electrovert electra operation manual

WAVE SOLDERING SYSTEM

OPERATION MANUALManual Part # 540-97-0

Speedline Technologies, Inc.Hwy. 5 South, Box 709 | Camdenton, MO 65020

Tel: 573-346-3341 | Fax: 573-346-6878

Electra

ii 2-9317-120-00-0 — Rev. 3 Operation

NOTE

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Electra™ Addendum

ATTENTION For shipments of the Electra™ Wave Soldering System shipped from the factory after 11/09/00, please refer to the Electra™ Addendum manual (part number 2-9317-121-00-0) supplied in the documentation package for the information pertaining to the following topics:

• Installation of the Operator Interface Moveable Console• Exhaust Specifications• Finger Cleaner Access and Maintenance Information

N O T E

Electra™ Addendum

NOTE

Electra

Operation 2-9317-120-00-0 — Rev. 3 iii

WAVE SOLDERING SYSTEM

OPERATION MANUALManual Part #3-9317-120-00-0, Revision 3

Text Part #2-93167-120-00-0, Revision 3Copyright© 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, 28, 1999

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iv 2-9317-120-00-0 — Rev. 3 Operation

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Operation 2-9317-120-00-0 — Rev. 3 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 of new maintenance personnel.

This manual includes operating instructions for this equipment available at the time this manual wasapproved for printing. Electrovert® reserves the right to make changes in design and specifications and/ormake improvements in the product without imposing any obligations upon itself to install them onpreviously manufactured products.

SPEEDLINE TECHNOLOGIES, INC., ELECTROVERT®

SALES AND SERVICES OFFICESSpeedline Technologies, Inc. Main Offices

Speedline Technologies, Inc.Sales & Marketing1111 W. North Carrier ParkwayGrand Prairie, TX 75050Fax: 972-606-1700Tel: 972-606-1900

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

P.O. Box 709Camdenton, MO 65020Fax: 573-346-6878Tel: 573-346-3341

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 Regional 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 7SOFax: 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

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vi 2-9317-120-00-0 — Rev. 3 Operation

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Operation 2-9317-120-00-0 — Rev. 3 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

Speedline Technologies, Inc.Hwy. 5 South, Box 709 | Camdenton, MO 65020

Tel: 573-346-3341 | Fax: 573-346-6878

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viii 2-9317-120-00-0 — Rev. 3 Operation

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Operation 2-9317-120-00-0 — Rev. 3 ix

Graphic

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

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x 2-9317-120-00-0 — Rev. 3 Operation

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Operation 2-9317-120-00-0 — Rev. 3 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 oca 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.

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Table of Contents

SECTION 1:SECTION 1: GENERAL 1.1 HAZARDS ...................................................................................................................................................1

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

1.2 SAFETY PRECAUTIONS .............................................................................................................................7 1.3 SAFETY PROCEDURES FOR REMOVAL OF DROSS...............................................................................8

Procedure Checklist...................................................................................................................................8 1.4 EXHAUST VENTILATION & CLEANING .....................................................................................................10 1.5 LOCKOUT/ TAGOUT CHECKLIST...............................................................................................................11

SECTION 2:TECHNICAL DATA 2.1 SPECIFICATIONS AND FACILITY REQUIREMENTS FOR INSTALLATION..............................................13

SECTION 3:ELECTRA™ SOFTWARE OVERVIEW 3.1 MAIN SCREEN ...........................................................................................................................................19

Elements of the Main Screen....................................................................................................................19 3.2 MENU BAR .................................................................................................................................................20

File ...............................................................................................................................................................20Machine ......................................................................................................................................................22View .............................................................................................................................................................23Modules ......................................................................................................................................................24Configuration..............................................................................................................................................25Help .............................................................................................................................................................26

SECTION 4:ELECTRA™ SOFTWARE OPERATION AND DESCRIPTION 4.1 FUNCTIONS ................................................................................................................................................27

Load Recipe ................................................................................................................................................27Save Recipe F6 ...........................................................................................................................................28Save Recipe As New… ..............................................................................................................................28Global Recipe Edit ......................................................................................................................................29Backup Files… ...........................................................................................................................................31Restore Files… ...........................................................................................................................................32Logon F8…..................................................................................................................................................33logoff............................................................................................................................................................33Print Recipe ................................................................................................................................................33Exit ...............................................................................................................................................................34Manual F4 ..................................................................................................................................................35Auto Start F2...............................................................................................................................................37Auto Stop F3 ...............................................................................................................................................38Alarms F5 ....................................................................................................................................................38Auto-StartUp Status …..............................................................................................................................40Logs … ........................................................................................................................................................41Maintenance Timers … .............................................................................................................................43Process Notes …........................................................................................................................................45

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xiv

Trending ...................................................................................................................................................... 46Text View … ................................................................................................................................................ 49Quick View …............................................................................................................................................. 50

4.2 MODULES DIALOG BOX FEATURES ....................................................................................................... 51Conveyor ..................................................................................................................................................... 52Fluxer .......................................................................................................................................................... 61Solder Pot ................................................................................................................................................... 69Hot Knife..................................................................................................................................................... 83Lower Preheat 1 (Convection)................................................................................................................... 83Lower Preheat 1 (Radiant)......................................................................................................................... 83Lower Preheat 2 & 3 ................................................................................................................................... 89Upper Preheat 1 - 3 .................................................................................................................................... 89Pyrometer ................................................................................................................................................... 89Analog I/O................................................................................................................................................... 90Digital I/O ................................................................................................................................................... 91

4.3 CONFIGURATION FEATURES................................................................................................................... 92Alarms ........................................................................................................................................................ 92Data Log ..................................................................................................................................................... 93Modules ...................................................................................................................................................... 95Quick View.................................................................................................................................................. 114Security ....................................................................................................................................................... 115Specials ...................................................................................................................................................... 121Units............................................................................................................................................................ 122

