Operating Instructions_VF335_en.pdf - 第9页
Table of contents 8.6.7 Check the nitrogen flow rate to the solder nozzle ......................................................................... 329 8.6.8 Solder level monitoring Checking input pressure .............…
Table of contents
6.15.3 Prerequisites for installing a nozzle ................................................................................................254
6.15.4 Tutorial: Installing a new solder nozzle ..........................................................................................255
6.15.4.1 Entering a new nozzle into the nozzle table.................................................................255
6.15.4.2 Determining the [Warm offset] for a wave power of 1% .............................................259
6.15.4.3 Determining [Warm offset] for a 75% wave power and adjusting the gradient ..........261
6.16 Flux unit Flux application module: flux control (option) ...............................................................................263
6.17 Versascan (option) ........................................................................................................................................ 268
6.18 Versaeye inspection system (option)............................................................................................................269
6.19 Solder feed with turret bar container (option) ............................................................................................. 272
7 Treatment of messages and malfunctions.......................................................................................................279
7.1 Displaying messages and errors.................................................................................................................... 280
7.2 The [Messages] editing dialog.......................................................................................................................281
7.3 Message types............................................................................................................................................... 282
7.4 Message description ..................................................................................................................................... 283
7.5 The bottom toolbar....................................................................................................................................... 284
7.6 The [Messages administration] dialog ..........................................................................................................285
8 Service and maintenance................................................................................................................................287
8.1 Service table.................................................................................................................................................. 289
8.2 Read this first!............................................................................................................................................... 292
8.2.1 Nationally valid safety and accident prevention regulations .........................................................292
8.2.2 Safe system operation ....................................................................................................................292
8.2.3 For your safety................................................................................................................................292
8.2.4 Service work on the spray fluxer ....................................................................................................292
8.2.5 Maintenance work at the soldering pot .........................................................................................293
8.2.6 Before service and maintenance work ...........................................................................................294
8.2.7 Service work on preheaters............................................................................................................296
8.2.8 Service in multi-shift operation ......................................................................................................296
8.2.9 Open and secure the hood via the PC ............................................................................................297
8.2.10 Handling of gas pressure springs ....................................................................................................298
8.3 Lubricants, auxiliary agents, tools................................................................................................................. 299
8.3.1 Lubricants used...............................................................................................................................299
8.3.2 Use of high-temperature grease in the hot area............................................................................300
8.3.3 Cleaning agents used......................................................................................................................300
8.3.4 Tools and auxiliary materials ..........................................................................................................301
8.4 Maintenance work to be performed before each shift ................................................................................ 303
8.4.1 Conveyor profiles and chains: visual inspection.............................................................................303
8.4.2 Solder nozzles: Visual inspection (selective soldering module) .....................................................304
8.4.3 Selective soldering module: Clean the solder pot ..........................................................................305
8.5 Maintenance work to be performed daily .................................................................................................... 313
8.5.1 Sensors: visual inspection...............................................................................................................313
8.5.2 Spray fluxer cleaning.......................................................................................................................314
8.5.3 Dynamic IR emitters with glass plate: Visual inspection and cleaning ...........................................316
8.5.4 Compressed air heating: Visual inspection.....................................................................................318
8.5.5 Solder feeding: visual inspection ....................................................................................................320
8.6 Maintenance work to be performed weekly ................................................................................................321
8.6.1 Checking the EMERGENCY STOP function ......................................................................................321
8.6.2 Suction in the process room visual inspection ...............................................................................322
8.6.3 Suction in the flux material storage space visual inspection ..........................................................323
8.6.4 Checking the function of the differential pressure switch (suction) ..............................................323
