Vectra Installation Manual

WAVE SOLDERING SYSTEM

INSTALLATION MANUALManual Part #3-9317-130-00-0

Hwy. 5 South, Box 709 | Camdenton, MO 65020 Tel: 573-346-3341 | Fax: 573-346-6878

Speedline Technologies, Inc.

Vectra

ii 2-9317-130-00-0 — Rev. 1 Installation Manual

Vectra

Installation Manual 2-9317-130-00-0 — Rev. 1 iii

WAVE SOLDERING SYSTEM

INSTALLATION MANUALManual Part #3-9317-130-00-0, Revision 1

Text Part #2-9317-130-00-0, Revision 1

Copyright© 1999 Speedline Technologies, Inc.

This manual may not be reproduced, stored in a retrieval system, or transmitted in part or in whole. Photocopyting, recording, or

other forms of reporduction is prohibited without written permission of Electrovert®.

Published April 16, 1999

Vectra

iv 2-9317-130-00-0 — Rev. 1 Installation Manual

Vectra

Installation Manual 2-9317-130-00-0 — Rev. 1 v

TO OUR CUSTOMERSThe purpose of this manual is to help obtain the greatest possible return on your investment. It is suggestedthat new operators study the applicable sections of this manual thoroughly before operating the equipment.It is futher suggested that the manual be used as a reference by maintenance personnel and as a text fortraining new maintenance personnel.

This manual includes instructions for this equipment available at the time this manual was approved forprinting. Electrovert® reserves the right to make changes in design and specifications and/or makeimprovements in the product without imposing any obligations upon itself to install them on previouslymanufactured products.

SPEEDLINE TECHNOLOGIES, INC., ELECTROVERT®

SALES AND SERVICE OFFICESSpeedline Technologies, Inc. Main Offices

Speedline Technologies, Inc.Electrovert®

Product & Technology CenterP.O. Box 709Camdenton, MO 65020Fax: 573-346-5554Tel: 573-346-3341

Technical Service Support Group &Customer Service Parts DepartmentSpeedline Technologies, Inc.Electrovert®

P.O. Box 709Camdenton, MO 65020Fax: 573-346-0002 or 573-346-6878Tel: 800-737-8110 or 573-346-3341e - m a i l :

[email protected]

Speedline TechnologiesEducational Services &Customer Support Center580-A Tollgate RoadElgin, IL 60123Fax: 847-289-3797Tel: 847-695-5750

Regional Service Centers

North East Regional Service Center472 Amherst St. Suite 6Nashua, NH 03063Fax: 603-880-8757Tel: 603-883-2488

South East Regional Service Center200 Technology Dr.Alpharetta, GA 30005Fax: 770-442-1987Tel: 770-475-6100

North Central Regional ServiceCenter580-A Tollgate RoadElgin, IL 60123Fax: 847-289-3797Tel: 847-695-5750

North West Regional Service Center2968 Scott Blvd.Santa Clara, CA 95054Fax: 408-727-0672Tel: 408-727-4650

South West Regiona l Serv iceCenter1111 W. North Carrier ParkwayGrand Prairie, TX 75050Fax: 972-606-1700Tel: 972-606-1900

International Service Centers

Northern Europe & U.K.Electrovert U.K. Ltd.The Technology CentreUnit 1, Pincents Kiln Industrial ParkPincents KilnCalcot, ReadingBerks., U.K. RG31 7SDFax: 44 11-8-930-1401Tel: 44 11-8-930-1400

Electrovert Singapore10 Kian Teck CrescentSingapore 628876Fax: 65-861-7337Tel: 65-861-1661

JapanElectrovert-Seitec Co., Ltd.1538 Kanoya-choHachioji City, Tokyo 193 JAPANFax: 81-426-23-8350Tel: 81-426-23-7722

Northern EuropeSpeedline Technologies S.A.R.L.65 Avenue du General De GaulleImmeuble le Promethee77420 Champs-Sur Marne, FranceFax: 33 160-05-6129Tel: 33 160-06-8181

Central EuropeSpeedline Technologies, GmbhDaimlerstrasse 1ED-63303Dreieich, GermanyFax: 49 6103-832119Tel: 49 6103-8320

Speedline Technologies ItalyVia Liguria 2/28I-20068 Peschiera Borromeo (MI)ItalyFax:39- 2 - 5530.8468Tel: 39- 2 - 5530.8339

Vectra

vi 2-9317-130-00-0 — Rev. 1 Installation Manual

Vectra

Installation Manual 2-9317-130-00-0 — Rev. 1 vii

EQUIPMENT MANUAL QUESTIONNAIREThe purpose of this questionnaire is to provide feedback from our customers regarding the effectiveness of the equipment manuals. Please complete the following questions and return to Speedline Technologies, Inc., Electrovert®. Your comments are appreciated.Customer _______________________________________________________________________________________Address ________________________________________________________________________________________Contact ________________________________________________ Date____________________________________Machine Type ___________________________________________Manual Part Number______________________Translated Manual Language ______________________________ Part Number_____________________________Option Manual __________________________________________Part Number_____________________________1. How often do you refer to the technical manual package?

q Frequentlyq Occasionallyq Seldomq Never

2. In what instances do you refer to the technical manual package?q To verify process informationq To reference procedures (operational, maintenance)q To order/identify partsq Other (please specify) ____________________________________________________________________

3. How do you rate the overall layout of the manual package?q Information easy to findq Information difficult to findq If difficult, please explain__________________________________________________________________

4. How do you rate our manuals in comparison to your other capital equipment suppliers?q Higher qualityq Same general qualityq Lower quality

If same general or lower quality, please explain _______________________________________________________________________________________________________________________________________________________

5. How do you rate the accuracy of the technical information?q Very accurateq Somewhat accurateq Not accurateq Can you provide examples, with page number indicated? ______________________________________

_______________________________________________________________________________________6. What tools would make the manuals easier to use and/or find information?

q Indexesq Glossariesq Improved Table of Contentsq Other __________________________________________________________________________________

7. Who are the main users of your equipment manuals?q Operatorsq Maintenance personnelq Process Engineersq Other __________________________________________________________________________________

8. How do you rate the quality of the language translation (if applicable)?q Very accurateq Somewhat accurateq Not accurate

If somewhat or not accurate, can you elaborate?____________________________________________________________________________________________________________________________________________________________________________________________________________________________

Please add any additional comments about our manuals on the back of this page. Please return to:

Technical Publications Department at the address listed below

Hwy. 5 South, Box 709 | Camdenton, MO 65020 Tel: 573-346-3341 | Fax: 573-346-6878

Speedline Technologies, Inc.

Vectra

viii 2-9317-130-00-0 — Rev. 1 Installation Manual

Vectra

Installation Manual 2-9317-130-00-0 — Rev. 1 ix

The serial tag information is to be filled by the user for technical support purposes. Please have the followinginformation available when contacting Technical Support or when placing parts orders:

Machine NameModel Number

Mechnical and Electrical Serial NumbersItem/Kit Description

Vectra

x 2-9317-130-00-0 — Rev. 1 Installation Manual

Vectra

Installation Manual 2-9317-130-00-0 — Rev. 1 xi

COMMON SAFETY WARNING LABELSThe following warning labels are used throughout this manual:

Notes point out informationin this manual that may be ofassistance to the operation

or maintenance of the machine.

Caution notices areused in this manual toca l l a t tent ion to a

situation that could cause damage toequipment.

Warning notices areused in this manual toemphasize hazardous

vol tages, h igh temperatures, h ighcurrents, or other conditions that couldcause personal injury.

Danger notices areused in this manual towarn the operator that

DEATH may result if a procedure isomitted or improperly performed.

Vectra

xii 2-9317-130-00-0 — Rev. 1 Installation Manual

Vectra

xiii

Table of ContentsTo Our Customers ................................................................................................................................................vElectrovert Sales and Services Offices ..............................................................................................................vMachine Serial Tag ...............................................................................................................................................ixCommon Safety Warning Labels ........................................................................................................................xi

SECTION 1: GENERAL1.1 HAZARDS .......................................................................................................................................................1

Lead Hazards.........................................................................................................................................................1Facts You Should Know About Lead ...................................................................................................................2Burn hazards.........................................................................................................................................................4Vapor Hazards .......................................................................................................................................................4Fire Hazards ..........................................................................................................................................................4Mechanical Hazards.............................................................................................................................................5Electrical Hazards.................................................................................................................................................5Nitrogen Hazards..................................................................................................................................................5Compressed Gas Hazard......................................................................................................................................6

1.2 SAFETY PRECAUTIONS.................................................................................................................................71.3 SAFETY PROCEDURES FOR REMOVAL OF DROSS...................................................................................81.4 EXHAUST VENTILATION & CLEANING.........................................................................................................101.5 LOCKOUT/ TAGOUT CHECKLIST ..................................................................................................................11

SECTION 2: TECHNICAL DATA2.1 INSTALLATION SPECIFICATIONS AND FACILITY REQUIREMENTS .........................................................132.2 SYSTEM DIMENSIONS ..................................................................................................................................17

SECTION 3: INSTALLATION PREPARATION3.1 RECEIVING INSTRUCTIONS..........................................................................................................................193.2 INSTALLATION PLANNING ...........................................................................................................................193.3 INSTALLATION CHECKLIST ..........................................................................................................................20

SECTION 4: REQUIRED EQUIPMENT AND TOOLS4.1 PROTECTIVE CLOTHING................................................................................................................................214.2 TOOLS AND MATERIALS...............................................................................................................................214.3 EXPENDABLE ITEMS.....................................................................................................................................214.4 RIGGING EQUIPMENT...................................................................................................................................21

SECTION 5: SHIPPING ARRANGEMENT5.1 SHIPMENT ITEMS ..........................................................................................................................................235.2 SHIPPING CONFIGURATION........................................................................................................................23

Domestic ...............................................................................................................................................................23International ..........................................................................................................................................................23

5.3 LIFTING AND HANDLING THE VECTRA.......................................................................................................24

SECTION 6: UNPACKING INSTRUCTIONS6.1 DOMESTIC SHIPMENTS ...............................................................................................................................256.2 INTERNATIONAL SHIPMENTS .....................................................................................................................276.3 INSTALL SYSTEM LEVELING FEET................................................................................................................286.4 UNPACKING AND GENERAL INSPECTION ................................................................................................29

Internal Foam Fluxer.............................................................................................................................................29Conveyor ................................................................................................................................................................29Preheaters .............................................................................................................................................................29

Vectra

xiv

Solder Module....................................................................................................................................................... 29Electrical ............................................................................................................................................................... 29Inspection ............................................................................................................................................................. 30

SECTION 7: INSTALLATION AND SETUP7.1 MONITOR AND KEYBOARD INSTALLATION.............................................................................................. 317.2 ADJUST HEIGHT AND LEVEL MACHINE .................................................................................................... 347.3 CONVEYOR INSTALLATION CHECK............................................................................................................ 35

