Technical_reference
Technical Service Manual 1 Revision Dat e: August 2004 XPM 2 Reflow Soldering / Curing Systems Technical Reference M anual
Technical Service Manual 1 Revision Date: August 2004
XPM
2
Reflow Soldering / Curing Systems
Technical Reference Manual
Technical Service Manual 2 Revision Date: August 2004
TABLE OF CONTENTS
TABLE OF CONTENTS _______________________________________________________________ 2
PURPOSE OF THIS MANUAL & WHO SHOULD USE IT ____________________________________ 4
CONTROL PANEL SYMBOLS__________________________________________________________ 5
GLOSSARY OF TERMS GLOSSARY OF TERMS & MEASUREMENT CONVERSIONS ___________ 6
MEASUREMENT CONVERSIONS------------------------------------------------------------------------------------------------------------------8
A - CONTROL SYSTEM OPERATION ____________________________________________________ 9
OVEN CONTROL SYSTEM OVERVIEW----------------------------------------------------------------------------------------------------------9
HEAT CONTROL OVERVIEW---------------------------------------------------------------------------------------------------------------------- 10
POWER DISTRIBUTION OVERVIEW------------------------------------------------------------------------------------------------------------10
COMPUTER AND CONTROLLER OVERVIEW ----------------------------------------------------------------------------------------------- 11
CONVEYOR OVERVIEW ---------------------------------------------------------------------------------------------------------------------------- 12
FAN CONTROL OVERVIEW------------------------------------------------------------------------------------------------------------------------ 13
HEAT CONTROL OVERVIEW---------------------------------------------------------------------------------------------------------------------- 14
HEATING CELL DESCRIPTION ------------------------------------------------------------------------------------------------------------------- 16
B - HEATING SYSTEM _____________________________________________________________ 18
PROBLEMS AND POSSIBLE SOLUTIONS (The most likely cause is listed first)-------------------------------------------- 18
HEATING PROBLEMS ------------------------------------------------------------------------------------------------------------------------------- 18
HEATER TESTING PROCEDURE----------------------------------------------------------------------------------------------------------------- 36
TEST PROCEDURE FOR HEATER GROUND CONTINUITY-----------------------------------------------------------------------------40
MAXIMUM HEATERS ON---------------------------------------------------------------------------------------------------------------------------- 40
MAXIMUM PHASE IMBALANCE------------------------------------------------------------------------------------------------------------------ 40
THERMOCOUPLES ----------------------------------------------------------------------------------------------------------------------------------- 40
TEST PROCEDURE ----------------------------------------------------------------------------------------------------------------------------------- 40
HEATER PLATE REPLACEMENT ---------------------------------------------------------------------------------------------------------------- 41
TEST PROCEDURE FOR HEATER CONTROL-----------------------------------------------------------------------------------------------41
CELL FAN MOTORS----------------------------------------------------------------------------------------------------------------------------------42
TEST PROCEDURE FOR MOTOR RESISTANCE ------------------------------------------------------------------------------------------- 42
CELL FAN MOTOR ROTATION CHECK-------------------------------------------------------------------------------------------------------- 42
VERIFYING CELL FAN SPEED-------------------------------------------------------------------------------------------------------------------- 42
CELL FAN ASSEMBLY REMOVE AND REPLACE PROCEDURES-------------------------------------------------------------------- 43
HEATER REMOVE AND REPLACE PROCEDURES---------------------------------------------------------------------------------------- 49
C - CONVEYOR____________________________________________________________________ 53
CONVEYOR TYPES----------------------------------------------------------------------------------------------------------------------------------- 53
PROBLEMS AND POSSIBLE SOLUTIONS (The most likely cause is listed first)---------------------------------------------- 56
CONVEYOR PROBLEMS---------------------------------------------------------------------------------------------------------------------------- 56
CONVEYOR BELT, CHAIN & RAIL SERVICE------------------------------------------------------------------------------------------------- 69
REMOVE AND REPLACE CONVEYOR BELT ------------------------------------------------------------------------------------------------69
