller by using two counter inputs on the existing controller. Using the timer/counter compare outputs oftimer 1 and timer 2 of the Atmega161 micro-controller derives the two frequency generator outputs. Timer 1 has 16-bitresolution and is used to send measured value information, while timer 2 has 8-bit resolution and is used to send rangeand alarm information. The Neutronics model 3100 analyzer has six ranges and automatically changes ranges tomeasure from 0ppm to 100% concentration.Dipswitch 4 on S1 is used to enable the use of the two frequency generator outputs through software when the switch isset to the ON position. Oxygen analyzer related parameters in the recipe editor are not displayed when the atmosphere setting is for air on aswitching atmosphere oven or on an air only oven. A graphic LED indicator is displayed in the oxygen analyzer field toindicate that the “ready to measure signal” is present from the oxygen analyzer. The oxygen analyzer reading is includedin trending and data logging.


POLAR COOL™ OPTION

Polar Cool™ is:

Standard (on Nitrogen ovens) An option (on all ovens)

DESCRIPTION:

The Polar Cooling™ system is self-contained and mounted to and integrated with the oven. This system does notrequire any external service connections to the Reflow Oven.

OPERATION:

The Polar Cool System uses an air-to-liquid-to-air heat collection and discharge system. A cooling fluid (Vitronics SUPERCOOL Part No. 3313350) is pumped through heat exchangers in the cooling cells. Heat is absorbed into the fluid, andthen carried by the cooling fluid to a radiator-fan unit. The heat removed from the cooling cells in the tunnel is thendischarged into room.Two reusable, easy to remove heat exchangers are mounted in each of the 2, 3 or 4 cooling cells. (The number ofcooling cells depends on the Oven Model)


The following diagram shows the Polar Cooling™ option configured for an oven with three cooling zones. (Two or fourcooling zones would be similar)

PolarCool ™ and Control Cooling Plumbing Schematic

The cooling fluid is Vitronics SUPER COOL cooling fluid, Part No. 3313350. During normal operation, the coolingfluid will be warmer than the “dew point temperature” of the room and not warmer than the frame of the oven.Two thermocouples sense the coolant temperature, which is displayed on the Oven Control Software screen.

DO NOT SUBSTITUTE ANY OTHER FLUID AS COOLANT IN THIS SYSTEM!


The Polar Cooling™ and Control Cooling system is comprised of three major elements:1) Heat exchangers,2) Radiator-Fan Unit,3) Reservoir-Pump Unit

HEAT EXCHANGERS:

A “cold plate” and a “flux-capture filter” fin assembly combined form a cell heat exchanger.The cold plate is a gas-to-liquid heat-absorbing aluminum assembly with tubing connections and a serpentine path insidefor coolant flow.

The aluminum fume capture filter/fin element is housed within an aluminum “clam-shell” housing which is seated againstthe cold plate. This assembly conducts heat to the cold-plate as well as filters flux vapors from the oven gas.

The filters require periodic maintenance, but can be removed and replaced using a simple hand tool (There is no liquidconnection). Two cam locks in the air recirculation slots of the cooling cells secure the clamshell assembly. Once thecam locks are released, the "clam shell" housing can be removed from the cell and opened to expose the filter.

Used filters can be cleaned with isopropyl alcohol and reused, or discarded.

“Clam-Shell” Assembly with fume-capture filters


RADIATOR-FAN UNIT:

The radiator-fan units are at the rear of the Oven, mounted to the top frame under the sheet metal panels near the Off-load (Exit) end of the Oven. Air is forced through the radiator by an axial fan.

Proper operation and cooling cannot take place without adequate airflow through the radiator-fan unit(s).

RADIATOR-FAN UNIT


RESERVOIR -PUMP UNIT:

The Reservoir-Pump Unit is mounted on the frame at the rear of oven.

The reservoir is a 1.6 Gallon stainless steel tank. The level switch in the reservoir monitors coolant level and the flowswitch checks return flow. The high-pressure switch trips at 60 PSI. A periodic check of the coolant level in the reservoiris necessary.