Optional Finger Cleaner ....................................................................................................................................... 367.4 INSTALL LIGHT TOWER OPTION.................................................................................................................. 367.5 INSTALL FOAM FLUXER OPTION................................................................................................................. 38

External Foam Fluxer Installation........................................................................................................................ 38Aerator Cleaning Reservoir ................................................................................................................................. 42Install PAAR Flux Density Controller (FDC) Option ........................................................................................... 42

7.6 INSTALL PREHEATERS................................................................................................................................. 43Install Optional Radiant Preheaters.................................................................................................................... 43

7.7 UNPACK AND INSPECT SOLDER POT ....................................................................................................... 45

SECTION 8: FACILITY CONNECTIONS8.1 CONNECT FACILITY EXHAUST ..................................................................................................................... 498.2 CONNECT FACILITY POWER......................................................................................................................... 50

Conduit and Electrical Connections................................................................................................................... 518.3 COMPRESSED AIR CONNECTION .............................................................................................................. 528.4 NITROGEN CONNECTION ............................................................................................................................ 53

SECTION 9: FILLING THE SYSTEM9.1 FILL FINGER CLEANER RESERVOIR............................................................................................................ 559.2 FILL FOAM FLUXER RESERVOIR ................................................................................................................. 579.3 FILL SOLDER POT.......................................................................................................................................... 58

Roll Out Solder Pot............................................................................................................................................... 58Fill Solder Pot with Solder ................................................................................................................................... 61

Vectra

Installation 2-9317-130-00-0 — Rev. 1 1

SECTION 1: GENERAL

1.1 HAZARDSOperation of this equipment exposes personnelto potential health hazards.

LEAD HAZARDS

Exposure to Lead Hazard– Exposure to Lead in anyform may cause serious

health hazards.

Breathing lead dust, which is nearly invisible,can cause lead poisoning.

Always ensure the solder system ventilation ison and operating at the specifications listed inthis manual prior to working around the solderpot.

To avoid inhalation, wear the proper safetyapproved breathing apparatus recommendedby the solder supplier for use with wavesoldering equipment.

Vectra

2 2-9317-130-00-0 — Rev. 1 Installation

FACTS YOU SHOULD KNOW ABOUT LEADNorms for lead in air

The following table shows the tolerable rangesof lead-in-air, as seen by different countries.

* time weighted average over 8 hours

** time weighted average over 40 hours

(a) = for inorganic lead and lead arsenate; 0.05 for lead chromate.

(b) = Interim standard to June 1986 for secondary plants, June 1991 for primary plants, when 0.05 mg/m3 standard becomeseffective. This standard is no longer an ambient standard, but a permissible exposure limit (PEL) standard, which in some areas ofsome plants may be attained by worker self-protection and/or administrative standards, subject to negotiation. When the engineeringcontrolled average limit standard (ECALS) under the original criteria equalled the PEL there was a de-facto ambient air standard butcompliance solely by engineering controls is no longer required.

(c) = Values for inorganic lead compounds, lead acetate, lead phosphate and lead sub-acetate arecalculated as lead. Value for leadchromate is calculated as chromate.

The tables found on pages 14 and 15 were compiled by the International Lead and Zinc StudyGroup in 1991.

Country Maximum Lead Level (mg/m3) Date Operative Legal Status

Argentina 0.15 n/a legal

Canada 0.15(a)

(time-weighted average) 1976-1991 legal

France 0.15** 1988 legal

Germany 0.10* 1986 recommendation

Japan 0.15 1972 legal

Britain 0.15* Aug 1981 legal

United States 0.100 (b) June 1981 legal

Mexico 0.15 recommendation

Spain 0.15 1986 legal

Sweden 0.10 (total)**0.05 (respirable)**

1982 legal

EEC 0.15** 1986 legal

Ireland 0.15 1975 recommendation

Italy 0.15* local authority require-ment

Netherlands 0.15**0.10

19871986

recommendationlegal

Norway 0.05 (c) 1981 recommendation

Vectra


Norms for lead in blood

The following table shows the tolerable rangesof lead-in-blood, as seen by different countries.

(a) = New Foundland, Nova Scotia, New Brunswick, Prince Edward Island, Manitoba, Saskatchewan.

(b) = Alberta

(c) = Ontario and Yukon

(d) = British Columbia

(e) = A PbB level of between 70 and 80 mg Pb/100 ml blood shall be allowed if the ALAU (Amino Laevulinic Acid in Urine remainslower than 20 mg/g creatine or the ZPP (Zinx Protoporphysin) level remains lower than 20 mg/g haemoglobin or the ALAD (DeltaAminohaevulinic Acid Dehydratase) level remains greater than six European units.

(f) = France follows EED norms.

(g) = First action level 30 mg/100 ml; second action level 50 mg/100 ml.

(h) = Recommended value for pregnant women is less than 20 mg/100 ml (1.0 mol/l; less than 30 mg/100 ml (1.5 mol/l) for womenplanning pregnancy.

(i) = Quoted as 2.5 mol./l.

(j) = Quoted as 3.0 mol./l.

(k) = See EEC

(l) = Worker must leave workplace at these levels and may return at 40 mg/100 ml lead in blood level.

Country Maximum Lead Level (mg/m3) Date Operative Legal Status

Canada 0.50 mg/l (a) 0.52 mg/l (b) 0.70 mg/l (c) 0.80 mg/l (d)

1976 - 1991 legal

EEC 70 (with exception to 80) (e) 1988 legal

France 70 (with exception to 80) (f) 1988 legal

Germany 70, men30, (women under 45) 1988 legal

Ireland 80 1976 recommendation

Italy 70 code of practice

Japan 60 1972 legal

Netherlands 70(f) 1987 legal

Norway 50 (max.)(h) (2.5 mol/l)

Spain 70 (ALA > 20)80 (ALA < 20)

1963 legal

Sweden 50(i) in three consecutive periodic checks or 60(j) in one check 1985 legal

Thailand 70 recommendation

Britain 70 men (with exceptions to 80)(k) 40 women 1986 legal

United States 50 (l) March 1983 legal

Vectra


BURN HAZARDS

Liqu id Meta l - HotSurfaces Burn Hazard

The solder pot containsmolten solder at temperatures up to 343 o C(651 o F). Hot

solder causes serious burns. Always wearsafety protective clothing such as high

temperature gloves and safety glasses whenworking in or around the solder pot.

Solder Eruptions - BurnHazard

When a surface area onthe solder's surface becomes stressed orreaches its pasty range temperature, theupward force may result in a solder eruptionwhich may cause serious burns. Alwaysremain aware of this hazard when heating acold solder pot.

Always wear the appropriate safety glassesand protective clothing.

Hot Components andSurfaces - Burn Hazard

The preheaters, solderpot, rail guards, parts of the conveyor, andother exposed metal and glass surfaces arepotent ia l burn hazards to personne lperforming maintenance or operation.Components and sur faces can reachtemperatures in excess of 66 o C (150 o F)which may cause serious burns. Allow hotcomponents to cool whenever possible priorto performing maintenance. Always wearsafety garments or equipment when workingwith or around hot components.

Violent Reaction to HotSolder - Burn Hazard

Do not permit water, fluxor any other liquidous material to enter thesolder pot. A violent reaction results in theprojection of tiny droplets of hot solder andhot gasses into the air which may causeserious burns. Always wear safety garmentsor equipment when working with or aroundhot components.

VAPOR HAZARDS

Hazardous Vapors CanCause Serious Illness

D u r i n g t h e w a v esoldering process, it is normal for noxiousfumes or vapors to be produced as a result ofthe interaction between flux, solvent, solder,and heat being applied to the printed circuitboard. If inhaled, the noxious fumes cancause serious illness. Always maintainproper exhaust and wear the recommendedpro tec t i ve sa fe t y a r t i c les . Adequateprotective clothing consists of approvedsafety glasses, long-sleeved garment, acidresistant smock, heat protective gloves,approved steel toe safety shoes, and arespirator approved for use when workingaround noxious fumes or vapor.

FIRE HAZARDS

Flux and Solvent FireHazard

Keep flux solutions andsolvents away from sparks, flames andexcess heat. Ensure that product passingover the preheat section does not carry overexcess flux. Excess flux can drip on thepreheaters; the flux can ignite. Closelymonitor the wipe-off action of the fluxerairknife to ensure excess flux is removed.Keep a fire extinguisher specifically for useon fires of this type close to the machine.

Fire Hazard - Flux VaporsMay Accumulate

Ensure the sys temexhaust is on and operating. Hazardousvapors which are allowed to accumulatecould result in a flash fire, auto ignition of theflux and solvent or explosion. Fires of thisnature are extremely dangerous, and ifpersonnel are exposed to this hazard, thirddegree burns or even death could occur. If afire of this nature does occur, immediatelyturn off power to the exhaust system, asoxygen will fuel the fire.

Vectra


MECHANICAL HAZARDS

Moving Parts, PinchPoints - Bodily InjuryMay Occur

Moving parts of the wave soldering systempresent a potential hazard to body parts. Stopconveyors, motors, pumps, or other movingparts prior to performing maintenanceprocedures. Ensure safety covers are inplace.

While the system is operating, keep long hairtied up or back to prevent entanglement.Keep loose clothing, jewelry and hands awayfrom pinch points, drive belts, and drivegears and sprockets.

Dismemberment or other serious bodilyinjuries can occur if this warning is notfollowed.

ELECTRICAL HAZARDS

Electrical Shock Hazard- Serious Burns MayOccur

Operation of this equipment exposes theoperator or maintenance personnel tosituations which may result in electricalshock i f procedures are not proper lyfollowed. Electrical shock can cause seriousburns.

Ensure that electrical enclosure doors orsafety panels are in place during normaloperation to avoid exposure to electricals h o c k h a z a r d s . W h e n p e r f o r m i n gmaintenance procedures using ammeters,volt meters, or ohm meters, electrical shockhazard is present. These procedures must beperformed only by a licensed electrician orelectrical engineer familiar with testing livevoltage. Always disconnect main powerbefore performing maintenance wheneverpossible.

Hazardous Voltage -can Shock, Burn orcause Death

This equipment may be configured to operatewith high voltage ranging from 230, 380, to480 volts. There is a risk of electric shockw h e n p e r f o r m i n g i n s t a l l a t i o n o rmaintenance voltage testing. High voltage

can shock, burn or cause death. Use extremecaution when performing voltage andamperage tests on live voltage. These typesof procedures must be performed only by alicensed electrician or electrical engineerfamiliar with testing live voltage.

High Amperage - DoNot Touch - can causeDeath

Electrical current used in the nitrogen flowcontrol unit can kill or cause other seriousin jur ies . Do not touch l i ve e lect r ica lcomponents inside the nitrogen electricalenclosure.

Always disconnect power prior to attemptingrepairs to the nitrogen flow control unit. Thisfeature must be installed or serviced by alicensed electrician or qualified electricalengineer.