4.4 USING ON-LINE HELP............................................................................................................................... 124Help Topics ................................................................................................................................................. 124

SECTION 5:THEORY OF OPERATION 5.1 GENERAL MACHINE OPERATION........................................................................................................... 127

SECTION 6:SETUP 6.1 CONVEYOR................................................................................................................................................. 128

System Leveling ......................................................................................................................................... 128Conveyor Leveling ...................................................................................................................................... 129Rail Parallelism .......................................................................................................................................... 129

6.2 Finger Cleaner............................................................................................................................................ 131Filling The Reservoir .................................................................................................................................. 131Air Pressure Setting................................................................................................................................... 132

6.3 Fluxer (Foam).............................................................................................................................................. 132Installing the Aerators ............................................................................................................................... 132Filling The Reservoir (Foam) ..................................................................................................................... 134Flux Density Check .................................................................................................................................... 135Airknife Air Adjustment............................................................................................................................. 135Aerator Air Adjustment ............................................................................................................................. 135Filling the reservoir (Wave)........................................................................................................................ 135Opti-Flux® Spray Fluxer ............................................................................................................................. 135

6.4 Solder Module ............................................................................................................................................ 136Inspecting the Solder Level....................................................................................................................... 136Lambda™ Air Nozzle Setup ....................................................................................................................... 136Turbulent Chip Nozzle Setup..................................................................................................................... 138Rotary Chip Nozzle (Air) Setup ................................................................................................................. 139Con2Tour and Con2tour Plus Wave Setup .............................................................................................. 140Rotary Chip Nozzle (N2) Setup.................................................................................................................. 145IR Preheat Setup........................................................................................................................................ 146Vectaheat™ Setup...................................................................................................................................... 148

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SECTION 7:STARTUP 7.1 EXHAUST ....................................................................................................................................................151 7.2 SYSTEM ACTIVATION.................................................................................................................................151 7.3 RECIPE SELECTION ...................................................................................................................................152 7.4 CREATING A NEW RECIPE .......................................................................................................................152

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Operation 2-9317-120-00-0 — Rev. 3 1

SECTION 1: GENERAL

1.1 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 in this manual prior toworking around the solder pot.

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

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2 2-9317-120-00-0 — Rev. 3 Operation

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 becomes effective. This standard is no longer an ambient standard, but a permissible exposurelimit (PEL) standard, which in some areas of some plants may be attained by worker self-protection and/oradministrative standards, subject to negotiation. When the engineering controlled 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 lead chromate is calculated as chromate.

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

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Operation 2-9317-120-00-0 — Rev. 3 3

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 (AminoLaevulinic Acid in Urine remains lower than 20 mg/g creatine or the ZPP (Zinx Protoporphysin) level remainslower than 20 mg/g haemoglobin or the ALAD (Delta Aminohaevulinic Acid Dehydratase) level remainsgreater than six European units.

(f) = France follows EED norms.

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

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

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4 2-9317-120-00-0 — Rev. 3 Operation

(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 women planning 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.

Both tables were compiled by the International Lead and Zinc Study Group in 1991.

BURN HAZARDS

Liqu id Meta l - HotSurfaces Burn Hazardfaces Burn Hazard

The solder pot contains molten solder attemperatures 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.

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Operation 2-9317-120-00-0 — Rev. 3 5

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.

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 be

performed 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 voltagecan 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.

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6 2-9317-120-00-0 — Rev. 3 Operation

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 consultingElectrovert and the gas supplier. Other gasescould inter fere wi th the process andintroduce additional safety hazards.

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.

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Operation 2-9317-120-00-0 — Rev. 3 7

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.

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8 2-9317-120-00-0 — Rev. 3 Operation

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.

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Operation 2-9317-120-00-0 — Rev. 3 9

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.

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10 2-9317-120-00-0 — Rev. 3 Operation

1.4 EXHAUST VENTILATION & 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. Regularcleaning prevents contaminant build-up,reduces the risk of fire, and improves theefficiency of your exhaust system.

On some Electrovert Systems,wave soldering cannot beginunless the exhaust ventilation

system is on and the widows and doors areclosed. These safety interlocks protect theuser against the escape of hazardous fumesand provide safe operation of the system.

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Operation 2-9317-120-00-0 — Rev. 3 11

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 Electra™. 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

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12 2-9317-120-00-0 — Rev. 3 Operation

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.

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SECTION 2: TECHNICAL DATA

2.1 SPECIFICATIONS AND FACILITY REQUIREMENTS FOR INSTALLATION

NOTE1 Refer to the Power Table on page 14 to calculate and select the powerconfiguration and facility power disconnect requirements for the machine. It is theresponsibility of the customer to provide any electrical disconnect (fusible or breaker

type), external to the system, capable of protecting the Electra™ at the amperages specified forthe voltage selected. The values listed are at maximum power consumption during full load start-up. Power consumption is lower at stabilized process conditions, but varies on processparameters and product loading. Typical conditions draw 30 - 50% of full load value (based on 30 -50% duty cycle) at steady state operating conditions.

NOTE1 The Electra™ is equipped with a main disconnect switch which is not fused.It is recommended that the main supply power be supplied to the machine via a wall-mounted fused 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)40 - 480 VAC, 3 phase, 60 Hz (3 wires, 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 preheat panel.

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 preheater added

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

Schematic Reference

All Voltages: Electrical Schematic # 8-1701-001-01-2

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14 2-9317-120-00-0 — Rev. 3 Operation

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

NOTE 2 Add 14 Amps to the F.L.A. for 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

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Operation 2-9317-120-00-0 — Rev. 3 15

Grounding Requirements

10 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 Electra™ is configure with a 2.0 in. ole 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 - 550 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

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16 2-9317-120-00-0 — Rev. 3 Operation

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 eight (8) bars, each weighing up to 1 kg (2.2 lbs.)