The coolant return line is submerged near the bottom of the reservoir to reduce aeration of the coolant and to help assurecondensation of any returning vapor. The supply line to the coolant pump is in the bottom of the reservoir with a valve fordraining the system. The check valve in the supply line prevents coolant flow back to the reservoir. It also permitscleaning the in-line strainer without draining the heat exchangers.

The flow switch and level switch are inputs for the Oven Control Program display of the LOW FLOW - LOW COOLANTalarm.

TESTING:The motor and supply circuit should be tested. If the Voltage is NOT within the 100 to 120V range recommended, thetransformer connections should be changed according to the changeover chart.

1) Allow the motor to reach a stable temperature with the oven hot.

2) The case temperature of the motor should not exceed 80°C. A normal Pump Motor Case temperature isabout 70 - 80°C at 115V.

3) The internal temperature cut off switch is set for 150° C. (case temperature about 100° C.)

4) If the motor is over temperature, operating at 100 to 116 VAC, it should be replaced.


EXTERNAL COOLING LIQUID SUPPLY OPTION

DESCRIPTION:

Heat in the cooling cells is absorbed by heat exchangers (two heat exchangers per top cooling cell) and conducted awayby the cooling fluid supplied by an external cooling system. The external cooling system should meet the followingspecifications:

Supply Pressure: 20 to 40 psi [1.38 to 2.76 bar]Flow Rate: 1 to 3 gpm [4.55 to 13.64 lpm]Inlet Connection: 1/2" N.P.TOutlet Connection: 1/2" N.P.T.

NOTE: Vitronics Soltec does not provide hose, clamps and hardware for connections between the reflow system and theexternal cooling liquid supply (chiller, plant water, etc.).


NOTE: This diagram shows the external plumbing connection configured for an oven with two cooling cells.

OPERATION:The External Cooling Liquid Supply Option is designed to be activated and operated with the reflow system at all times. Itrequires a temperature-controlled flow of clean coolant at a constant pressure and flow to the heat exchanger(s). Thecoolant temperature should remain above the local dew point when operating to avoid condensation inside the coolingcells. The system can be drained by using the supplied hose and ball valve attached to the inlet plumbing leg.

SAFETY AND CONTROLS:

Inlet High Pressure Switch: Set to 50 psi, alarms when supply pressure is greater than 50 psi.Inlet Shut Off Valve: Solenoid valve used to stop flow when machine is inactiveInlet Pressure Gauge: Gauge used to monitor inlet pressureInlet Thermocouple (T/C 1): Monitors inlet cooling liquid temperatureOutlet Thermocouple (T/C 2): Monitors outlet cooling liquid temperatureFlow Switch: Set to 1gpm, alarms when flow falls below set pointCheck Valve: Prevents outlet from back filling system

COOLANT SPECIFICATION:Recommended:Vitronics Super Cool Part No. 3313350Distilled Water (recommend use of an additive to prevent algae growth)Lab grade Propylene Glycol mixed with Distilled Water (20%-80% mixture)

NOTE: De-ionized water or other coolants that will react negatively with the materials used in the system must not to beused. This will void the machine warranty.


RAIL ADJUST:

MANUAL RAIL ADJUST

Manual Rail Adjust is:

Standard, (installed on all ovens with an edge rail conveyor) An option, (NOT installed on all ovens)

DESCRIPTIONA PTC (Positive Temperature Coefficient Thermister) limits inrush current and a diode bridge rectifies the 120 VACcontrol power for the Rail Adjust Drive Motor. The selector switch mounted at the end of the oven enable this DC voltageto be applied to the Rail Adjust Drive Motor (providing that the controller has enabled the manual rail adjust function). Depending upon the polarity of the signal applied to the motor, the motor operates in one direction or the other moving therails closer together or further apart. Two limit switches at one end of the oven open the circuit and stop the motor at theend of travel in or out.

OPERATION

Run the “Manual rail adjust” within the Oven Control Program. NOTE: This operation may require a password.