NITROGEN HAZARDS

Asphyxiation Hazard

The air inside the systemcabinet or any enclosed

space being inerted with nitrogen removesthe oxygen from the air. The absence or lackof oxygen can cause asphyxiation, dizziness,headache, fainting or nausea. This presentsa hazard to personnel operating or servicingthe equipment. Always turn off the nitrogensupply and vent the system enclosure withair prior to performing any maintenanceprocedures.

Use Only Nitrogen orProcess could beaffected

Only nitrogen (4 ppm in purity or less) shouldbe used in the machine. Do not substitute orcombine other gases without first consultingSpeedline/ Electrovert and the gas supplier.Other gases could interfere with the processand introduce additional safety hazards.

Vectra


COMPRESSED GAS HAZARD

Compressed Nitrogen -Excessive pressurecould cause explosion

of Nitrogen Flow Meters.

Do not connect the Nitrogen Flow Controlunit to a nitrogen source that exceeds 690kPa (100 psi). Exploding flow meters are apotential hazard to workers stationed in frontof the control panel. Compressed gas cancause projectiles, gas burns to exposedareas of the body, and asphyxiation. It isrecommended that nitrogen is delivered at aregulated pressure, at least 103 kPa (15 psi)less than the supply line pressure.

Vectra


1.2 SAFETY PRECAUTIONSNo-smoking Signs

Post large, visible “NO-SMOKING” signs in thework area. Establish a means of monitoring andenforcing this regulation.

Fire Extinguishers

If your machine is equipped with an automaticfire suppression system, ensure that theextinguishing reservoir is filled and primedprior to operating the machine. If your machinedoes not have an automatic fire suppressionsystem, keep an approved CO2 fire extinguishernear the machine at all times.

Familiarize yourself with the operation and useof your fire extinguisher.

When extinguishing a flux fire, first turn off thesystem’s input power. Do not point theextinguisher directly at the flux or solder.

Breathing Masks

Ensure that dross removal operations arecarried out without exposing operators ormaintenance personnel to excessive airbornelead particles. All operators and maintenancepersonnel must be provided with an NIOSH(National Institute for Occupational Safety andHealth) or MSHA (Mine, Safety and HealthAdministration) approved respirator which willprovide effective protection from lead dust andfumes up to ten (10) times the permittedexposure limit. Refer to your solder supplier'sMSDS's -Material Safety Data Sheets, forspecific breathing apparatus requirements foruse with wave soldering applications.

Safety Garments

Always wear protective clothing when required.Additional protective clothing is required whenservicing a hot machine or handling hotcomponents. Safety clothing consists of aprotective mask or safety goggles, hightemperature gloves, long-sleeved garment, acidresistant smock, and approved steel toe safetyshoes.

Operators must remove all protective clothingand wash thoroughly before eating, drinking orsmoking. Under no circumstances shouldeating, drinking or smoking be permittedaround the machine, or where lead is present.

Safety Data on Fluxes, Solvents, and other Chemicals

Never store flammable materials around thevicinity of the wave soldering machine. Heatfrom the solder pot, preheaters and sparks fromthe motors could ignite flammable materials.Never place items, flammable or not, on themachine.

This presents a fire hazard due to the operatingtemperature of the entire machine. Ensure thatthe Mater ial Safety Data Sheets for thechemicals being used in the machine are keptreadily available at all times. This data will beuseful in the event of an emergency.

Housekeeping

Good housekeeping and cleaning of thisequipment on a continuously monitoredmaintenance schedule is extremely importantto the safety and reliability of the equipment'soperation.

Vectra


1.3 SAFETY PROCEDURES FOR REMOVAL OF DROSS

Exposure to LeadHazard - Exposure toLead in any form may

cause serious health hazards.

Breathing lead dust, which is nearly invisible,can cause lead poisoning. Always ensure thesolder system ventilation is on and operatingat the specifications listed in this manualprior to working around the solder pot.

To avoid inhalation, wear the proper safetyapproved b rea th ing appara tusrecommended by the solder supplier for usewith wave soldering equipment.

PROCEDURE CHECKLISTUse the following procedure for handling and removing dross from the solder pot:

The dross container must have a lid and beclosed to prevent dust scattering duringhandling and transport of dross. Airborneparticles can be minimized by dampening thedross with water once it has cooled to roomtemperature.

Make arrangements to ensure that all thenecessary tools, respirators, and safetyequipment are available to remove drosswithout exposing operators to excessiveexposure to dross particles. Personnel must beprovided with protective garments and gloves toprevent contamination of personal clothing andhands.

The solder pot and the container to which thedross is transferred must be enclosed andunder effective exhaust ventilation. A methodshould be developed for dross removal withinthe enclosure. Where this is not practical, thepossibility of providing local exhaust ventilationshould be considered to minimize the escape ofdross particles into the atmosphere.

Under these circumstances, the operatorshould be provided with a suitable oral-nasalrespirator, which provides effective protectionfrom lead in the form of dross and exhaustfumes up to 10 times the permitted exposurelimit.

Know and abide by safety regulations.

Use a designated container.

Make advanced preparations.

Make sure the area is adequately ventilated.

Wear an approved respirator designated for the protection against airborne lead particulate.

Arrange for reclamation of the waste by an authorized reclamation facility that specializes in the handling of these type of materials.

Store protective clothing and wash thoroughly.

Vectra


Liquid Meta l - HotSurfaces Burn Hazard

The solder pot containsmolten solder at temperatures up to 343 oC(651 oF) which causes serious burns. Alwayswear the recommended safety protectiveclothing such as high temperature glovesand safety glasses when working in oraround the solder pot.

Return the dross to a secondary smelter forreclamation of metal contents either directly orthrough a scrap metal trader.

Personnel are to remove overalls or any otherprotective clothing, and store it in a place wherei t wi l l not spread contaminat ion. Washthoroughly before eating, drinking or smoking.Under no circumstances should eating,drinking or smoking be permitted whileoperators are working around lead.

Most countries specify a control limit forairborne particles, blood lead levels and otherbio logical parameters . Reference locallegislation to ensure you comply with medicaland biological requirements.

Vectra


1.4 EXHAUST VENTILATION AND CLEANINGClean the exhaust ventilation system on aregular basis.

Because fumes generated during the normalwave soldering process contain lead particles,it is essential to install an adequate exhaustvent i lat ion system capable of removingpotentially dangerous lead emissions from themachine. Refer to the Technical Data Sectionon page 15 for precise data on the type andcapacity of exhaust required for the system.

1. Establish an exhaust filtration system. Afiltration system which is based onactivated carbon as a filter medium isrecommended. This system must beplaced in line with the exhaust ventingsystem so that the emissions created fromthe soldering processes are captured. Alsoensure that the units do not interfere withthe soldering operations.

2. Monitor the lead content of the air in theworkplace at regular intervals duringoperations. Check air quality on a regularbasis. Due to variables in the environmentsuch as opening or closing windows ordoors; changes in the movement of airthroughout the course of a working day, itis necessary to update readingsperiodically during operations.

3. On a scheduled basis, dismantle andclean the exhaust ventilation duct workand filtration media using the appropriatesafety measures for handling lead.Regular cleaning prevents contaminantbuild-up, reduces the risk of fire, andimproves the efficiency of your exhaustsystem.

On some Speedline/ ElectrovertSystems, wave soldering cannotbeg in un less the exhaus t

ventilation system is on and the widows anddoors are closed. These safety interlocksprotect the user against the escape ofhazardous fumes and provide safe operationof the system.Lockout/ Tagout Checklist

Vectra


1.5 LOCKOUT/ TAGOUT CHECKLISTThis checklist is provided to serve only as a means to review the required energy sources that must beisolated before performing maintenance or calibration procedures on the Vectra™. Since Lockout andTagout procedures and policies vary from one company to the next, Electrovert recommends followinginternal policy and procedure outlined by the facility's management.

I. ENERGY SOURCE IDENTIFICATION

Electrical Power:

440 - 480 VAC, 3 phase, 60 Hz

380 - 415 VAC, 3 phase, 50 Hz

200 - 240 VAC, 3 phase, 60 Hz

110 - 120 VAC, 1 phase, 60 Hz

UPS (Uninterruptible Power Supply) Backup

Compressed Air

Compressed Nitrogen (N 2)

Fire Suppression System (CO 2)

Heat (Burn Hazard):

Convection (Vectaheat™) Heaters

IR Preheaters

Solder Pot

Stored Energy:

Front Doors (when raised)

Front Tailgate Door (when unlatched)

II. NOTIFY ALL AFFECTED EMPLOYEES OF LOCKOUT PROCESS

III. TURN OFF ALL OPERATING CONTROLS (SWITCHES, SYSTEM DISCONNECT…

IV. LOCKOUT ALL ENERGY SOURCES

Electrical Power

UPS

Compressed Air

Compressed N 2

CO 2

Sources of Heat

Stored Energy

Vectra


If procedures must be continuedpast the person's shift who appliedthe l ockou t , ensure tha t an

employee who is working on the lock outequipment applies their lockout device and theprevious remove theirs.

V. ISOLATE ALL ENERGY SOURCES BY BLOCKING, BLEEDING, AND VENTING STORED ENERGY. ENSURE HEATERS ARE COOL OR WEAR THE APPROPRIATE PROTECTIVE CLOTHING BEFORE PROCEEDING.

BLOCK ALL STORED ENERGY.

VI. LOCKOUT ALL SWITCHES AND ENERGY IN THE OFF OR SAFE POSITION.

Lockout/ Tagout service disconnect

Use plug lockout on UPS

Lockout ball valve for Nitrogen

Lockout ball valve or disconnect compressed air

Lockout CO2 source

VII. TEST OPERATING CONTROLS.

Test keyboard, monitor, switches, and UPS to ensure off status.

VIII. RETURN ALL OPERATING CONTROLS TO THE OFF POSITION.

Ensure any switch tested is in the off position before proceeding.

IX. PERFORM REQUIRED TASK.

Complete assembly, repair, calibration

X. REMOVE LOCKOUT DEVICES.

Ensure equipment is fully assembled.

Ensure all tools have been removed.

All affected employees have been notified.

Lockout device must be removed by the employee who applied the device.

Ensure lockout of equipment has been communicated between shifts.

Vectra

Installation Manual 2-9317-130-00-0 — Rev. 1 13

SECTION 2: TECHNICAL DATA

2.1 INSTALLATION SPECIFICATIONS AND FACILITY REQUIREMENTS

Refer to the Power Table on page 14 to calculate and select the power configuration andfacility power disconnect requirements for the machine. It is the responsibility of thecustomer to provide any electrical disconnect (fusible or breaker type), external to the system,

capable of protecting the Vectra at the amperage specified for the voltage selected. The values listed areat maximum power consumption during full load start-up. Power consumption is lower at stabilizedprocess conditions, but varies on process parameters and product loading. Typical conditions draw 30 -50% of full load value (based on 30 - 50% duty cycle) at steady state operating conditions.

The Vectra™ is equipped with a main disconnect switch which is not fused. It isrecommended that the main supply power be supplied to the machine via a wall-mountedfused disconnect in accordance with local codes.