FINGER CLEANER

Reservoir Capacity: - Liters (3.7 gal.)

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Operation 2-9317-120-00-0 — Rev. 3 17

Figure 1: Electra™ Footprint Drawing

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18 2-9317-120-00-0 — Rev. 3 Operation

Electra™

Operation 2-9317-120-00-0 — Rev. 3 19

SECTION 3: ELECTRA™ SOFTWARE OVERVIEW

3.1 MAIN SCREEN

ELEMENTS OF THE MAIN SCREEN

Figure 2: Elements of the Main Screen

• The Control Icon appears at the upper lefthand corner of the window. Clicking theControl Icon pops up a control menuused to manipulate the window usingthe keyboard.

• The Title Bar lists the name of the programand the current recipe.

• The Menu Bar is directly below the title bar.It contains menu headings with pull-downmenus when clicked.

• The Manual Mode (MAN) Button puts theElectra™ machine modules into manualoperation when clicked. When in Manualmode, each module must be manually

activated via the software control panel forthat module.

• The Auto Start (GO) button auto starts thesystem when clicked. All modules withpredetermined set points start upautomatically.

• The Stop button auto stops the systemwhen pressed all modules previouslyoperating are turned off.

• The Minimize button removes the windowfrom view, but places the application on thewindow’s Task Bar as a button formultitasking. To bring the window back intoview, simply click the application button onthe task bar.

Title Bar Menu Bar

Manual Mode Button

Stop Button

Minimize ButtonMaximize Button

Close Button

Status BarDisplays Present Mode

Displays the number of PCB’spresently in the system

Control Icon

Auto Start Button

Interior LightsOn/Off Button

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20 2-9317-120-00-0 — Rev. 3 Operation

• The Close button closes the Electra™software program when clicked.

• The Status Bar displays information aboutthe program.

• The Mode window displays the presentmode the system is in.

• The PCB’s in Machine window displays thenumber of circuit boards presently beingprocessed through the system.

3.2 MENU BARThe MENU bar contains Menu headings, whichwhen clicked, reveal specific commands orfunctions possible for that Menu category. Thefollowing are the Menus and their commandswith a brief description of their function.

FILE

Figure 3: File Pull-Down Menu

Load Recipe … F7

Opens a window “Load Recipe” when clicked.Allows the operator to load an existing Recipe.Hot key is F7. (See Load Recipe).

Save Recipe F6

Click on Save Recipe to save the current recipeand any changes to it. Hot key is F6. (See SaveRecipe).

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Operation 2-9317-120-00-0 — Rev. 3 21

Save Recipe As New …

Opens a window “Save Recipe” when clicked.Allows the operator to save the existingrecipe as another recipe (file) name. (SeeSave Recipe As New).

Global Recipe Edit

Opens a Global Recipe Edit dialog box whenclicked. Displays all recipe names stored in therecipe directory. Allows the user to update ormake changes to parameters of all, or specificrecipes selected in the Recipes list.

Backup Files …

Backup Files is a utility that permits the user toarchive system and recipe files that are on thecomputer’s hard drive — to the floppy drive “A”by default.

Restore Files …

Restore Files is a utility that permits the user tores to re sys tem and rec ipe f i l es to thecomputer’s hard drive — from the floppy drive“A” by default.

Logon … F8

With the Security feature enabled, the usermust first Logon on to the system before theoperator may perform tasks given to them viaSecurity Access.

Logoff …

Logging off from the system disables anyfunction the present operator’s security accesshad allowed while the Security feature wasenabled.

Print Recipe

Use this command to print the current recipeparameters — if a printer is connected.

Test Watchdog

Shuts down the Electra™ and tests thewatchdog hardware.

Exit

Quits the Electra™ program and prompts theoperator to save the recipe.

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22 2-9317-120-00-0 — Rev. 3 Operation

MACHINE

Figure 4: Machine Pull-Down Menu

Manual F4

Puts the system into manual operation ofmachine modules. Hot key is F4. (SeeManual Mode).

Auto Start F2

Auto starts the machine. F2 is the hot key.

Auto Stop F3

Auto stops the machine. F3 is the hot key.

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Operation 2-9317-120-00-0 — Rev. 3 23

VIEW

Figure 5: View Pull-Down Menu

Alarms … F5

Displays a list of alarms. Hot key is F5. (SeeAlarms)

Auto-Startup Status

Provides the user the current status of the autostart sequence.

Logs

Disp lays a window wi th Event Log andMaintenance Log tabs.

Maintenance Timers …

When clicked, displays a list of all modules andspecific components within each machinemodule that require maintenance at certainintervals. Each item listed is associated with at imer tha t genera tes an a la rm whenmaintenance is required for that item. Note thatthere are different levels indicated for variousintervals. Each level is associated with theElectra™ Maintenance schedule.

Process Notes …

A utility provided to write notes specific to arecipe. This tool can be useful in passinginformation between operators.

Trending

Allows operators and Process Engineers theability to configure, create, and inspect DataTrends of specific parameters for process andtroubleshooting.

Text View

Displays a text view of parameters.

Quick View

Displays a quick view window of parameters.

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24 2-9317-120-00-0 — Rev. 3 Operation

MODULES

Figure 6: Modules Pull-Down Menu

Conveyor

Allows viewing of conveyor parameters in apop-up window.

Fluxer

Allows viewing of fluxer parameters in a pop-upwindow.

Solder Pot

Allows viewing of solder pot parameters in apop-up window.

Hot Knife

Allows viewing of Hot Knife parameters in apop-up window.

Lower Preheater 1

Allows viewing of lower preheat #1 parametersin a pop up window.

Lower Preheater 2


Lower Preheater 3


Upper Preheater 1

Allows viewing of upper preheat #1 parametersin a pop up window.