This activates the rail enable output relay A1-K19. Nothing happens until the rail in/out button is turned. Turn the railin/out button in one direction. If the rail motor does not turn, turn the button in the other direction. If the motor still doesnot turn, refer to the Oven Schematics and perform the following test procedure:

1 - Disable the manual rail adjust.2 - Remove the bridge rectifier in the circuit (it should be connected to wires 307,2, 1024, and 1034 at the X10 terminals).

3 - Enable the manual rail adjust: A1-K19 should energize4 - Select “Rail IN”: A1-K21 & A1-K9 should energize .5 - Select “Rail OUT”: A1-K22 & A1-K9 & K8 should energize.6 - If the rail in/out selections do not function, there MAY be a wiring error with the rail selector switch.7 - After the rail selection logic has been corrected, check to see that the wiring to the motor is correct.8 - Disable the manual rail adjust.9 - Replace the bridge rectifier in the circuit connected to wires 307, 2, 1024, and 1034. (Connect wire 1034 to the (+) terminal, wire 1024 to the (-) terminal, wire 307 to AC! And wire 2 to AC2 at the X10 terminals).10 - Using an Ohmmeter in the control enclosure, verify that there is continuity through each rail limit switch. (If either the switch is wired incorrectly or the rail is pressed up against the limit ,there should not be continuity through the switch.11- Enable the manual rail adjust.12- Check the operation of both the “in” and the “out” adjust switch positions.13 - Disable the manual rail adjust.


AUTO RAIL ADJUST

Auto Rail Adjust is:


DESCRIPTION

The Oven Control Program automatically adjusts the rail in/out to meet the board size entered in the PRODUCT file in theOven Control Program.

OPERATIONRun the Automatic rail adjust within the Oven Operation Program. NOTE: This operation may require a password.(The direction of travel of the rail and the speed of the width adjust may be selected by choices in the Oven OperationProgram.)

1. Set the rail adjust speed to MAX and select either IN or OUT to move the rail.2. With the rail width adjustment enabled, select MIN for minimum width speed adjustment. The rail movement should

decrease to a very slow rotation, or stop. 3. Using a Voltmeter on the armature of the Rail Adjust Drive Motor output points, adjust the output voltage to 15 VDC.

The IR COMP potentiometer on the auto rail DC drive should be set to the midpoint position. The TORQUEpotentiometer on the auto rail DC drive should be set to 90%.

4. Run the rail width calibration routine in the Oven Control Program.

While conducting the following tests ensure that the rail does not move to its minimum or maximum value and stop. Therail adjust system is designed to stop at these positions.

5. Verify that the DC drive card is receiving 120 VAC power between terminals L1 and L2. If not, verify that K37 & K38are energized.

6. Check that the I/O board relay A1-K9 is energized.7. Measure and verify that the voltage at wire number 1039 at PX9-20 on the I/O board is +10 VDC.8. If voltage is present, check the wiring at the signal input of the DC Drive.9. If the preceding steps check out, measure the DC voltage output of the DC drive circuit board between terminals A1

and A2. Voltage present should be 90-130 VDC. If there is no voltage present, the drive circuit board is likely to bedefective. Otherwise, adjust the SIGNAL ADJUST potentiometer on the DC drive board to produce the 90-130 VDC.

If steps 1-9 have been performed and the rail motor still does not operate, refer to the Oven Schematics and proceed withthe following:

1. Verify that “rail out” control relays K8, A1-K9, A1-K19 & A1-K22 are energized.2. If A1-K9 is not energized, confirm that A1-K19 & A1-K22 are energized.3. If A1-K19 & A1-K22 are energized, check the associated wiring.4. If the rail motor still does not turn, press an e-stop switch to disable 120 VAC control power.5. Check connections to the K8 relay.6. Using an Ohm meter, verify that there is continuity through each rail limit switch (If either the switch is wired incorrectly or the rail is pressed up against the limit switch, there should be no continuitythrough the switch.)7. Pull out the E-stop recently pressed and reset the E-Stop in the Oven Control Program.