European Customers:

To comply with EMC Directive 89/336/EEC on electromagnetic compatibility, power cables to the machinemust be run in rigid or flexible metal conduit.

ELECTRICAL

Standard Power Sources (See Note 1)440 - 480 VAC, 3 phase, 60 Hz (4 wires: 3 phase, ground)380 - 415 VAC, 3 phase, 50 Hz (5 wires: 3 phase, neutral, ground)

Power Consumption

Basic System full load start-up 46.7 kW @ 380 and 440 VAC

add 10.4 kW for each additional optional platen preheater.

add 12.6 kW for Gas Knife

Standard operating power consumption: (NOTE 2)

380 VAC 440 VAC Configuration

71 amps 61 amps Base machine (3 preheats)

16 amps 14 amps add to base machine value for each optional platen preheater added

30 amps 17 amps add to base machine valuefor CoN 2 tour Plus™/ AccuKnife™ option

Schematic Reference

All Voltages: Electrical Schematic # 8-1701-505-03-6

Vectra

14 2-9317-130-00-0 — Rev. 1 Installation Manual

NOTE 1 Multiply the total F.L.A. by 1.25 tocalculate Service Amps

NOTE 2 Add 14 Amps to the F.L.A. f6or eachadditional preheater (up to 6 total)Add 17 Amps to the F.L.A. for theCoN2Tour Plus™/ AccuKnife™.

NOTE 3 Add 15 Amps to the F.L.A. for eachadditional preheater (up to 6 total).Add 18 Amps to the F.L.A. for theCoN2Tour Plus™/ AccuKnife™.



NOTE 6 Add 27 Amps to the F.L.A. for eachadditional preheater (up to 5 total or4 with the CoN2Tour Plus™/AccuKnife™. Add 34 Amps to theF.L.A. for the Hot Gas/ Air Knife.

NOTE 7 Add 30 Amps to the F.L.A. for eachadditional preheater (up to 5 total or4 with the CoN2Tour Plus™/AccuKnife™. Add 36 Amps to theF.L.A. for the CoN2Tour Plus™/AccuKnife™.

NOTE 8 Add 25 Amps to the F.L.A. for eachadditional preheater (up to 5 total or4 with the CoN2Tour Plus™/AccuKnife™. Add 31 Amps to theF.L.A. for the CoN2Tour Plus™/AccuKnife™.

NOTE 9 Due to the physical size of themain internal disconnect, 200 - 240VAC machines are limited to aconfiguration of five (5) preheaters,or four (4) preheaters and aCoN2Tour Plus™/ AccuKnife™.

POWER (See NOTE 1)

Base Machine 440 VAC (See Note 2)

kVA 45.9

F.L.A. 60

Service 75 Amps


kVA 53.7

F.L.A. 64

Service 81 Amps


kVA 45.9

F.L.A. 70

Service 88 Amps


kVA 53.7

F.L.A. 75

Service 94 Amps


kVA 45.9

F.L.A. 120

Service 150 Amps


kVA 53.7

F.L.A. 129

Service 161 Amps


kVA 39.3

F.L.A. 114

Service 143 Amps

Vectra


Grounding Requirements

The system must beprovided with anelectrical earth ground

for the main power cabinet inaccordance with local electricalcodes and standards. Ensure earthground is connected to ground, orplace a copper rod driven to earth onthe supply side of any “earth trip”system. This procedure must complywith safety and fire regulations toshut down the system if a shortingcondition develops.

NOTE 1 The Vectra is configured with a 2.0 in. hole in the top, rear of the cabinet for conduit connection.Systems configured as 200 - 240 VAC require the standard 2.0 in. hole to be enlarged to accept 3.0in. conduit. Refer to local codes or restrictions pertaining to the use of conduit materials.

NOTE 2 The flow meters on the machine are calibrated for 295 kPa (44 psi). The gas fed line to themachine must be sized to maintain the required flow rate at 335 kPa (50 psi) at the machinepressure regulator. Shut-off valve and pressure gauge to be fitted to feed line per local codes.

NOTE 3 It is recommended that the customer install regulating slide gate dampers on the exhauststacks to allow proper balancing of the exhaust system.

NOTE 4 The customer’s ventilation system must be capable of providing 8 mm (0.3 in.) water staticpressure at the machine stacks; the blower must be sized to ensure that the required flow ratesare available at the machine; actual size depends on the customer’s individual system.

NOTE 5 The ventilation duct must be of seamless, galvanized or stainless steel material due to thepotentially corrosive nature of the fumes generated in the wave soldering process.

CONDUIT (SEE NOTE 1)

200 - 240 VAC 3.0 in.

380 - 480 VAC 2.0 in.

COMPRESSED AIR/ NITROGENSUPPLY (SEE NOTE 2)

System: - 1/2 in. fitting- Max. line pressure: 830 kPa (120 psig) @ 30-40 SCFMclean, dry, and oil free

Optional CoN2Tour™ Plus™/AccuKnife™

- 1/2 in. (separate) fitting- Nitrogen/ Air pressure: 415 - 830 kPa (60 - 120 psig)

EXHAUST REQUIREMENTS(SEE NOTES 3 - 5)

- Two (2), 152 mm (6 in.) exhaust ports at the top of the cabinet- 20 M3/min (700 cfm) @ 25.4 mm (1.0 in.) of water staticpressure to be measured at each of the machine exhaust ports

Vectra


FOAM FLUXER

Capacity: - 14.6 Liters (3.85 US gal.) with the flux level at 25 mm (1.0 in.above the aerator stones.

Paar FDC: - Flux and thinner feed bottles to be supplied by user.

SOLDER CAPACITY

Single Wave:Dual Wave Configuration:

- 839 kg. (1,850 lbs.)- 821 kg. (1,810 lbs.)

Wire Feeder: - 1/8 in. diameter wire

Bar Feeder: - Holds up to ten (10) bars, each weighing up to 1 kg (2.2 lbs.)

FINGER CLEANER

Reservoir Capacity: - 12.30 Liters (3.25 gal.)

Vectra


2.2 SYSTEM DIMENSIONS

Figure 1: System Footprint Drawings

MACHINE REQUIREMENTS:

1. Exhaust: 1200 M3/ HR (700 CFM) @ 2.54 mm (1 in.) H2O Static Pressure per Stack2. Power input size: 2 in. for 380V - 480V for 2 in. conduitor 3 in. for 200V - 240V for 3 in. conduit.3. System air requirements: 1/2 in. NPT fitting, .84 - 1.13 M3/ min. (30 - 40 CFM) @ 483 - 690 kPa (70 - 100 PSI)

NOTE: Dimensions may vary ± 127 mm (0.5 in.)

459 mm(18.07 in.)Maximum

WidthFront Edge of PCB

Fold DownTailgate

Solder Pot

882 mm(34.72 in.)

1016 mm(40.00 in.)

1452 mm(57.17 in.)

1828 mm(71.97 in.)

2250 mm(88.58 in.)

70 mm(2.76 in.)

1518 mm(59.76 in.)

370 mm(14.57 in.)

844 mm(33.23 in.)

Nitrogen Inlet½ in. NPT Fitting

Air Inlet½ in. NPT Fitting

Hot Gas Knife Inlet½ in. NPT Fitting

135 mm(5.31 in.)

120 mm(4.72 in.)

85 mm(3.35 in.)

193 mm(7.60 in.)

1666 mm(65.59 in.)

444 mm(17.48 in.)

683 mm(26.89 in.)

140 mm(5.51 in.)

673 mm(26.50 in.)

95 mm(3.74 in.)

Ø 152 mm(5.98 in.) 2 Places

Keyboardand Monitor

2289 mm(90.12 in.)

349 mm(13.74 in.)

Rollout Stand

Power InputSee Note 2

632 mm(24.88 in.)

198 mm(7.80 in.)

783 mm(30.83 in.)ConveyorEntrance

762 mm(30.00 in.)

Load GuideEntrance

147 mm(5.79 in.)

351 mm(13.82 in.)

195 mm(7.68 in.)

2096 mm(82.52 in.)

2806 mm(110.47 in.)

3196 mm(125.83 in.)

377 mm(14.84 in.)

459 mm(18.07 in.)

100/180 mm(3.94/7.09 in.)

AdjustableLeveling

1174 mm(46.22 in.)Conveyor

Exit

77 mm(3.03 in.)

3740 mm(147.24 in.)

590 mm(23.23 in.)Light Tower Exhaust Stack (2 Places)

of SprocketCL

of SprocketCL

Vectra


Vectra


SECTION 3: INSTALLATION PREPARATION

3.1 RECEIVING INSTRUCTIONSThoroughly inspect the shipment whenreceived. If damage or loss is detected, enter alldetails on the freight bill or receipt and have itsigned by the carrier agent. Failure to follow thisprocedure may result in the carrier refusing tohonor the claim. The carrier furnished thenecessary forms for filing a claim.

When damage is not readily apparent until theequipment has been unpacked, file a claim forconcealed damage. Within 48 hours of deliveryand as soon as any concealed damage isdiscovered, furnish a written or telephonerequest to the carrier for inspection.

Keep all cartons, packing materials, andpaperwork. The carrier furnishes an inspectionreport and the necessary forms for filing theconcealed damage claim.

3.2 INSTALLATION PLANNINGPrior to performing installation procedures,review the contents of this manual.

Allocate sufficient floor space for efficientoperation and system accessibility from allsides. Refer to the system footprint drawingsupplied in the enclosed DocumentationPackage.

In selecting a site location, keep in mindrequi rements for fac i l i t y to equipmentconnections such as an electrical drop,compressed air, exhaust, nitrogen, entranceand exit conveyors.

Clearance behind the system is especiallyimportant s ince serv ice operat ions areperformed from the rear of the machine. Theadditional 2 m (6 ft) of space required at therear of the machine for the roll-out solder potstand is normally adequate. The same space isrecommended for the front and sides exceptwhere the sys tem is in - l ine w i th o therautomated equipment, i.e., auto insertionequipment or PCB (printed circuit board)cleaning equipment.

Install the system on a solid (anti-vibration),level floor, capable of supporting the machine’sweight. When fully loaded with solder theestimated maximum machine weight is 3087 kg(6800 lbs). Six (6) leveling feet support themachine.

When considering a site for installation, it isalso important to keep in mind the flammabilityof the materials (i.e., fluxes and thinners) usedduring normal operation and maintenanceprocedures. Provide adequate protection fromthese types of materials and their hazards forthe sys tem and opera t ing and se rv icepersonnel.

Allow additional space for the storage ofprocess materials such as flux, thinner, andsolder. The storage containers used, especiallyfor flux and thinner, should be remote and/orprotected to minimize the risk of a fire outsidethe wave soldering system.

Vectra


3.3 INSTALLATION CHECKLISTUse the following checklist for organization andrecord keeping purposes. Failure to recordproblems with installation or factors requiredfo r p roper ins ta l l a t i on may resu l t inunscheduled down time.