Pyrometer

Allows viewing of pyrometer parameters in apop-up window.

Analog I/O

Allows viewing of analog I/O points in a pop-upwindow.

Digital I/O

Allows viewing of digital I/O points in a pop-upwindow.

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Operation 2-9317-120-00-0 — Rev. 3 25

CONFIGURATION

Figure 7: Configuration Pull-Down Menu

Alarms

Permits the operator to set alarms for variousevents.

Data Log

Allows the user to log data specific to selectedparameters, to a file for reference.

Modules

Used to configure machine components.

Quick View

The user may configure which parameters areto be displayed in the Quick View window.

Security

A password utility for supervisors. Allowsconfiguration of specific rights within thesystem software for various levels of security foroperation and maintenance.

Specials

Used to configure special features that are notstandard on the Electra™.

Units

Allows the user to define the unit of measure tobe displayed where ever parameters aremeasured. Selections are Imperial, Metric, andMixed. See Units Configuration.

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26 2-9317-120-00-0 — Rev. 3 Operation

HELP

Figure 8: Help Pull-Down Menu

Help Topics

Lists Help topics.

About Electra

Displays program information, software versionnumber, and copyright.

Figure 9: About Electra™ screen

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Operation 2-9317-120-00-0 — Rev. 3 27

SECTION 4: ELECTRA™ SOFTWARE OPERATION AND DESCRIPTION

4.1 FUNCTIONSThis section provides the user complete descriptions of each of the functions selectable from the Menu Barand how they affect machine operation. Any shortcut procedures available within the functions are alsodescribed in this section.

LOAD RECIPEUse the Load Recipe function to load an existing recipe (file) into the system.

Load Recipe can be accessed by ay one of the following methods:

• Click on the Load Recipe Icon just below the Menu Bar — opens a Load Recipe dialog box.• Click on File on the Menu Bar, then click on Load Recipe — opens a Load dialog box.

Figure 10: Select Load Recipe

• Press the F7 function key on the keyboard— opens a Load Recipe dialog box.Once the Load Recipe dialog box is open,double click on the recipe name to beloaded.When loaded, the recipe name appearsnext to “Electra™ - Current Recipe:” in thewindow’s title bar.

Figure 11: Load Recipe dialog box

Select the recipe from the window with a single leftclick; then right click to bring up a window to “rename”or “delete” the selected recipe.

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28 2-9317-120-00-0 — Rev. 3 Operation

SAVE RECIPE 6Use the Save Recipe function to save anychanges made to the currently loaded recipe.

Any one of the following methods can be usedto perform the Save Recipe function:

• Click on the Save Recipe icon justbelow the Menu Bar.

• Click on File on the Menu Bar, then click onSave Recipe.

Figure 12: Select Save Recipe

• Press the F6 function key on the keyboard.The save function occurs invisibly. Nodialog box appears for this feature.

SAVE RECIPE AS NEW…Use the Save Recipe As New function to namethe existing recipe to another recipe name,a l lowing the new recipe to acquire theparameters of the previous.

This feature is most useful when creatingrecipes for new product with close similaritiesof others, without having to individually createeach specific parameters, one item at a time.

To perform the Save Recipe As New… function:

• Click on File on the Menu Bar, then click onSave Recipe As New — opens a SaveRecipe dialog box.

Figure 13: Select Save Recipe As New…

Once the Save Recipe dialog box is open,use the keyboard to enter the new recipename. Use the default “recipes” folder tosave the recipe into unless a specific folderhas been created previously for your needs.If a different folder is required, click on the

icon until the correct folder appears in

the Save in text box. (See Figure 14).

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Operation 2-9317-120-00-0 — Rev. 3 29

Figure 14: Save Recipe Dialog Box

GLOBAL RECIPE EDIT• Click on File on the Menu Bar, then click on

Global Recipe Edit — opens a GlobalRecipe Edit dialog box.

Figure 15: Select Global Recipe Edit

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30 2-9317-120-00-0 — Rev. 3 Operation

Figure 16: Global Recipe Edit dialog box

Recipes

Displays all recipe names stored in the Recipedirectory.

• Double click on a recipe name to updatethe parameter list with that recipe’s values.

• Click on a recipe name to select it.All recipe names selected are updatedwith the active values in the parametername list.

Select All• Click on the Select All button to select

all the recipe names listed underRecipes.

Clear All• Click on the Clear All button to deselect

all recipe names listed under Recipes.

Parameters to Edit

Lists the Active parameters that may beupdated in selected recipe(s). A check in thebox indicates the parameter active.

NameDisplays parameter names. (As perMachine Configuration).ValueDisplays the parameter value to bemodified.Activate AllPlaces a check in the boxes for all existingparameters.

Deactivate AllRemoves the check in the boxes for allexisting parameters.

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Operation 2-9317-120-00-0 — Rev. 3 31

BACKUP FILES…Utilize the Backup Files utility to archive systemand Recipe files that are on the computer’shard drive.

Click on File on the Menu Bar, then click onBackup Files to access the Backup utility.

Figure 17: Select Backup Files…

A Backup Files dialog box is displayed.

Figure 18: Backup Files dialog box

Options

Click on the check box to select one or both filesystems to Backup.

• System Files• Recipe FilesA check mark in the check box indicates it isselected for backup.

Selecting System Files prompts the utility tobackup all system software files.

Selecting Recipe Files prompts the utility tobackup only the files in the Recipe folder.

Path Selection

PathIndicate the Path where the files selected inOptions, are getting backed up from.Select PathClick on the Select Path button to modifythe default Path.

Start

Click on the Start button to start the backup.

Cancel

Click on the Cancel button to terminate thebackup.

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32 2-9317-120-00-0 — Rev. 3 Operation

RESTORE FILES…Utilize the Restore Files utility to restore systemand Recipe files to the computer’s hard drive.

Click on File on the Menu Bar, then click onRestore Files to access the Restore utility.