After the ‘rail out’ function has been tested, the ‘rail in’ function check out should be greatly reduced. Activate the ‘rail in’function in the Oven Operation Program (this is assuming you have already logged into the software as previouslydescribed). The parts of the auto rail circuit which can be a problem, is the ‘direction relay’ K8 and the ‘rail in’ limit switch. The test procedure for these components would be the same as described for the ‘rail out’ circuit.

The final check out procedure is to verify that the linear transducer feedback signal is being received and processed bythe computer. (If the linear transducer is operating and connected properly, the loop feedback value should be 2 – 10 VDC)

Run the “Manual rail adjust” within the Oven Operation Program. NOTE: This operation may require a password.

When the rail is moving inward, the value should decrease. If the transducer loop feedback value is not within theprescribed range, check the wiring from the transducer to the controller. The transducer signal output is 0 to +10 VDC. The signal level from the transducer is then reduced to a 60 mV level by a voltage divider circuit. A possible error withthis circuit is incorrect resistor values used on the voltage divider circuit. Verify the polarity of the transducer signal outputto be correct.


SMEMA INTERFACE

The SMEMA Interface is:


DESCRIPTION

(SMEMA is the acronym for Surface Mount Equipment Manufacturer’s Association)The SMEMA electrical interface option for the Reflow Oven is intended to comply with the SMEMA Electrical InterfaceStandard 1.2. It provides signals from the Reflow Oven to the upline/downline equipment in the process line.A PLC is mounted inside the electrical enclosure; a photo-sensor is mounted on brackets above each end of theconveyor(s). A 14 pin round connector is mounted on each end of the Reflow Oven. The SMEMA interface receivespower from the Reflow Oven to operate. (The PLC operates two SMEMA circuits.) The SMEMA interface accepts a'Board Available' signal from the upline (onload side) of the Reflow Oven on pins 3&4 of the onload connector. It replieswith a 'Busy' signal on pins 1&2 of the onload connector to the machine upline. On the downline (offload) side, a 'BoardAvailable' signal is sent on pins 3&4 and looks for a 'Busy' signal to come back on pins 1&2 of the offload connector.Because the Reflow Oven should not be stopped with product in the heat zone, the busy signal coming from the downlineend is used to generate the busy signal for the upline equipment without stopping the Reflow Oven. When all of theconditions are ‘False’, the Reflow Oven is “not busy” and will accept more product from the upline equipment. If any ofthe conditions are ‘True’, the Reflow Oven will transmit a "busy" signal to the upline equipment. This should stop theupline equipment from sending product to the Reflow Oven, thus preventing a product buildup.The upline “busy” signal can be a result of one (or more) of the following:1. Board at ‘on-load’2. Board Jam at off-load3. Downline machine has not sent ‘ready’ signal for 2 boards4. Oven is NOT ‘Process Ready’5. The (settable) spacing between boards has not been satisfied.The busy signal from the Reflow Oven to the upline piece of equipment is designed to provide a space equal toapproximately 1/2 the product length between each product under normal operation. The board available signal sent fromthe upline equipment is not implemented because the oven should not be stopped and started. The board available signalsent from the Reflow Oven to downline equipment is a notification of product coming out of the oven.When a board's leading edge passes under the onload sensor it triggers the busy signal to be true (on) for 1.5 boardlengths. This tells the upline equipment feeding the Reflow Oven to wait for 1.5 board lengths before feeding anotherpiece to the Reflow Oven. When the board exits the oven and the leading edge passes under the offload sensor, ittriggers the board available signal to go true (on) 1 second later and to stay true for one board length. This signals thedownline equipment receiving product from the Reflow Oven to expect a board at that time. The 1-second delay is toignore false signals created when the photocell senses the conveyor belt.The PLC controls the delays and triggers the operation of the interface off of the process ready signal. If the machine isNOT process ready, the SMEMA interface will signal busy to the upline equipment.


SETUP

The SMEMA interface requires that the connections be made between adjoining machines and the Reflow Oven, usingthe SMEMA connectors at the onload and offload ends. The PLC is pre-programmed and the sensors are preset at thefactory. The SMEMA interface is installed and fully tested at the factory before shipping. The user should not need toadjust the SMEMA interface after initial connections have been made.