Table 1: Installation Check List

Location:

q Adequate floor space

q Adequate clearances above and around the system

q Level surface at installation location

Adequate facility connections for:

q Compressed air

q Exhaust

q Nitrogen (optional)

q Electrical hook-up

Describe any inadequate requirements:

Component Installation/Check:

q Conveyor is level

q Finger mask is installed correctly (optional)

q Inspect seals on nitrogen tunnel

q Air knives and aerators are installed

q Entrance end load guides are installed

q Exit end chain guards are installed

q Solder pot is level

q Solder drain valve is closed and secure

Shipping Damage:

q Check for system damage:

Describe any system damage:

System Leveling:

q Level “X” axis at front and rear of system lower deck

q Level “Y” axis at entrance and exit end system lower deck

q Adjust leveling feet and recheck axis on all sides

q Lock all leveling pads

Complete Utility Connections:

q Verify system voltage, phase, and Hz rating

q Check electrical power connections

q Check for proper exhaust connection

q Verify pump rotation

q Inspect optional nitrogen connection

q Air connection

NOTES:

Table 1: Installation Check List

Vectra


SECTION 4: REQUIRED EQUIPMENT AND TOOLS

4.1 PROTECTIVE CLOTHING• Approved safety glasses• Steel toe safety shoes• Approved respirator (for lead particulate)• Gloves (for handling cold solder)• High temperature gloves

4.2 TOOLS AND MATERIALS• Pry bars• Claw hammers• Electrician's pliers• Wire cutters and strippers• Volt/ Ohm meter• Clamp ammeter• Carpenter's level• 10, 12, and 15 in. Crescent wrenches• ¾, 1-½ in. deep socket and ratchet• Phillips head screwdrivers• Set of metric open/box end wrenches• 5/16 in. Allen wrench• Channel lock pliers• Set of metric sockets

4.3 EXPENDABLE ITEMS• Lint-free cloths• Glass cleaner• Flux• Thinner• Solder

4.4 RIGGING EQUIPMENTSix (6) Ton capacity fork lift with six (6) foot forkextensions

Figure 2: Fork Lift

Vectra


Vectra


SECTION 5: SHIPPING ARRANGEMENT

This manual makes reference to both standardand optional configurations. Disregard optionsthat do not apply to your system configuration.

5.1 SHIPMENT ITEMS• One (1) Vectra™ Wave Soldering system• Cardboard box –

Strapped to one end of the skid includes:Monitor and keyboard, Installation,Operation, and Maintenance Manuals,documentation package with systemdrawings and bills of material, tool kit,aerator reservoir (foam fluxer only), six (6)leveling feet, optional CO2 related hoses,

connectors and cables; conveyor loadguides.

• Optional CO2 bottle strapped to the skid in

front of the machine.• Optional Opti-Fluxer flux container

strapped to one end of the skid.• Optional external fluxer module (not on

skid).

5.2 SHIPPING CONFIGURATIONFollow the procedures which apply to yourshipment destination.

DOMESTICVectra™ domestic shipments are bolted andstrapped to a skid, and wrapped in moistureprotective plastic.

Figure 3: System Bolted to Skid

INTERNATIONALVectra™ international shipments are alsobolted and strapped to a skid, wrapped inmoisture protective plastic, then completelycrated.

Figure 4: International Crated System

Follow the procedures which apply to yourshipment’s destination.

Vectra

24 2-9317-130-00-0 — Rev. 1 Installaton Manual

5.3 LIFTING AND HANDLING THE VECTRA™

The Vectra™ can weighup to three (3) tons ormore , depend ing on

system configuration. To avoid possiblebodily injury or damage to equipment do notattempt to move the equipment by other thanrecommended means.

It is the responsibility of the customer toprovide any rigging equipment or devicesrequired to transport the skidded or cratedsystem to the site of installation.

Use a forklift with a 3600 kg (8000 lb) liftingcapacity to lift and handle the Vectra™.

Figure 5: Four (4) Ton Capacity Forklift

When the shipment arrives at the destinationfacility, keep it in the crate or on the skid untiltime to start the installation. This minimizes thechance of system damage while moving itthrough the facility.

Vectra


SECTION 6: UNPACKING INSTRUCTIONS

6.1 DOMESTIC SHIPMENTSRead this section in i ts entirety prior toperforming any unpacking procedures toprevent damage to the equipment. Perform allsteps in the order in which they are presented.

1. Using a fork lift, position the skiddedsystem at its final installation site.

2. Carefully remove the plastic moistureprotective covering from the system.

3. Cut and remove any strapping securingcardboard or wooden boxes to the skid.These boxes contain additional systemcomponents.

Figure 6: Remove Packaging Materials

4. If applicable, also remove strappingsecuring any optional items such as CO2

extinguishing bottles, flux containers, orother components.

5. Carefully remove all components cut free inthe previous step and position them in asafe place close to the site of installation.

6. Carefully cut and remove any additionalstrapping securing the Vectra system to theskid. See Figure 6: Remove PackagingMaterials.

Vectra


7. The Vectra™ system mounts on 2 x 8 in.wooden planks with foam shock pads, andsecured with bolts to the skid. Bolts arefactory installed in six (6) leveling footlocations (three [3] in front; three [3] inback), with twelve (12) shipping plates atthe underside of the system frame.Additional hardware (bolts with jam nuts)secure the shipping plates to the 2 x 8 in.wooden planks which are bolted to the skid.

Use a 3/4 in. deep socket wrench andratchet to remove the double jam nuts fromeach of the bolts securing the shippingplates to the wooden planks.

Figure 7: Unbolt System from Skid

8. Once all jam nuts are removed from theshipping plates, carefully position a 3600 kg(8000 lb) capacity fork lift with 1.9 meter (sixft) extensions at their widest setting, underthe frame of the Vectra™.

9. Lift at the center of gravity point, locatedjust right of center facing the front of thesystem or just left of center facing the rearof the system.

Ensure the forks make proper contact withthe front and rear edges of the system baseframe.

Figure 8: Position forks under front and rear edges

Figure 9: Remove System from Skid

10. After the fork lift is in place, carefully andslowly raise the machine off of the skid highenough to remove the shipping plates fromthe underside of the system frame.

11. Use a 1 1/2 in. socket with ratchet toremove the six (6) bolts from the levelingpad mounting holes.

12. Proceed immediately to Section 6.3: InstallSystem Leveling Feet on page 28.

Base of Cabinet

3/4 in. Deep Socket

Jam Nuts

Shipping Plate

2 x 8 in. PlankFoam Shock Pad

2 x 8 in. Plank

Skid

Vectra


6.2 INTERNATIONAL SHIPMENTS1. Using a fork lift, position the crated system

at its final installation site.

2. Using pry bars and claw hammers,carefully dismantle the wooden crate in the

following sequence, taking care not todamage the system.

1st remove the top of the crate2nd remove any additional top bracing3rd remove the ends of the crate4th remove the sides of the crate

Figure 10: Crate Dismantling

3. Once the crate is dismantled, perform Step2 through Step 12 of Section 6.1: DomesticShipments on page 25.

Vectra


6.3 INSTALL SYSTEM LEVELING FEET1. Locate and open the cardboard box

containing the six (6) system leveling feetand two (2) leveling feet for the solder potstand.

2. While the system is still elevated above theskid, install the six (6) leveling feet into thesix (6) threaded nuts welded under the baseof the machine, and two (2) leveling feetinto the threaded fittings under the solderpot stand.

Figure 11: Install Leveling Feet

3. Install the feet so they extend between 4.0–12.0 cm (1.5–4.8 in.), depending on theheight required for incoming or exitingconveyors.

Figure 12: Leveling foot installed

4. Adjust all leveling feet (6) to the sameheight, then tighten the locking nut.

Figure 13: Adjust the height of each leveling foot to the same measurement

5. Once ALL the leveling feet are installed,slide the skid out from under system.

6. Carefully and slowly, lower the machine tothe floor.

Locking Nut

Base of Machine

Leveling Foot

Vectra


6.4 UNPACKING AND GENERAL INSPECTIONCarefully remove packing materials from thelocations listed below:

• Remove strapping from around theVectra™ cabinet.

• Remove the styrofoam blocks at the front ofthe Vectra from between the hoods and thecabinet.

It is necessary to open rearaccess doors and the front of thesystem to gain access to some

packing materials. Use the 5/16 in. Allen keyto open rear fluxer, electrical, and solder potaccess door.

Disregard installation instructions that do notapply to your system configuration.

INTERNAL FOAM FLUXER 1. Open the fluxer section rear cabinet doors

and remove the packing on ends of flux,thinner and recirculation pumpsubmersible ends.

2. From the front of the machine locate thefluxer front access panel and removepacking tape.

3. Remove strapping from around rear of fluxreservoir.

4. Remove strapping from around entire fluxermodule.

5. Remove the tie wrap from the hood supportrod and the tape from the fluxer nozzle.

CONVEYOR1. Remove the tape from each of the conveyor

width adjust optional covers (3), and theconveyor drive cover.

2. Remove the tape from the manual widthadjust hand crank at the load end of theconveyor.

PREHEATERS1. Remove the strapping and styrofoam

padding from around each Vectaheat™preheater module.

Figure 14: Preheat packaging materials

2. Carefully remove the tape and styrofoampadding securing the optional pyrometerwire guide chain.

SOLDER MODULE1. Open the solder section rear cabinet doors

and remove the strapping from the roll-outsolder pot stand.

ELECTRICAL1. Remove the “Zerust” vapor capsules from

the inside of the rear electrical enclosure.

2. Remove tape, bubble packing andstyrofoam from optional system statustower at the top of the cabinet.

3. Remove the tie wraps securing the powercord for the optional CO2 control box at theexit end of the cabinet.

4. Inspect the parts that are crated or boxedseparately. Carefully unpack these separatecontainers ensure there is no damage tothe components.

Vectra


INSPECTION1. The monitor, mounting assembly, and

keyboard are packed separately. Installthese components only after the system'sheight is adjusted and leveled, and thesystem is in its position for operation. Donot throw away any boxes or packingmaterials until it is verified that all systemcomponents are accounted for.

2. Machines that are shipped either by oceanvessel or by air contain moisture absorbentbags inserted in electrical cabinets toprevent moisture buildup and corrosion ofcomponents. For the same reason, motorvents and exposed shafts or moving partsmay also be taped or sealed with specialsealants. Remove all moisture absorbentbags and tape. Use mineral spirits and aclean rag to wipe off the sealant substanceand tape adhesives.

3. Visually inspect for concealed damages. Inparticular, inspect the glass panels thatinstall over the preheaters after uncratingthem.

4. Check for damage to any of the sensitiveinstruments and controls.

5. Check for dents or punctures through theenclosure.

6. Verify that there are no missingcomponents. All machines are suppliedwith a tool and accessories kit, anInstallation, Operation and MaintenanceManual, electrical drawings, and bills ofmaterial.