Figure 19: Select Restore Files…

A Restore Files dialog box is displayed.

Figure 20: Restore Files dialog box

Options

Click on the check box to select one or both filesystems to Restore

• System Files• Recipe FilesA check mark in the check box indicates it isselected to restore.

Selecting System Files prompts the utility torestore all system software files contained onthe backup disk(s).

Selecting Recipe Files prompts the utility torestore only the files in the Recipe folder thatare contained on the backup disk(s).

Path Selection

PathIndicate the Path where the files selected inOptions, are getting restored to.Select PathClick on the Select Path button to modifythe default Path.

Start

Click on the Start button to start the restorefunction.

Cancel

Click on the Cancel button to terminate therestore function.

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Operation 2-9317-120-00-0 — Rev. 3 33

LOGON… F8Use any one of the following methods toperform the Logon/Logoff function.

• Click on the Logon icon just below

the Menu Bar.• Click on File on the Menu Bar, then click on

Logon.

Figure 21: Select Logon…

• Press the F8 function key on the keyboardfor Logon.

A Logon dialog box pops up.

Figure 22: Logon dialog box

User Name

• Type in your User Name.

Password

• Type in your Password.

See Administrator to allocate aUser Name and a Password.

L o g o n / L o g o f f a r e u s e d i nconjunction with the Securityfunction.

LOGOFFFor Logoff, the function occurs invisibly, noDialog Box pops up for this feature.

To access Logoff, click on File on the Menu Bar,then click on Logoff…

Logoff is only active if the user is currentlylogged on.

Figure 23: Select Logoff…

PRINT RECIPEUse this command to print a document. Thiscommand displays a Print dialog box, where theuser may specify the range of pages to beprinted, the number of copies, the destinationprinter, and other printer setup options.

Shortcuts

Toolbar:Keys:CTRL+P

• To access the Print Recipe function, clickon File on the Menu Bar, then click on PrintRecipe.

If connected to a network printer via theoptional Network Card, printing is to thedefault network printer. The optional RJ-45(10-Base T) connector is located at the loadend of the Electra™.

If printing to a parallel printer connection,ensure that the printer is connected to theparallel printer port at the load end of theElectra™, and ensure print is set up inWindows NT®.

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34 2-9317-120-00-0 — Rev. 3 Operation

EXITQuits the Electra program and prompts theoperator to save the recipe.

To exit the Electra program perform one of thefollowing:

• Click on File on the Menu Bar, then click onExit.

Figure 24: Select Exit

• Click on the X at the upper right handcorner of the window status bar.

Figure 25: Click on the X to exit the program

A dialog box pops up confirming system shutdown.

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Operation 2-9317-120-00-0 — Rev. 3 35

MANUAL F4When the system software starts up, themachine is in the Auto Stop mode — the STOP

icon button appears depressed.

To switch to Manual mode select one of thefollowing methods:

• Click on the MAN icon button .

• Select Machine on the Menu Bar, then clickon Manual — a check mark appears next toManual when in the manual mode.

Figure 26: Select Machine Manual Mode

The machine mode is also displayed on thewindow Status Bar in the lower right area of theElectra™ window.

The Auto Stop icon button no longer

appears depressed.

The MAN icon button appears depressed.

In the Manual mode , each funct ion orsubsystem must be manually activated.

The following provides the user an example ofmanually starting or activating a module’sfunctions.

Example:While in MAN mode, select Modules on theMenu Bar, then select solder pot.A Solder Pot dialog box is displayed.

Figure 27: Solder Pot dialog box

Note that the column to the right within thedialog box is labeled Manual. Just belowManual, a series of START buttons are listacross from the function associated with it.Some are available for selection, and some aregrayed, indicating they are not yet available forselection.

Click on the START button directly acrossfrom Solder Temperature. Holding thepointer device cursor over the disabledbuttons displays a “tool tip” indicating thereason for the button being disabled.• The START button changes to Stop.• The LED’s next to Heater Element and

Solder Temperature illuminate green,indicating the solder pot heaters arenow activated.

• Notice that the value under Actualstarts to increase, indicating theheaters are heating up to the SetPoint value.

• Once the Solder temperature reaches218 °C (425 °F), other Start functions

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36 2-9317-120-00-0 — Rev. 3 Operation

listed under Manual becomeselectable.

• Other machine functions may bestarted without the solder reachingtemperature, and must be startedmanually to activate them in Manualmode.

• The following functions may be startedimmediately upon entering Manualmode:

• The following functions are DEPENDENT upon first meeting specific criteria before becoming

selectable for Start:

MODULE FUNCTION

Conveyor Conveyor SpeedConveyor WidthLead Clearance

Fluxer (any) Start

Solder Pot Solder TemperatureLead Clearance

Hot Knife Pressure

Lower Preheater 1 Temperature

Lower Preheaer 2 Temperature

Lower Preheater 3 Temperature

Upper Preheater 1 Temperature



Pyrometer Width

MODULE FUNCTION DEPENDENT

Conveyor Finger Cleaner OnConveyor Width

Conveyor must be onConveyor must be stoppedConveyor must be stoppedRollout, CBS width, and Pyrometer width OFF

Solder Pot Solder WavesLead Clearance

Solder Temperature 218 °F (425 °F)Conveyor must be OFFConveyor width must be OFFRollout, CBS width, and Pyrometer width Off

Hot Knife Heater TemperatureWire/ Bar Feeder

Air PressureLow Solder Level

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Operation 2-9317-120-00-0 — Rev. 3 37

AUTO START F2The Auto Start function allows automaticenabling of all modules or functions within amodule, that have been selected withinMachine Configuration (See Configuration).

To view which modules and features arepresently configured for the machine:

• Click on View on the Menu Bar, then clickon Auto Startup Status — opens an AutoStartup Status dialog box.