OPERATION

Action by the Reflow Oven operator is not necessary for the SMEMA interface to function. As long as the upline /downline connections are made and a component failure has not occurred, operation will be automatic when the ReflowOven is powered up.

NOTEOvens with a Dual Rail conveyor (with two sets of rails and chains) have two separate sets SMEMA Interface sensorsmaking separate input(s) to the PLC.Each conveyor must be ready to receive product before it independently sends a “Ready” signal to its respective “upline”equipment.Either conveyor can send a “Product at Offload” signal to the “downline” equipment.


SMEMA machine interfacefor Vitronics SMEMA04 January 22, 2004

using the Allen Bradley MicroLogix 1200 PLC.

There are two test procedures below. The first test is for PLC units that are installed in an oven, and the second is forPLC units being tested separately from the oven (stand-alone). The stand-alone test specifies input and outputconnections instead of devices (sensors, upstream / downstream machines, etc.). The tests are otherwise identical.

Allen Bradley MicroLogix 1200PLC Terminal Connections

PLC terminal Wire # Description24 COM 2007 DC common from PLC, On-load (SX200-4,SX201-4), Off-load

(SX202-2,SX203-2)24 VDC 2003 24VDC from PLC, COM 0, COM 1IN 0 - Not usedIN 1 2008 On-load lane #1 product sensorIN 2 2038 On-load lane #2 product sensorIN 3 2009 Oven readyIN 4 2018 Off-load lane #1 product sensorIN 5 2048 Off-load lane #2 product sensorIN 6 2014 Downstream machine lane #1 ready (SX202-1) W189AIN 7 2044 Downstream machine lane #2 ready (SX203-1) W189BIN 8 - Not usedIN 9 - Not usedIN 10 - Not usedIN 11 - Not usedIN 12 - Not usedIN 13 - Not usedCOM 0 2003 Input common for IN 0 through IN 3 (24VDC)COM 1 2003 Input common for IN 4 through IN 13 (24VDC)L1 18 115 VAC hotNEUT 2 115 VAC neutralG G Protective groundDC 0 2020 Output common for OUT 0 (SX200-1) W190AOUT 0 2022 Oven ready to upstream lane #1 (SX200-2) W190ADC 1 2040 Output common for OUT 1 (SX201-1) W190BOUT 1 2042 Oven ready to upstream lane #2 (SX201-2) W190BDC 2 2021 Output common for OUT 2 and OUT 3 (SX202-3) W189AOUT 2 2023 Product available to downstream lane #1 (SX202-4) W189AOUT 3 - Not usedDC 3 2051 Output common for OUT 4 and OUT 5 (SX203-3) W189BOUT 4 2053 Product available to downstream lane #2 (SX203-4) W189BOUT 5 - Not used (Always on when PLC is in run mode)DC 4 - Output common for OUT 6 through OUT 9OUT 6 - Downstream lane #1 alarm (product jam or not ready)OUT 7 - Downstream lane #2 alarm (product jam or not ready)OUT 8 - Not usedOUT 9 - Not used


PLC SMEMA program logic tableLogic states 1=ON (corresponding led on PLC is active), 2=OFF, X=Don’t care

IN 1

(200

8) O

n-lo

ad la

ne #

1 se

nsor

IN 2

(203

8) O

n-lo

ad la

ne #

2 se

nsor

IN 3

(200

9) o

ven

read

y

IN 4

(201

8) O

ff-lo

ad la

ne #

1 se

nsor

IN 5

(204

8) O

ff-lo

ad la

ne #

2 se

nsor

IN 6

(201

4) D

owns

tream

lane

#1

read

y

IN 7

(204

4) D

owns

tream

lane

#2

read

y

OU

T 0

(202

2) O

ven

read

y to

lane

#1

upst

ream

OU

T 1

(204

2) O

ven

read

y to

lane

#2

upst

ream

OU

T 2

(202

3) P

rodu

ct a

vaila

ble

to la

ne #

1 do

wns

tream

OU

T 4

(205

3) P

rodu

ct a

vaila

ble

to la

ne #

2 do

wns

tream

OU

T 6

Lane

#1

dow

nstre

am a

larm

OU

T 7

Lane

#2

dow

nstre

am a

larm

Operation

1 X 1 X X 1 X 1 X X X 0 X Lane #1 Start transfer of product from lane #1 upstream

1 X 1 X X 1 X 0 X X X 0 XLane #1 Oven ready to upstream shuts off during transferand remains off for additional time based on potentiometerzero setting on PLC for product spacing