Vectra


SECTION 7: INSTALLATION AND SET-UP

7.1 MONITOR AND KEYBOARD INSTALLATIONT h e c o m p u t e r m o n i t o r, m o u n t i n g a r massembly, and keyboard are removed prior toshipment to prevent damage during transit.Perform the procedures that follow in the orderthey are presented to insure installation issuccessful.

Figure 15: Computer monitor, mounting arm assembly, and keyboard

T h e c o m p u t e r m o n i t o r, m o u n t i n g a r massembly, and keyboard mount at the unloadend of the Vectra™.

1. Locate the cardboard box containing themonitor pivot arm and the monitor basewith keyboard support bracket.

2. Using a phillips head screwdriver, removethe four (4) screws securing the cover tothe pivot arm before installing the pivot armon the vertical support shaft.

Figure 16: Pivot arm, cover, and vertical support shaft

3. Install one end of the pivot arm over thepivot shaft on the vertical support shaft atthe unload end of the Vectra™ cabinet.

4. Install the monitor base and keyboardsupport bracket on the extended end of thepivot arm so that the pivot shaft inserts intothe hole.

Figure 17: Install monitor base and keyboard support bracket

Use cau t ion whenhandling the cardboardbox con ta in ing the

computer monitor. Do not drop the boxcontaining the monitor — damage will result.

5. Remove the computer monitor from itscontainer.

Pivot Arm

Cover

Remove screws

Vertical SupportShaft

Monitor Base and Keyboard Support Bracket

Pivot ArmPivot Shaft

Vectra


6. Position the monitor so that the screenfaces the keyboard tray. Install the monitorbase onto the support bracket, aligning theconnecting tabs with the proper slots in thebase.

Figure 18: Position the computer monitor

7. Once the tabs are aligned, install themonitor on the bracket and apply pressurefrom the front of the monitor until it snapsin place.

Figure 19: Snap monitor in place

8. Locate the keyboard from the contents ofthe cardboard box in the shipment.

9. Install the keyboard by setting it on thekeyboard support bracket installedpreviously in step four (4).

Figure 20: Install Keyboard

10. Remove the packaging tape from the video,video power, and keyboard cables at theunload end of the cabinet, at the monitorsupport shaft.

11. Connect the video cable labeled CA 253from the cabinet to the video cable from theback side of the monitor.

Figure 21: Connect the video cable

12. Connect the monitor power cable labeledCA 254 from the cabinet to the power

Bracket

Align tabs

Apply Pressureto snap in place

Vectra


connection at rear of the monitor (seeFigure 22).

Figure 22: Connect the monitor power cable

13. Connect the keyboard cable labeled CA 252from the cabinet to the keyboard connectoron the cable coming from the keyboard.

Figure 23: Connect the keyboard cable

14. Re-install the cover removed in step two (2)on the pivot arm — install the cover so thatthe three (3) cables connected in steps 11 -13 are inside the cover, securing andprotecting the cables (see figure below).

Figure 24: Re-install the cover on the pivot arm

15. Secure the cover with the hardwareremoved in step two (2) — tighten all four(4) screws securely using a phillips headscrewdriver.

Figure 25: Secure cover with hardware

Before insta l l ing thecover onto the wire wayand bracket, be sure toposition the cables so

they lay flat over the bracket to preventpinching when installing the wire way cover.Fai lure to so wi l l result in equipmentdamage.

Rear of MonitorPower

Video Cable

Keyboard Cable

Connection

Pivot Arm Cover

Pivot ArmVideo, Power,and KeyboardCables

Monitor

CAUTION

Vectra


7.2 ADJUST HEIGHT AND LEVEL MACHINEThe Vectra™ is positioned on six (6) leveling feetused for height adjustment and systemleveling. The height chosen for operationdepends upon local regulations or the heightsof the entrance and exit conveyors.

1. Using a 15 in. Crescent wrench, adjust allleveling feet evenly so that the machine isat its approximate required height.

2. Place a level on the underside of themachine's frame along its length, front andrear (see Figure 26).

3. Adjust the leveling feet using a 15 in.Crescent wrench as shown in Figure 28 tobring the machine into level, making surenot to change the set height of the Vectra™.

4. Place a level on the loadend linear bearingThomson shaft ofthe conveyor asdepicted in thephotograph ofFigure 27. This isto verify that theVectra™ islevel acrosstheconveyorwidth.Repeat this stepat the unload endof the conveyor.

W h e ninterfacingwi th o ther

conveyors, it is important toadjust the machine height toallow for smooth transition. The connectionheight depends on the conveyor incline anglefor wave soldering. The distance from thefloor to either end of the conveyor varies withthe angle of the conveyor. The factory setVectra conveyor angle is a six (6) degreeincline.

Figure 27: Level conveyor width at Thomson shafts

5. Using the 15 in. Crescent wrench, adjustthe leveling feet to bring the conveyor intolevel, making sure not to change the setheight of the Vectra™.

Figure 26: System Leveling

Figure 28: Adjust leveling feet

Vectra


7.3 CONVEYOR INSTALLATION CHECKTo protect the conveyor while in transit, theconveyor rails are secured using two (2) braceswith mounting hardware. A brace is installedon the conveyor across both rails at the loadand unload ends of the conveyor.

1. Use a 17 mm box wrench to remove the two(2) M10 hex nuts and bolts from each of theconveyor shipping braces.

Save the hardware removedfrom the load and unload endconveyor shipping brackets to

be re-used to install the load end load guidesand unload end finger cleaner covers.

Figure 29: Remove load end conveyor brace

Figure 30: Remove unload end conveyor brace

2. The load guides are already bolted andsecured to the conveyor rails, each with asingle bolt. Install the M10 bolts removed

from the load end conveyor shippingbrackets in the mounting holes indicated inthe photograph below. Tighten securelyusing a 17 mm box wrench.

Figure 31: Install load guide hardware

3. Install the M10 hex nuts removed from theunload end conveyor shipping brackets,onto the threaded bolts indicated in thephotograph below (one per rail).

Figure 32: Install M10 nuts on threaded bolts at unload end of each conveyor rail

Remove M10 Bolts

Remove M10 Nuts

Vectra


OPTIONAL FINGER CLEANER1. If configured with the optional Finger

Cleaner, install the finger cleaner guards atthe unload end of the conveyor rails.

Figure 33: Install finger cleaner guards

2. Secure the finger cleaner guards using thetwo (2) thumb screws (per guard) provided.

Figure 34: Secure guards with thumb screws

3. Access thefinger cleanerreservoir fromthe rear of thesolder moduleenclosure.Ensure thatthe fingercleanerreservoirdrain valve isclosed tight topreventdripping uponfill.

Figure 35: Finger Cleaner Drain Valve

7.4 INSTALL LIGHT TOWER OPTIONThe light tower option includes all necessarywiring and installation hardware. The lighttower is packaged on the top of the system'scabinet.

A hole is provided in the top of the cabinet nextto the tower. The wiring is already run throughthe hole.

To install the optional light tower:1. If it has not already been done, remove the

packaging from the light tower at the toprear of the cabinet.

Figure 36: Remove packaging from stat

2. Using the 5/16 in. Allen key supplied in thetool kit, unlatch the rear electricalenclosure.

3. Switch the disconnect to the open positionto open the doors.

4. With the enclosure open, position the towerupright and insert the threaded end of thepipe through the hole provided in the top ofthe cabinet so that the nut is flush on thetop of the cabinet.Drain Valve in

Closed Position

Vectra


Figure 37: Position the tower upright

5. Locate the nut on the inside of theenclosure on the status tower wiring.

6. Slide the nut up over the wires on to thethreaded end of the chrome pipe andtighten securely using a crescent wrench.

Figure 38: Secure light tower with nut

7. Close the enclosure and latch it using the5/16 in Allen key, then turn the disconnectto the off position.

Position tower upright

Threaded end of pipe

Hole in top of cabinet

Top nut

NutThreaded end

View inside of Electrical Enclosure

Wires fromlight tower

Vectra


7.5 INSTALL FOAM FLUXER OPTIONThe foam fluxer option may be configuredinternally to the Vectra™ cabinet or in anexternal cabinet, separate from the Vectra™.Follow the installation procedure that applies toyour system configuration.

EXTERNAL FOAM FLUXER INSTALLATIONThe foam fluxer module is configured with aslide-out drawer for ease of operation andm a i n t e n a n c e . P e r f o r m t h e f o l l o w i n gprocedures to install the cabinet and to ensurethe fluxer is level:

1. The external fluxer cabinet is shipped on aseparate skid. The cabinet is bolted to theskid with four (4) shipping plates and 1/2 x1 1/2 in. lag bolts. Use a 3/4 in. socketwrench to remove each of the four (4) lagbolts from the skid.

2. Position a forklift under the fluxer cabinetso that the forks extend under the cabinet.

Figure 39: Position forklift under fluxer cabinet

3. Carefully, raise the fluxer cabinet highenough off of the skid to remove theleveling feet.

4. The leveling feet must be removed in orderto remove the shipping brackets. Use asmall crescent wrench to remove the four(4) leveling feet.

5. Once the shipping brackets have beenremoved from the leveling feet, re-installthe leveling feet so that they extendapproximately the same distance on eachfoot.

Figure 40: Re-install the leveling feet after removing the shipping brackets

DO NOT lock the leveling footlocking nut at this point.

6. Slide the skid out from under the fluxercabinet.

7. Using the forklift, position the externalfluxer cabinet within a close proximity tothe load end of the Vectra™ conveyor sothat the front of the fluxer cabinet faces inthe same direction as the front of theVectra™.

8. Cut and remove any strapping or plasticwrap from around the external fluxercabinet.

Vectra


9. Open the hood of the external cabinet toverify whether or not the Vectra™ load endconveyor rail extensions will interfere withthe flux module prior to sliding the cabinetinto operating position (see figure below).

Figure 41: Open flux cabinet hood and verify clearance between flux module and rails

10. If the rail extensions interfere with the fluxmodule, slide the fluxer out from the rear ofthe cabinet.

• To slide the fluxer out from the rear ofthe cabinet, first use a 5/16 in. Allenwrench,suppliedwith thetool kit, tounlatchthe fluxercabinetrearaccessdoor.

Figure 42: Unlatch the rear access door

• Pull the release latch at the right rear ofthe flux module to unlock it fromposition.

Figure 43: Rear view of external fluxer - latch

• Slide the fluxer out from the rear of thecabinet.

Figure 44: Foam Fluxer Rear View

External Fluxerwith Hood Open

Conveyor RailExtensions

Flux Module

Vectra Cabinet

Pull Latch Release

Vectra


11. Once the flux module is slid out, carefullyslide the external fluxer cabinet toward theload end of the Vectra™ so that the frontedge of both cabinets align.

DO NOT slide the cabinet uptight to the Vectra™ at this point.

Figure 45: Slide the external fluxer toward the Vectra load end of cabinet

12. There is a wire way access hole on the sideof the external fluxer cabinet that faces theload end of the Vectra™ cabinet. This holemust align with the receptacle for the boarddetect photocell connection and pressureswitch connector from the Vectra™cabinet. Adjustment of the external fluxercabinet leveling legs may be required toalign the wire way hole properly with thereceptacle and connectors. Additionalpositioning of the fluxer cabinet may alsobe required for alignment.