Figure 28: Select View, Auto Startup Status

The Auto Startup Status dialog box displaysall items affected by Auto Startup and theirpresent state.

Figure 29: Auto Startup Status dialog box

When the system software starts up, themachine is in the Auto Stop mode — the STOPicon button appears depressed.

In order to Auto Start the Electra the solder potheaters must be enabled.

The GO (Auto Start) icon located just below theMenu Bar, remains disabled until the solder potheaters are enabled.

• To verify whether or not the heaters areenabled for Auto Startup, check the LED onthe solder pot Operation tab screen.

A text box pops up for a few seconds,displaying the actual temperature ofthe solder pot. This only indicates thesolder pot temperature, not the heaterstatus.

Figure 30: Solder pot area of graphic screen

If the temperature appears to beincreasing, the heaters are more thanlikely enabled.If the temperature does not appear tobe increasing, the heaters have not yetbeen enabled.

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38 2-9317-120-00-0 — Rev. 3 Operation

Once the heaters are enabled and over 218 °C(425 °F) operating temperature, the GO iconbecomes selectable for Auto Start mode.

The Auto Start function can be enabled in eitherof two (2) methods:

1. The solder pot heaters can be manuallystarted in the Manual mode. Once theheaters reach 218 °C (425 °F) temperature,

the GO icon button becomes

selectable for Auto Start mode.

2. Enabling and setting of times On and Offfor the Timer within the Timer tab of theSolder Pot dialog box, and then saving thechanges, allows the system’s solder potheaters to be enabled by the timer uponmachine start up. This function is notRecipe dependent. (See Enabling andSetting the Solder Pot Timer).

When the Timer is enabled, and thetime On and time Off values have beenset and saved, the machin still comesup in the Auto Stop mode, but theheaters now come on. When 218 °C(425 °F) temperature is reached, the GO

icon button becomes available for

selection.

When the GO icon button is

clicked, Auto Start mode activates.

AUTO STOP F3The Electra™ machine always comes up in theAuto Stop mode.

The STOP button icon appears depressed.

The Stop button remains depressed until eitherthe MAN or GO buttons are clicked.

While in either the MAN or GO mode, and theSTOP button is clicked, Auto Stop immediatelyand sequentially turns off (stops) all functionsof the Electra™ with the exception of the solderpot heaters. Unless the heaters are manuallyshut off, or an alarm condition arises in thesolder pot heater circuit, the heaters will remainenabled.

Use Auto Stop whenever shutting the machinedown.

Select the Auto Stop mode by any one of thefollowing methods.

• Click on the STOP button icon .

• Press the F3 function key on the keyboard.• Select Machine on the Menu Bar, then click

on Auto Stop in the drop-down list box — acheck mark appears next to Auto Stopwhen in the Auto Stop mode.

The STOP button appears

depressed.The mode is also displayed on thewindow Status Bar in the lower rightarea of the Electra™ window.

The MAN or GO button icons

no longer appear depressed.

ALARMS F5Access the Alarms dialog box to view anyexisting alarms or to Acknowledge them.

Alarms can be accessed by any one of thefollowing methods:

• Click on the Alarms icon just below the

Menu Bar — opens an Alarms dialog box.• Click on View on the Menu Bar, then click

on Alarms — opens an Alarms dialog box.

Figure 31: Select View Alarms

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Operation 2-9317-120-00-0 — Rev. 3 39

• Press the F5 function key on the keyboard -if the main graphic window is the activewindow — opens an Alarms dialog box.

Figure 32: Alarms Status Dialog Box

The alarm(s) may appear in any one of three (3)colors of text. Refer to the table for the colorindication or alarms:

• Click the Acknowledge button to clear thealarms.

ALARM COLOR INDICATIONS

Color Indication

Green the alarm has cleared — it is nolonger an alarm

Yellow the alarm is still active but has been acknowledged

Red the alarm is still active

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AUTO-STARTUP STATUS …The Auto-Startup Status is basically a viewingutility.

This feature does not perform a specificfunction other than allowing the user to viewthe status, at any time, of the modules or theirfeatures configured for Auto-Startup.

• Select Auto-Startup Status by clicking onView on the Menu Bar, then clicking onAuto-Startup Status in the drop-down listbox.

Figure 33: Select View, Auto-Startup Status

An Auto-Startup Device dialog box displays allitems affected by Auto-Startup, and theirpresent state.

Figure 34: Auto-Startup Device Dialog Box

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LOGS …Logs is basically a viewing utility.

This feature displays an Event Log/MaintenanceLog file when clicked.

Select Logs by clicking on View on the MenuBar, then clicking on Logs in the drop-down listbox.

Figure 35: Select View, Logs

Event Log

Click on the Event tab to select it.

The Event Log file chronicles changes andevents that have occurred in the machineprogram.

Figure 36: Log View dialog box

Maintenance Log

Click on the Maintenance tab to select it.

The Maintenance Log file chronicles changesa n d e v e n t s t h a t h a v e o c c u r r e d i n t h eMaintenance Timers Screen.

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Operation 2-9317-120-00-0 — Rev. 3 43

MAINTENANCE TIMERS …This utility is recommended for use by Operatorand Maintenance personnel, and to be used asa guide for schedul ing and per formingmaintenance on specific modules.

The Maintenance Timers dialog box displays alist of all components requiring maintenance atspecific intervals.

• Click on View on the Menu Bar, then clickon Maintenance Timers in the drop-downbox.

Figure 37: Maintenance Timer dialog box

The items listed in the left hand column are thecomponents or modules that require service atspecific intervals.

To view additional components or moduleslisted in the left hand column, use the scroll barat the right of the dialog box to scroll down thelist.