X X 1 X X 0 X 0 X X X 1 XLane #1 on-load product transfer is suspended afterdownstream lane #1 ready signal is absent beyond 30seconds

X X X 1 X X X X X 1 X 0 X Lane #1 transfer of product to downstream

X X X 1 X X X 0 X 1 X 1 X Lane #1 product jam alarm occurs after product has beenpresent at the off-load sensor beyond 180 seconds

X 1 1 X X X 1 X 1 X X X 0 Lane #2 Start transfer of product from lane #2 upstream

X 1 1 X X X 1 X 0 X X X 0Lane #2 Oven ready to upstream shuts off during transferand remains off for additional time based on potentiometerone setting on PLC for product spacing

X X 1 X X X 0 X 0 X X X 1Lane #2 on-load product transfer is suspended afterdownstream lane #2 ready signal is absent beyond 30seconds

X X X X 1 X X X X X 1 X 0 Lane #2 transfer of product to downstream

X X X X 1 X X X 0 X 1 X 1 Lane #2 product jam alarm occurs after product has beenpresent at the off-load sensor beyond 180 seconds


Allen Bradley MicroLogix 1200 Terminal Detail

Procedure for testing the SMEMA Machine Interface on an ovenThe SMEMA operation of each lane is independent in the PLC. Each lane can be tested separately or together withouteffecting the other.

1) Allow the oven to get into a process ready state by operating a belt recipe or by installing a jumper wire between theIN 3 and the 24 COM terminal on the PLC. IN 3 on the PLC should be on.

Lane 1 Testing2) Install a mating connector on the off-load connector of the oven with a jumper installed between pins 1 and 2, cable

W189A to provide the downstream machine ready signal to the PLC. Or install a jumper wire on the electrical panelon terminal block X30 between wire numbers 2014 and 2007. IN 6 on the PLC should be on.

3) Connect the flashlight end of the test equipment to the on-load connector of the oven, cable W190A or install 2 wiresin a mating plug connector on pins 1 and 2 and connect the free ends to an external ohm meter or continuity tester.

4) OUT 0 on the PLC should be on and the test equipment on the on-load end of the oven should be on to indicate thatthe oven is ready to accept product from the upstream machine lane 1.

5) Turn the top potentiometer (zero) on the PLC fully counter clockwise for minimum product spacing. Thepotentiometers on the Allen Bradley PLC are located behind a removable access plate on the front lower left of thePLC below the Allen Bradley logo.

The test equipment on the on-load of the oven should follow OUT 0 on the PLC in the following tests.

6) Run a test product under the on-load sensor for lane 1 and verify that OUT 0 goes off on the PLC while the product isunder the on-load sensor and remains off for an additional second after the on-load sensor is clear.


7) Turn the top potentiometer (zero) on the PLC ½ turn clockwise. Run a test product under the on-load sensor for lane#1 and verify that OUT 0 remains off approximately 30 seconds after the on-load sensor is clear.

8) Return the top potentiometer (zero) on the PLC to the fully counter-clockwise setting.

9) Remove the mating connector on the off-load connector of the oven or the jumper wire that was installed previously instep 2. Verify that after 30 seconds OUT 0 is off on the PLC to indicate that the oven is no longer ready to acceptproduct on lane #1.

10) Run a product or object under the off-load sensor for lane #1 and verify that OUT 2 on the PLC comes on andremains on until the off-load sensor is clear to indicate that product is available to a downstream machine.

Lane 2 Testing

1. Install a mating connector on the off-load connector of the oven with a jumper installed between pins 1 and 2, cableW189B to provide the downstream machine ready signal to the PLC. Or install a jumper wire on the electrical panelon terminal block X30 between wire numbers 2044 and 2007. IN 7 on the PLC should be on.