13. Once the wire way hole and connectors arealigned, insert the yellow wire with theconnector labeled CA137 (Board Detect

Photocell connection) through the wire wayhole in the external fluxer cabinet, thenslide the external fluxer cabinet up tight tothe load end of the Vectra™.

14. Locate the plug connector inside the rear ofthe external fluxer labeled P203 (E-stop andexhaust pressure switch connector). Plugthis connector into the receptacle alignedin the wire way hole.

15. If it is not already connected, connect theplug labeled CA97-1 (exhaust pressureswitch) to the receptacle on the exhaustpressure switch inside the fluxer cabinet.

Figure 46: Connections - pressure switch, e-stop, board detect photocell

16. Slide the flux module back into the externalcabinet — secure the flux module with thelatch mechanism.

Slide fluxer cabinettoward Vectra™

Align front edgeof both cabinets

Exhaust pressure switchConnect CA 97-1

Yellow wire from Vectra™CA 137 (Board Detect

P 203

Wire way hole

Inside External Fluxer Cabinet

Photocell)

Plug intoreceptacle onVectra™

Vectra


17. Verify that the external fluxer cabinet islevel. Place a level on the X and Y axes ofthe cabinet; using a small crescent wrench,

adjust the leveling feet of the external fluxercabinet accordingly.

Figure 47: Level both the X and Y axes of the cabinet

18. Once the external fluxer cabinet is level,verify that the fluxer module is level.

• Place the level on both the X and Y axesof the flux nozzle.

Figure 48: Level both the X and Y axes of the flux nozzle

• If leveling is required,adjust any of the four(4) leveling screws onthe base of thesliding drawer.

Figure 49: Fluxer leveling screws

19. Inspect all hoses and hoseconnections. Ensure thereare no loose connections;no pinched or kinked hoses.

To p r e v e n tcontamination offlux and aerator

clogging, ensure that the airsupply to the flux airknife andaerator is clean, dry, andfiltered (oil free).

Leveling Screw

LevelingNut

LockingNut

Rear View of FluxerRear View of Fluxer

Vectra


AERATOR CLEANING RESERVOIR1. Locate the Aerator Cleaning Reservoir from

the contents of the cardboard box.

2. Install the reservoir on the mountinghardware provided on the left rear wall nearthe internal fluxer module.

Figure 50: Aerator Cleaning Reservoir

INSTALL PAAR FLUX DENSITY CONTROLLER (FDC) OPTIONThe customer is responsible to obtain flux andthinner bottles separately.

Check for a winterization tag onthe fluxer module indicatingyour s ys tem was sh ipped

between 10/1 and 5/1. During that time, theoptional foam or wave fluxers, and the fingercleaners were tested at the factory usingwindshield washer fluid. Flush fluxers andfinger cleaner systems for approximately 3 - 5minutes using thinner or solvent applicableto your process requirements.

1. At the rear of the fluxer, place thesubmersible fitting from the pump labeledM20 Flux Drain Pump into an appropriateflux draining container.

2. Place the submersible fitting from thepump labeled M21 Flux Add Pump into theflux supply container.

3. Place the submersible fitting from thepump labeled M22 Thin Add Pump into thesolvent or thinner supply container to beused for thinning the flux being used.

Figure 51: PAAR FDC and Flux Replenishment Probes

Vectra


7.6 INSTALL PREHEATERS

INSTALL OPTIONAL RADIANT PREHEATERSVectras configured with optional radiantpreheaters are shipped with the preheatersremoved to prevent damage during shipment.Perform the procedures outlined to installradiant preheaters.

1. Lift the Vectra™ hood open above thepreheat modules.

2. Locate the tailgate door latch mechanismat the end of the tail gate closest to thesolder pot. Slide the latch out of its lockingmechanism to allow the tailgate door to beopened (see figure below). Secure the latchin its open position utilizing the keyed openposition.

Figure 52: Tailgate latch mechanism

3. Open the tailgate door to access thepreheat modules.

Figure 53: Open the tailgate door

4. Locate the radiant preheater(s) from thecontents of the shipment and carefullyunpack them.

Figure 54: Unpack the preaheater

5. Position the glass face up (lower preheat)and the handle facing out from the system— gently slide the preheater into theappropriate lower slides under the conveyorrails.

DO NOT slide the preheater allthe way in yet.

Figure 55: Slide the preheater into the slides

Solder Pot

Door Latch

Slide in thisdirection, thenlock in position

Tailgate

Slides underConveyor Rails

Glass face up

Vectra


6. Secure the conduit connector to the fittingon the underside of the preheater assemblyusing a pair of channel lock pliers. Tightensecurely.

Figure 56: Secure the conduit connector under preheater

7. Feed the opposite end of conduitcontaining the preheat connector underthe conveyor rails to the back of theelectrical enclosure.

Figure 57: Feed conduit and connector to rear of enclosure

8. Reach in from the rear of the Vectra™cabinet via internal flux module doors toaccess the connector.

9. Plug the preheat connector into theappropriate preheat receptacle at the rearof the electrical enclosure.

Figure 58: Plug preheater into receptacle

Vectra


7.7 UNPACK AND INSPECT SOLDER POTThe solder module is secured in position for shipping purposes. Five (5) shipping brackets are installed on the solder pot module prior to packing.

Tools required to remove the shipping brackets and level the solder pot stand:• 5/16 in. Allen wrench• 10 mm socket• 13 mm socket• Ratchet• 12 in. Crescent wrench• 10 in. Crescent wrench• Bubble level

To remove solder pot shipping hardware:1. Locate the two (2) shipping brackets at the

rear base of the solder module.

2. Using a 10 mm socket and rachet, removethe four (4) M6 x 16 hex head bolts, M6locks, and M6 flat washers from the two (2)brackets.

Figure 59: Remove solder pot shipping brackets

Vectra


3. At either side of the rear solder pot thereare two (2) additional shipping brackets.Using a 13 mm socket with ratchet, removethe four (4) M8 x 30 hex head bolts, M8locks, and M8 flat washers from each of thebrackets.

Figure 60: Remove solder pot side shipping brackets

4. The final solder module shipping bracket islocated over the top front of thesolder pot. From the front of theVectra™ open the front hoods overthe solder pot and preheatersections.

5. Use a 10 in. Crescent wrench toremove the 15/16 in. double jam nutsfrom either side of the bracket

6. Remove the bracket.

7. Reinstall the double jam nuts ontoeach threaded shaft.

8. Jam the nuts tightly at the top of thethreaded shafts to enable removal ofthe threaded shafts.

9. Once the jam nuts are tightened securely, remove the threaded shafts using the jam nuts to back them out.

Figure 61: Remove solder pot top shipping bracket

10. Using an industrial strength vacuum cleaner, remove any debris from the solder pot to prevent contamination of the solder when filling the pot.

Vectra


11. Inspect and verify that the solder drain valve and backup plug are tightly closed.

12. Verify that the thermocouple(s) is in its well on the top lip of the solder pot.

To level the solder pot stand:1. Slide the solder pot roll out stand out to its

fully extended position.

Figure 62: Slide out the roll out stand

2. Place a bubble level on either roll out trackto level the stand on its X axis.

Figure 63: Level roll out stand

3. Place the bubble level across the crossframe of the stand to verify it is level on its Yaxis.

4. Using a 12 in Crescent wrench, adjust thetwo (2) leveling feet to bring the stand intolevel.

Figure 64: Adjust leveling feet and set locking nuts

5. Once the stand is level, adjust the lockingnuts on the leveling feet to their highestposition — tighten securely using the 12 inCrescent wrench.

X Axis

Y Axis

Vectra


To install the Jacking Stand Sprocket Guard:1. Using a 10 mm socket with ratchet, remove

the four (4) M6 bolts from the end frame ofthe solder pot jacking stand.

Figure 65: Remove bolts from end of jacking stand

2. Install the jacking stand sprocket guard onthe end of the jacking stand using the four(4) mounting holes and hardware that theM6 bolts were removed from in step 1 ofthis procedure.

Figure 66: Install the guard at the end of the jacking stand

Vectra


SECTION 8: FACILITY CONNECTIONS

8.1 CONNECT FACILITY EXHAUST

The fo l l ow ing exhaus tspecifications are to assist theuser in specifying an exhaust

blower capable of exhausting the system. Allexhaust measurements are to be measuredat the system exhaust port.

Contac t your l oca l HVAC (Hea t ing ,Ventilation, and Air Conditioning) specialistfor blower requirements and ventilationhook-up for your facility.

1. Connect the exhaust ducting to the two (2)exhaust stacks located at the top of theVectra™.

• The exhaust ports measure 152 mm (6in.) diameter. They are extended tofacilitate connection and toaccommodate damper installation.

2. Install dampers on each of the exhaustports at the top of the machine to allow finetuning and balancing of the exhaust flowfrom the system.

3. Install traps on each of the ducts tofacilitate removal of residue buildup.

Fai lure to connect anadequate exhaust systemmay expose operating

personnel to the hazards of fire and airbornelead particles. Never attempt to operate awave soldering system that is not connectedto an exhaust ventilation system. The wavesolder system is configured with an internalsafety pressure sensor. Proper exhaust flowmust be sensed in order for the system tooperate.

Table 2: Exhaust Port Data

EXHAUST PORT*

REQUIREMENTS

1 20 m3./ min. @ 2.54 cm (700 scfm @ 1.0 in.) H2O gage static pressure

2 20 m3./ min. @ 2.54 cm (700 scfm @ 1.0 in.) H2O gage static pressure

Total 40 m3./ min. @ 2.54 cm (1400 scfm @ 1.0 in.) H2O gage static pressure

* Due to the corrosive and flammable nature of flux fumes,use of corrosion-proof, nonflammable venting materials(i.e. seamless stainless steel) is recommended.

Vectra


8.2 CONNECT FACILITY POWER1. Inspect the electrical enclosure and

connections prior to applying power for thefirst time to ensure no wires came looseduring transit.

2. Verify that the lugs and terminal blocks aresecurely fastened.

3. After inspection and verification iscomplete, close the electrical enclosuredoors.

ELECTRICAL CHECK

HIGH VOLTAGE – CANSHOCK, BURN ORCAUSE DEATH

This equipment may be configured to operateusing high voltage ranging from 230, 380, to480 volts. When performing installation ormaintenance voltage testing, electric shockhazard exists. Use extreme caution whenperforming voltage and amperage tests onl ive voltage. A l icensed electr ician orelectrical engineer familiar with testing livevoltage must perform these procedure.

1. Ensure that the power connected to theVectra™ system corresponds to thatindicated on the electrical drawing and onthe serial number nameplate affixed to yoursystem. Locate the serial number tag onthe outside of the rear access door belowthe system disconnect.