8.6.5 Check the pneumatic system..........................................................................................................325
8.6.6 Check the nitrogen input pressure .................................................................................................327
Ersa GmbH Operating Instructions_VF335_en|Rev. 14|30/11/2017 viii/695
Table of contents
8.6.7 Check the nitrogen flow rate to the solder nozzle .........................................................................329
8.6.8 Solder level monitoring Checking input pressure...........................................................................330
8.6.9 Checking the nitrogen flow to the solder level monitoring............................................................332
8.6.10 Solder level monitoring: Check for proper operation.....................................................................333
8.6.11 Conveyor system: visual inspection................................................................................................334
8.6.12 Flux reserve: Visual inspection, cleaning ........................................................................................335
8.6.13 Spray fluxer: Cleaning the whole fluxer area..................................................................................336
8.6.14 Cleaning the selective soldering module .......................................................................................338
8.6.15 Visual inspection of the axis system (mechanics)...........................................................................339
8.7 Maintenance work to be performed monthly ..............................................................................................341
8.7.1 Cleaning the machine outside ........................................................................................................342
8.7.2 Switch cabinets and PC Visual inspection.......................................................................................343
8.7.3 Visual inspection of the differential pressure switches..................................................................344
8.7.4 Checking the pneumatic system (in general)..................................................................................345
8.7.5 Checking the nitrogen system (in general) .....................................................................................346
8.7.6 Selective soldering module: Visual inspection................................................................................347
8.7.7 Visual inspection of the axis system (electrics) ..............................................................................348
8.7.8 Visual inspection of the axis system (sensors)................................................................................350
8.7.9 Check the entire conveyor system .................................................................................................351
8.8 Maintenance work to be performed quarterly.............................................................................................352
8.8.1 Lubrication of the conveyor system, visual inspection of the round belts.....................................352
8.8.2 Backing up all data on the machine................................................................................................353
8.8.3 Spray fluxer: Visual inspection of the flux material filter ...............................................................354
8.8.4 Lubricating the Z-axis of the selective soldering module ...............................................................355
8.8.5 Lubricating the DIP soldering unit Z-axis ........................................................................................357
8.9 Service work to be performed semi-annually...............................................................................................359
8.9.1 Whole machine (calibration) ..........................................................................................................359
8.9.2 The whole machine (electrics)........................................................................................................359
8.9.3 Visual inspection, lubrication of the width adjustment..................................................................360
8.9.4 Solder sample .................................................................................................................................361
8.10 Service work to be performed annually........................................................................................................ 362
8.10.1 The whole machine (mechanics) ....................................................................................................362
8.10.2 Total electrical equipment in the switchgear cabinet ....................................................................363
8.10.3 Disassembling and cleaning the flux material storage tank. ..........................................................364
8.10.4 Turret bar container (option) Visual inspection, cleaning ..............................................................370
8.11 Service work to be performed when required.............................................................................................. 372
8.11.1 Supplementing flux material storage .............................................................................................372
8.11.2 Clean the spray head .....................................................................................................................377
8.11.3 Z-axis lubrication after 400 hours of operation..............................................................................377
8.11.4 Preparing solder nozzles.................................................................................................................378
8.11.5 Cleaning the gassing cap.................................................................................................................380
8.11.6 Gassing ring replacement ...............................................................................................................383
8.11.7 DIP soldering module (multiwave) with induction pump: Clean the solder pot ............................386
8.11.8 DIP soldering module (multiwave) with induction pump: Pump riser tube cleaning.....................400
8.11.9 DIP soldering module (multiwave) with induction pump: Solder pot replacement (optional) ......419
8.11.9.1 Preparation for solder pot replacement.......................................................................421
8.11.9.2 Mounting the traction aid on the machine ..................................................................422
8.11.9.3 Operating the lifting cart with the replacement rack...................................................423
8.11.9.4 Connecting the cold solder pot to the (optional) heating station and preheating it....425
8.11.9.5 Removing the cooled DIP solder pot from the machine...............................................427
8.11.9.6 Inserting the (optionally pre-heated) DIP solder pot into the machine .......................432
8.11.9.7 Changing the solder of the automatic solder supply (optional) ...................................437
Ersa GmbH Operating Instructions_VF335_en|Rev. 14|30/11/2017 ix/695