REMOVE AND REPLACE CONVEYOR RAILS AND CHAINS---------------------------------------------------------------------------- 74
DRIVE MOTOR SERVICE & REPLACEMENT ------------------------------------------------------------------------------------------------ 75
ENCODER SERVICE & REPLACEMENT------------------------------------------------------------------------------------------------------- 77
D- ELECTRICAL POWER & COMPUTER _______________________________________________ 78
ELECTRO - STATIC DISCHARGE PROCEDURES ( ESD)-------------------------------------------------------------------------------- 78
A.C. & D.C. POWER SUPPLIES -------------------------------------------------------------------------------------------------------------- 80
OVEN CONTROLLER _______________________________________________________________ 82
ADDRESSING DIP SWITCHES ON DI BOARD----------------------------------------------------------------------------------------------- 83
ADDRESSING LINKS ON AI BOARD------------------------------------------------------------------------------------------------------------ 83
CONTROLLER STATUS ----------------------------------------------------------------------------------------------------------------------------- 83
RS-232 SERIAL COMMUNICATION CHECK-------------------------------------------------------------------------------------------------- 84
COMPUTER SYSTEM -------------------------------------------------------------------------------------------------------------------------------- 86
CONTROL CIRCUIT----------------------------------------------------------------------------------------------------------------------------------- 86
ELECTRICAL GROUNDING OF OVEN---------------------------------------------------------------------------------------------------------- 87
Technical Service Manual 3 Revision Date: August 2004
E - ASSOCIATED SUBSYSTEMS _____________________________________________________ 88
TRUE N2 / AIR SWITCHING ------------------------------------------------------------------------------------------------------------------------ 88
BATTERY BACK-UP FOR PC, CONTROLLER, CONVEYOR, AND HOOD LIFTS------------------------------------------------- 89
PRODUCT TRACKING AND ALARM------------------------------------------------------------------------------------------------------------- 89
COMPUTER CONTROLLED EDGE-RAIL LUBRICATION--------------------------------------------------------------------------------- 90
AUTO CHAIN LUBE TANK/PUMP ASSY ------------------------------------------------------------------------------------------------------- 91
BOARD SUPPORT------------------------------------------------------------------------------------------------------------------------------------- 93
CONTROLLED COOLING--------------------------------------------------------------------------------------------------------------------------- 93
CONTROLLED EXHAUST SYSTEM (AIR ONLY OR OVENS EQUIPPED WITH AIR SWITCHING)------------------------- 94
INTEGRATED EXHAUST STACK FILTER------------------------------------------------------------------------------------------------------ 95
FLUX EVACUATION SYSTEM --------------------------------------------------------------------------------------------------------------------- 96
FUNCTION OF THE FLUX EVACUATION SYSTEM----------------------------------------------------------------------------------------- 97
HOODLIFTS---------------------------------------------------------------------------------------------------------------------------------------------- 99
THREE ACTUATOR SYSTEM---------------------------------------------------------------------------------------------------------------------105
INDEPENDENT ALARM SCANNER OVER-TEMP & ALARM/SHUTDOWN---------------------------------------------------------106
INDIVIDUAL CELL SENSING ---------------------------------------------------------------------------------------------------------------------107
HEATER CELL OVER-TEMPERATURE SWITCHES --------------------------------------------------------------------------------------110
LIGHT TOWER-----------------------------------------------------------------------------------------------------------------------------------------111
ON-BOARD OXYGEN (O2) ANALYZER-------------------------------------------------------------------------------------------------------112
POLAR COOL™ OPTION --------------------------------------------------------------------------------------------------------------------------114
EXTERNAL COOLING LIQUID SUPPLY OPTION ------------------------------------------------------------------------------------------119
RAIL ADJUST: -----------------------------------------------------------------------------------------------------------------------------------------121
SMEMA INTERFACE---------------------------------------------------------------------------------------------------------------------------------124
TEMPERATURE PROFILE PLOTTING (PRECISION PROFILING)--------------------------------------------------------------------132