2. If power does not match, DO NOTCONNECT IT TO THE MACHINE.

Figure 67: Serial Tag Location

3. Use a voltmeter to verify that the incomingpower supply agrees with the powerrequirements verified in step one (1) of thisprocedure.

4. Check each leg for proper voltage at thefollowing test points:

• L1–L2• L2–L3• L1–L3

5. The voltage reading must be within ±10%of the voltage listed on the serial tag.

6. If system voltage is within specifiedtolerance, proceed to the next step, Conduitand Electrical Connections.

7. If the voltage does not meet the specifiedtolerance indicated, do not connect poweruntil the power requirements have beenrectified.

Operating the Vectra™ atthe incorrect voltage canresu l t in equ ipment

damage and will void system warranty.

Serial Tag

Vectra


CONDUIT AND ELECTRICAL CONNECTIONSThe customer is responsible to provide anynecessary conduit and conduit connectors tothe top, rear of the Vectra system cabinet.

Refer to the following table for conduit sizes forspecific voltages:

1. Attach the necessary conduit fittings,connectors, and conduit to the top rear ofthe Vectra™ cabinet, in the 50.8 mm (2 in.)hole provided.

2. Install the conduit from the machine to thefacility power source.

3. Bring the facility power wiring to thesystem through the conduit.

4. Feed the wires through the conduit into theelectrical enclosure.

5. Locate the disconnect switch at the rear ofthe cabinet; connect the power lines to thecircuit breaker and the ground wire to theterminal block beside the circuit breaker.

6. Ensure all main power connections aresecure.

O n f i v e ( 5 ) w i r e s y s t e m s ,connect the neutral wire to theadditional (neutral) terminal

block.

7. Double check electrical grounding (e.g. hi-pot tester) before applying power for thefirst time.

Figure 68: Conduit and Electrical Connections

Table 3: Conduit Sizes

VOLTAGE CONDUIT SIZE

220-240 VAC 101.6 mm (3.0 in.)

380-480 VAC 50.8 mm (2.0 in.)

Standard configuration. For furtherdetails refer to Section 2: TechnicalData on page 13 of this manual.

Feed wires intoelectrical enclosure

Install conduit fittings, connectors and conduit to the 2.0 inhole (380 - 460 VAC) provided at the top of the rear

electrical enclosure

Connect incoming powerat the points indicated on theMain Breaker

GroundConnectionConduit attaches

to cabinet here

Electrical enclosure atthe rear of the Vectra™

Main PowerDisconnect

Vectra


8.3 COMPRESSED AIR CONNECTIONThe Vectra™ uses clean, (free from oil), dry, andfiltered, compressed air for the foam fluxer(foaming aerator and wipe off airknife), theoptional pyrometer (purge and cooling), and theoptional AccuKnife™ hot air debridging system.

The Vectra™ pneumatic system is designed toaccept standard industrial pressures from 414kPa (60 psi) minimum, to 828 kPa (120 psi)maximum.

Do no t pe rmi t the supp l i edpressure to drop below 414 kPa (60psi).

1. Before connecting facility air to the Vectraverify that the air supplied is clean, dry, andfiltered.

2. Remove the 1/2 in. plug from the 1/2 in.NPT fitting at the top rear of the cabinet.

3. Connect the facility compressed air to the1/2 in. NPTF fitting located to the right ofthe electrical enclosure, at the top rear ofthe Vectra cabinet.

Figure 69: Compressed Air and Nitrogen connections

Air Inlet

Nitrogen Inlet

Knife Inlet

Connect the “Air Inlet” fittingto the Facility Air supply

Air and N2 fittings arelocated at the top of thecabinet

Vectra


8.4 NITROGEN CONNECTIONI f your system does not use nitrogen forinerting, disregard this procedure.

When configured with the optional CoN2tour™or CoN2tour Plus™, the Vectra™ uses nitrogenfor inerting.

The Vectra™ nitrogen requirements are listed inTable 4 on page 53:

Table 4: Nitrogen Requirements

CoN2tour™

GENERAL REQUIREMENTS (CHIP AND A-WAVES)

Nitrogen Supply Quantity of One (1) 1/2 in. NPTM fitting 44 psi

N2 Consumption 725 SCFH (20 M3/ hr.)

CoN2tour Plus™

GENERAL REQUIREMENTS (CHIP AND A-WAVES)

Nitrogen Supply Quantity of one (1) 1/2 in. NPTM fitting 44 psi

AccuKnife™ Quantity of one (1) 1/2 in. NPTM fitting10–30 cfm (0.28–0.84 m3/min)@ 485-690 kPa (70–100 psi)

Nitrogen Consumption

≈725 SCFH (20 m3/ hr.)

Nitrogen Consumption

≈60–1800 SCFH (Nitrogen Knife™) (2–50 m3/ hr.)

CONNECTIONS

Single N2 Inlet Connect to the facility N2 supply.

CoN2tour Plus™ Two (2) N2 connections supplied.

Nitrogen Inlet con-nects to CoN2tour (Chip and A-Wave)Knife Inlet connects to the Hot Gas Knife Nitrogen supply.

Connect the facility nitrogen supply to the Vectra basedon the option configuration information listed.

Vectra


Vectra


SECTION 9: FILLING THE SYSTEM

9.1 FILL FINGER CLEANER RESERVOIRThe reservoir for the finger cleaner is locatedinside the rear of the solder module, just to theleft of the solder pot.

1. Use a 5/16 in. Allen wrench to unlatch therear access door to the solder module.

Figure 70: Access the finger cleaner

2. Remove the finger cleaner cover.

Figure 71: Remove Finger Cleaner Cover

3. Verify the drain valve for the reservoir iscompletely closed prior to filling.

4. Turn the drain valve to the closed position.

Figure 72: Finger cleaner drain valve

Drain Valve inClosed Position

Vectra


5. Fill the reservoir with solvent which iscompatible with your system’s processchemistry. Contact the Process Engineerresponsible for this equipment.

• The finger cleaner reservoir capacity isapproximately 12.3 liters (3.25 gallons).

• Fill the reservoir to a level 1/2 in belowthe top lip of the catch screen. Do notoverfill.

Figure 73: Fill Finger Cleaner Reservoir

6. Reinstall the finger cleaner cover.

7. Close the solder module rear access doorand latch it using the 5/16 in. Allen wrench.

Reservoir

Catch Screen

Fill to 1/2 in.below lip

Vectra


9.2 FILL FOAM FLUXER RESERVOIR1. Access the fluxer unit via the rear of the

system cabinet or external fluxer module.

2. Release the latch at the right rear of thefoam fluxer to allow the fluxer to be slid out.

3. Slide the fluxer out until it stops.

4. Verify that the drain valve for the fluxreservoir is closed.

Figure 74: Access Foam Fluxer, Close Drain Valve, Fill Reservoir

5. Flux capacity depends on systemconfiguration. Use Process Engineerapproved flux.

6. Fill the flux reservoir to a level of 2.54 cm(1.0 in.) above the aerators.

Table 5: Foam Fluxer Capacity Table

LITERS US GALLONS

17 4.5

Capacity based on normal flux level in the tank, measured 2.5 cm (1.0 in.) above aerators.

Rear of Fluxer

Flux ReservoirDrain Valve Latch

Flux ReservoirDrain Valve

Flux Reservoir

Fluxer Nozzle

Aerators

Vectra


9.3 FILL SOLDER POTDepending on customer requirements, somesystem solder pots are shipped pre-filled withsolder. For those systems already charged withsolder, disregard this procedure.

Always lower the solderpot prior to rolling it outon to the solder pot stand.

Failure to do so can result in damage to theconveyor fingers,o ther conveyorcomponents, ore v e n d a m a g es o l d e r p o tcomponents.

Figure 75: Rear view of Vectra™ closed

ROLL OUT SOLDER POTTo fill the solder pot with solder the pot must berolled out to the service position.

Before rolling the solder pot out, lower the potusing the solder pot jacking stand unit onwhich the solder pot sits.

Perform the following steps to activate power tothe Vectra™, lower the solder pot, and then rollit out.

1. Use a 5/16 in. Allen wrench to unlatch andopen the solder module rear access doors(see Figure 74).

2. Locate the handle on the roll out solder potstand just below the solder pot jacking

stand. Pull out on the handle to slide thesolder pot stand out to its fully extendedposition.

Figure 76: Slide out the solder pot stand

Roll out solder pot stand

Solder pot jacking stand

Pull out on handle here

Vectra


3. Activate the facility power to the Vectra.

4. Turn the disconnect switch at the rear ofthe Vectra to the ON position.

Figure 77: Disconnect Switch at Rear of Vectra™

5. When power is applied, the Vectra™software automatically starts up anddisplays the Vectra™ graphic interfacescreen.

Figure 78: Graphic Interface Screen

6. Using the pointer device, click on File,Logon… from the Menu Bar.

Figure 79: Click File, Logon…

7. The Logon dialog box is displayed.

Disconnect Switch

Vectra


Figure 80: Logon Dialog Box

8. In the User Name text box type Supervisor.

9. In the Password text box type Password.

10. Click on the OK button.

11. Click on the MAN icon button at the top ofthe graphics screen to put the Vectra™ inManual mode.

Figure 81: Click on the MAN icon button

12. Click on Modules, Solder Pot from theMenu Bar.

Figure 82: Solder module menu

13. The Solder Pot dialog box is displayed.

14. Click on the Maintenance tab.

Figure 83: Solder Maintenance Tab Dialog Box

The solder pot cannot be rolledout until the solder pot jackingstand is lowered to its down

position.

15. Under Jacking, click on the Solder PotDown Start button.

• The LED next to Solder Pot Downilluminates green until the down limitis reached [approximately 101.6 mm(4.00 in.)] The value associated withLead Clearance changes as the pot islowered. When the pot is all the waydown, a limit symbol displays next tothe Solder Pot Down Start button.

• The Start button for “Solder Pot Out”activates.

16. Click on the Start button for Solder Pot Out.

• The LED next to Solder Pot Outilluminates green until the pot reachesthe out limit; the out limit symboldisplays next to the Solder Pot OutStart button.

Vectra


FILL SOLDER POT WITH SOLDERSystem configuration determines the capacityof the solder pot. Capacities may vary slightly.

Bar, pellet, or ingot, 63/37 virgin solder isrecommended.

Exposure to LeadHazard – Brea th ingnearly invisible lead dust,

can cause lead poisoning. Prior to workingaround the solder pot ensure the soldersystem ventilation is on and operating at thespecifications listed in this manual. To avoidinhalation, wear the proper safety approvedbreathing apparatus recommended by thesolder supplier for use with wave solderingequipment.

• Systems configured with a single wave andpump require approximately 840 kg (1850lbs.) of solder.

• Systems configured with dual waves andpumps require approximately 82 kg (1810lbs.) of solder.

• It is recommended extra solder be readilyavailable. After running in a productionenvironment, solder level drops. Tomaintain the recommended solder level,add solder to the pot.

• Load the solder pot with solder (not all ofthe solder will fit into the pot until it ismelted).

Documents

Vectra Installation Manual