Most of the items listed in thele f t hand co lumn a re a l soassoc ia ted w i th a spec i f ic

module and Maintenance Timers tab. Theexception to this is the first three (3) itemslisted. Machine Level 1, Machine Level 2, andMachine Level 3, do not have MaintenanceTimers tabs within any module. These three(3) can be completed and cleared throughthe View Maintenance Timers dialog box.

Interval (hours)

Under the heading “Interval”, the amount oftime in hours is displayed between eachmaintenance period. The default values arelisted, however, the user may enter other values( o r “ 0 ” t o d i s a b l e ) b a s e d o n s p e c i f i cmaintenance requirements determined by theirfacility maintenance schedules and processrequirements.

When clicked on, the value under intervalbecomes highlighted and the Current ValueRange that may be entered is displayed at thebottom of the dialog box under “Current ValueRange”.

Time Remaining

The number displayed in the time Remainingcolumn represents the number of hours and

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minutes remaining before an alarm is triggeredto notify the operator or maintenance personnelthat maintenance is required on a specificcomponent or module.

When an alarm is triggered for maintenance onany of the items in the list, the time displayed inthe T ime Remain ing co lumn is usual l yrepresented in a negative number. This wouldindicate how many minutes have passed sincethe alarm was originally activated.

Figure 38: Time Remaining negative number

In addition, the alarm is also displayed in theMode display at the bottom of the Electra™main screen.

Figure 39: Maintenance Alarm message displayed

The alarm can be viewed by clicking on theexclamation icon just below the Menu Baron the Electra™ main screen.

Figure 40: Icon buttons below Menu Bar

Click on the Acknowledge button to view,silence, and acknowledge the alarm.

Figure 41: Maintenance Alarms Status

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Operation 2-9317-120-00-0 — Rev. 3 45

Total Run Time

The Total Run Time column displays the actualtime that this module has been ON sinceinstallation of the Electra™.

Complete

When a maintenance function has beenperformed and is complete for this module,

c l i ck on the Comple te bu t ton

associated with that module.

When clicked, the window “Maintenance Note”is displayed.

Figure 42: Maintenance Note window

To Enter a Maintenance Note:

Type in any maintenance note in this window. Itcan be as simple as “OK”. However, somethingmust be entered in this f ield in order tocomplete and clear the maintenance timer.

The note entered in this window is stored andcan be viewed in the Log View MaintenanceScreen.

Restore Default Intervals

Click on the Restore Default Intervals button torestore all interval values to their defaultsettings.

PROCESS NOTES …Use this utility to write notes specific to arecipe; may be useful to pass informationbetween operators.

• Click on View on the Menu Bar, then clickon Process Notes … in the drop-down listbox.

Figure 43: Select View, Process Notes …

A Process Notes window is displayedwhereby the operator may enter up to200 characters of notes.

Figure 44: Process Notes pop-up window

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TRENDING• Click on View on the Menu Bar, then click

on Trending in the drop-down list box.Additional Trending features are displayedfor selection.

Figure 45: Select View, Trending

The following describes each of the Trendingfeatures:

Create New Trend

Up to six (6) different windows can be created.This feature is available only if less than six (6)windows have already been created.

• Click on Create New Trend to open a newTrend Graph.

Trending may also be opened byclicking on the Trending icon

just below the Menu Bar.

Figure 46: Trend Graph window

Close Button• Click on the Close button to close the

Trend Graph window.Options Button• Click on the Options button to display

the following features:

Figure 47: Options features

Clear DataClick on Clear Data to clear all theaccumulated data for this window.

ColorBackground ColorSelect the color for the background.Text ColorSelect the color for the text and the gridif it exists.

ConfigureClick on Configure to open a ConfigureTrend Graph dialog box.

Figure 48: Configure Trend Graph dialog box

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• TitleEnter the a name to reference for thiswindow.

• Capture IntervalBoard BasedData is collected for the parametersselected each time the Electra hasprocessed this many boards. Click onthe bullet box to select it. A bulletappears in the bullet box whenselected.Time BasedData is collected for the parametersselected every X amount of time. Clickon the bullet box to select it. A bulletappears in the bullet box whenselected.

• Control Limit LinesShow LinesClick on the check box to place a checkmark in the box — clicking on the boxagain removes the check mark. ACheck mark in the box indicates thisfeature is selected.When selected, Lower Limit and UpperLimit lines appear in the trend graph.Lower LimitLower Limit may be selected if theShow Lines check box is selected. Adashed blue line appears on the trendgraph at the selected value. A ValueRange of -100,000.00 - 100,000.00 maybe entered for the Lower Limitparameter.Upper LimitUpper Limit may be selected if theShow Lines check box is selected. Adashed red line appears on the trendgraph at the selected value. A ValueRange of -100,000.00 - 100,000.00 maybe entered for the Upper Limitparameter.

• X-AxisShow Elapsed TimeClick on the check box to place a checkmark in the box — clicking on the boxagain removes the check mark. Whenselected, displays the time elapsedsince the trend was started, in the X-

Axis .If not selected, actual time is displayedon the X-Axis.

• Y-AxisAuto RangeClick on the check box to place a checkmark in the box — clicking on the boxagain removes the check mark. ACheck mark in the box indicates thisfeature is selected.When selected, the Y axis automaticallyranges from the minimum to themaximum of the data accumulated.Low RangeWhen Auto Range is not selected, aLow Range representing a minimumvalue, may be entered for the Y axis.High RangeWhen Auto Range is not selected, aHigh Range representing a maximumvalue, may be entered for the Y axis.

• Parameters To ShowThis section allows the user to select up tothree (3) parameters to be charted in thetrend graph. Click on the check box toplace a check mark in the box — clickingon the box again removes the check mark.A Check mark in the box indicates thisfeature is selected for trending.DeleteWARNING: Clicking on the Delete featurewill delete this window and all itsconfiguration.GridThe Grid feature allow the user to make one(1) of three (3) selections for the type of gridthat will be diaplayed on the Trend Graph:

Dotted Line - The grid appears as adotted line in the window graph.None - No grid appears in the windowgraph.Solid Line - The grid appears as a solidline in the window graph.