2. Connect the flashlight end of the test equipment to the on-load connector of the oven, cable W190B or install 2 wiresin a mating plug connector on pins 1 and 2 and connect the free ends to an external ohm meter or continuity tester.

3. OUT 1 on the PLC should be on and the test equipment on the on-load end of the oven should be on to indicate thatthe oven is ready to accept product from the upstream machine lane 2.

4. Turn the bottom potentiometer (one) on the PLC fully counter clockwise for minimum product spacing. Thepotentiometers on the Allen Bradley PLC are located behind a removable access plate on the front lower left of thePLC below the Allen Bradley logo.

5. The test equipment on the on-load of the oven should follow OUT 1 on the PLC in the following tests.6. Run a test product under the on-load sensor for lane 2 and verify that OUT 1 goes off on the PLC while the product is

under the on-load sensor and remains off for an additional second after the on-load sensor is clear.7. Turn the bottom potentiometer (one) on the PLC ½ turn clockwise. Run a test product under the on-load sensor for

lane #2 and verify that OUT 1 remains off approximately 30 seconds after the on-load sensor is clear.8. Return the bottom potentiometer (one) on the PLC to the fully counter-clockwise setting.9. Remove the mating connector on the off-load connector of the oven or the jumper wire that was installed previously in

step 2. Verify that after 30 seconds OUT 1 is off on the PLC to indicate that the oven is no longer ready to acceptproduct on lane #2.

10. Run a product or object under the off-load sensor for lane #2 and verify that OUT 4 on the PLC comes on andremains on until the off-load sensor is clear to indicate that product is available to a downstream machine.

End of on oven test.

Notes:When the flashlight for the on-load end is on, the oven is ready to accept product. The flashlight will come on if:1. The oven is process ready,2. There is no product under the on-load sensor,3. The downstream machine is ready, and4. No downstream alarm conditions have been detected by the PLC.A downstream alarm condition is indicated by OUT 6 for lane 1 and OUT 7 for lane 2.The SMEMA interface for each of the two lanes operates independently through shared inputs on the PLC. Thesecond lane can be left unconnected on an oven with only one lane of SMEMA interface.

If the PLC does not comply with any of the test conditions, then it needs to bereprogrammed or replaced.


Procedure for Stand-alone SMEMA Machine Interface Test

Required Equipment:Pre-programmed PLC - Vitronics Soltec part number 14769023 wire "cheater cord" - power cord with stripped back wires on one end and a plug for a 115 Volt outlet on the other10 jumper wires (24 to 16 AWG) each approximately 4 inches long.Small screwdriver (flat or phillips) for adjusting the trim potentiometers.

The SMEMA operation of each lane is independent in the PLC. Each lane can be tested separately or together withouteffecting the other.

1) Connect the following jumper wires: From 24VDC to COM 0 and to COM 1 terminals on the PLC. From 24 COM to I3 to I 6 and then to I 7 on the PLC. Connect one additional test wire on the PLC from the 24 COM terminal and leavethe other end unconnected (not touching anything).

2) Connect the 3 wire cheater cord to the power terminals: green or green/yellow to the protective earth ground, whiteor light blue to neutral ( NEUT ), and the remaining wire (typically red, black, or brown) to the "hot" or "line" terminal (L1 ).

3) Plug the cheater cord into a standard 115 Volt outlet. The lights on the PLC should flash for a few seconds, while thePLC is running self-diagnostics. The "power" and "run" lights on the front of the PLC should remain on.

Lane 1 Testing4) OUT 0 on the PLC should be on to indicate that the oven is ready to accept product from the upstream machine lane

1.5) Turn the top potentiometer (zero) on the PLC fully counter clockwise for minimum product spacing. The

potentiometers on the Allen Bradley PLC are located behind a removable access plate on the front lower left of thePLC below the Allen Bradley logo.

6) Touch and hold the free end of the test wire to the IN 1 terminal on the PLC. Verify that OUT 0 goes off on the PLCwhile the test wire is connected to IN 1 and remains off for an additional second after the test wire is moved off of theIN 1 terminal.