Table of contents
8.11.9.8 Completing the DIP solder pot replacement process...................................................438
8.11.10 Board fixation: Clean and lubricate slide surfaces..........................................................................439
9 Spare and wear parts......................................................................................................................................443
9.1 Read this first!............................................................................................................................................... 446
9.1.1 Nameplate and machine number...................................................................................................446
9.1.2 Target readers, permitted spare parts ...........................................................................................447
9.2 Machine frames ............................................................................................................................................ 448
9.2.1 Base module 150 ............................................................................................................................448
9.2.2 Base module 75 ..............................................................................................................................451
9.2.3 Additional module 150 ...................................................................................................................453
9.2.4 Additional module 75 .....................................................................................................................455
9.2.5 Additional module 1100 DIP...........................................................................................................457
9.2.6 Additional module 1300 DIP XL ......................................................................................................459
9.3 Spray fluxer and options ...............................................................................................................................461
9.3.1 Complete spray fluxer.....................................................................................................................461
9.3.2 Fixed spray head holder (single track)............................................................................................464
9.3.3 Fixed spray head support (dual track) ............................................................................................465
9.3.4 Accommodating the adjustable spray head ...................................................................................466
9.3.5 Spray monitoring (optional) ...........................................................................................................467
9.3.6 Flux material stockage....................................................................................................................468
9.3.7 Spray fluxer fiducial recognition.....................................................................................................469
9.3.8 Area-Spray head (Option)...............................................................................................................471
9.4 Positioning systems....................................................................................................................................... 472
9.4.1 Single pot positioning system (single track) ...................................................................................472
9.4.2 Z-axis single pot ..............................................................................................................................477
9.4.3 Double pot positioning system (dual track)....................................................................................478
9.4.4 Z-axis double pot (dual track) .........................................................................................................483
9.4.5 Z-axis excenter solder pot (fix, single track) ...................................................................................485
9.4.6 Positioning system for double solder pots with eccentric solder pot lids (80mm, fixed, double
stroke, single track) ........................................................................................................................486
9.4.7 Z-axis excenter solder pot (double stroke, single track).................................................................490
9.4.8 Positioning system for double solder pots with eccentric solder pot lids, y-variable ....................492
9.4.9 Z-axis excenter solder pot, y-variable.............................................................................................496
9.5 Transport system .......................................................................................................................................... 499
9.5.1 Fluxer unit conveyor system...........................................................................................................499
9.5.1.1 Fixed rail 1, (single track)..............................................................................................499
9.5.1.2 Flexible rail 1, (single track) ..........................................................................................502
9.5.1.3 Fixed rail 2, (dual track) ................................................................................................508
9.5.1.4 Flexible rail 2, (dual track) ............................................................................................511
9.5.2 Conveyor system preheater module ..............................................................................................514
9.5.2.1 Fixed rail 1, (single track)..............................................................................................514
9.5.2.2 Flexible rail 1, (single track) ..........................................................................................519
9.5.2.3 Fixed rail 2, (dual track) ................................................................................................523
9.5.2.4 Flexible rail 2, (dual track) ............................................................................................526
9.5.2.5 First stopper left, temperature resistant......................................................................528
9.5.2.6 First stopper right, temperature resistant....................................................................529
9.5.2.7 Second stopper left, (segmented preheating)..............................................................530
9.5.2.8 Second stopper right, (segmented preheating)............................................................532
9.5.3 Selective soldering unit conveyor system.......................................................................................534
9.5.3.1 Fixed rail 1, (single track)..............................................................................................534
9.5.3.2 Fixed rail 2, (dual track) ................................................................................................542
9.5.3.3 Flexible rail 1, (single track) ..........................................................................................549
Ersa GmbH Operating Instructions_VF335_en|Rev. 14|30/11/2017 x/695