7) Turn the top potentiometer (zero) on the PLC ½ turn clockwise. Touch and hold the free end of the test wire to the IN1 terminal on the PLC. Verify that OUT 0 remains off approximately 30 seconds after the test wire is moved off of theIN 1 terminal.

8) Return the top potentiometer (zero) on the PLC to the fully counter-clockwise setting.9) Temporarily disconnect the wire(s) connected to terminal I 6 on the PLC. Verify that after 30 seconds OUT 0 is off on

the PLC to indicate that the oven is no longer ready to accept product on lane #1.10) Touch and hold the free end of the test wire to terminal I 4 on the PLC and verify that OUT 2 on the PLC comes on

and remains on until the test wire is removed to indicate that product is available to a downstream machine.

Lane 2 Testing

1. OUT 1 on the PLC should be on to indicate that the oven is ready to accept product from the upstream machine lane2.

2. Turn the bottom potentiometer (one) on the PLC fully counter clockwise for minimum product spacing. Thepotentiometers on the Allen Bradley PLC are located behind a removable access plate on the front lower left of thePLC below the Allen Bradley logo.

3. Touch and hold the free end of the test wire to the IN 2 terminal on the PLC. Verify that OUT 1 goes off on the PLCwhile the test wire is connected to IN 2 and remains off for an additional second after the test wire is moved off of theIN 2 terminal.


4. Turn the bottom potentiometer (one) on the PLC ½ turn clockwise. Touch and hold the free end of the test wire to theIN 2 terminal on the PLC. Verify that OUT 1 remains off approximately 30 seconds after the test wire is moved off ofthe IN 2 terminal.

5. Return the bottom potentiometer (one) on the PLC to the fully counter-clockwise setting.6. Temporarily disconnect the wire(s) connected to terminal I 7 on the PLC. Verify that after 30 seconds OUT 1 is off on

the PLC to indicate that the oven is no longer ready to accept product on lane #2.

7. Touch and hold the free end of the test wire to terminal I 5 on the PLC and verify that OUT 4 on the PLC comes onand remains on until the test wire is removed to indicate that product is available to a downstream machine.

8. Unplug the cheater cord and remove all of the connections to the PLC. Lightly tighten all the screws before returningthe unit to its box.

End of stand-alone test.


TEMPERATURE PROFILE PLOTTING (PRECISION PROFILING)


Plotting a temperature profile provides a graphic display of temperature relative to time and distance at one or morepoints on a test PCB going through the oven. It also determines values of Peak Temperature, Liquidous Time andHeat/Cool slope. This helps fine tune the system for optimization of individual profile parameters on the PCB.

Oven Profiling, Profile Objectives and Definitions, Preparing Thermocouples & PCBs, and Plotting a TemperatureProfile are described in Process Manual.


DISCLAIMER OF LIABILITY AND CONTENT

THE INFORMATION CONTAINED IN THIS MANUAL IS SUBJECT TO CHANGE WITHOUT PRIOR NOTICEAND IS CORRECT TO THE BEST OF OUR KNOWLEDGE AT THE TIME OF PRINTING. VITRONICS-SOLTECCORPORATION ASSUMES NO RESPONSIBILITY FOR LOSS OR DAMAGES RESULTING FROM THE USE

OF THIS MANUAL EXCEPT AS EXPLICITLY STATED IN THE VITRONICS-SOLTEC OVEN WARRANTYSTATEMENT.

ALL RIGHTS RESERVED. NO PART OF THIS WORK COVERED BY COPYRIGHT HEREON MAY BEREPRODUCED IN ANY FORM OR BY ANY MEANS - GRAPHIC, ELECTRONIC OR MECHANICAL –

INCLUDING, BUT NOT LIMITED TO: PHOTOCOPYING, RECORDING, TAPING, OR STORAGE IN ANINFORMATION RETRIEVAL SYSTEM, WITHOUT THE PRIOR WRITTEN PERMISSION OF THE COPYRIGHT

OWNER.

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