Line With PointsFor each parameter, a point appears on thegraph for this window.PrintClick on the Print feature to print out anactive Trend Graph window; utilizes the

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printer defined in the Windows NT™

(Microsoft® Corp.) Setup.UnzoomClick on the Unzoom feature to restore thegraph window to normal size.

Start Button• Click on the Start button to Start the

trend graph.

If Board Based is selected underthe Capture Interval Optionconfiguration window, a board

must be sensed in the machine beforetrending starts.

Help Button• Click on the Help button to access on-

line Help for Trending.

Tile Trend Windows

The Tile Trend Windows feature is only availableif one (1) or more of the windows has alreadybeen opened.

All Trend Graphics

The All Trend Graphics feature is only availableif two (2) or more windows have been created.

Trend Graph 1

Click on Trend Graph 1, if it already exists, toview the graph.

Up to s i x ( 6 ) Trend Graphwindows can be created.

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TEXT VIEW …Text View is exactly as it is stated, a view of allmachine modules with their present Set Pointsand parameter Actuals in a text format.

Parameters may be monitored or changed.

Access the Text View dialog box using either ofthe following methods:

• Click on the Text View icon just below

the Menu Bar.• Click on View on the Menu Bar, then click

on Text View. Figure 49: Select View, Text View

Figure 50: Text View Dialog Box

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QUICK VIEW …Quick View is a viewing utility. It provides theuser a dialog box that displays only moduleparameters pertinent to the process that theuser has conf igured. Parameter valuesrepresent actual.

To open the Quick View dialog box:

• Click on View on the Menu Bar, then clickon Quick View in the drop-down list box orright click on the main screen.

Figure 51: Quick View dialog box

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4.2 MODULES DIALOG BOX FEATURESThe machine modules that appear in the drop-down list box under Module on the Menu Bareach contain generic buttons and features thatappear in their respective dialog boxes.

Each module’s dialog box contain the followingbuttons; each perform the function described:

• When clicked, the OK button

simply accepts the change made within thedialog box and closes it.

• When clicked, the Cancel

buttton cancels any changes made withinthe dialog box and closes it.

• When clicked, the Apply

button immediately applies and saves anychanges made within the dialog box to themodule being changed, and leaves thedialog box open.

• When clicked, the Help

button opens a dialog box displaying on-line help information about the currentmodule and its features.

Current Value Range

Each module’s dialog box also contains asection labeled Current Value Range. It islocated at the lower most section of the dialogbox.

The Current Value Range provides the user aselectable range when entering Set Pointvalues in specific modules.

Figure 52: Current Value Range field

EXAMPLE:

• While in the Conveyor dialog box, click inthe Conveyor Speed Set Point text box.

The present Set Point value becomeshighlighted, and the value range listedunder Current Value Range changes toa range 1.00 - 12.00. This means thatany value between 1.00 and 12.00 canbe entered in the Set Point. Any valueless than or greater than the specified

range will not be accepted. An errormessage dialog box appears when aninvalid range has been entered.

Figure 53: Error Message dialog box

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CONVEYORConveyor is a machine module dialog box.

Items appearing under Modules each havedialog boxes that can be opened using either ofthe following methods:

• Select Conveyor by clicking on Modules onthe Menu Bar, then clicking on Conveyor inthe drop-down list box.

Figure 54: Select Modules, Conveyor

• Position the pointer device over any part ofthe conveyor module on the graphicscreen.

Notice that the conveyor graphichighlights and a text box pops up withthe conveyor speed parameter.

• Single click on the graphic to open theConveyor dialog box.

Figure 55: Conveyor dialog box

The Conveyor dialog box contains five (5)separate tabs:

• Operation• Maintenance• Maintenance Timers• Troubleshooting• Conveyor Width Calibration

Operation Tab -

Within the Operation tab, specific parametersrelated to the conveyor module can be enteredor changed to meet the requirements of aspecific recipe.

These entries may be saved in the existingrecipe to a new recipe — or even to a specificboard without being saved.

Conveyor

Conveyor SpeedIn the Set Point text box, enter the speed atwhich the conveyor is to operate, either inimperial or metric units, whichever isapplicable for your system configuration.Actual represents the present speed atwhich the conveyor is operating.While in the Manual mode the Start buttonis selectable for manual start of theconveyor. When the conveyor is started, the

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LED associated with Conveyor Speedilluminates green. The Start button thenchanges to a Stop button for the next modeof operation.Auto mode will also eventually start theconveyor after all other machineparameters have been satisfied for AutoStart.Conveyor WidthIn the Set Point text box, enter the width atwhich the conveyor is to operate, either inimperial or metric units, whichever isapplicable for your system configuration.The value range for this parameter is 50.8 -508.0 mm (2.00 - 20.00 in.)For optional conveyor width machines (16,18, 20, and 24 in.) the appropriate valuerange is displayed in the Current ValueRange area of the dialog box.

The conveyor width set pointshould be equal to the width ofthe boards being processed.

Actual represents the present width atwhich the conveyor is set.While in the Manual mode the Start buttonis selectable for manual start of theconveyor width adjustment. When conveyorwidth is started, the LED associated withConveyor Width illuminates green. TheStart button then changes to a Stop buttonfor the next mode of operation.Auto mode will also eventually start and setthe conveyor width after the necessarymachine parameters have been satisfiedfor auto start.Finger CleanerA check mark placed in the check boxassociated with Finger Cleaner indicates itis selected for Auto Start mode. Whenselected for Auto Start mode, the fingercleaner will eventually start after thenecessary machine parameters have beensatisfied for Auto Start.Click on the check box to either place orremove the check mark in the box.The Finger Cleaner Start button onlybecomes selectable once the conveyor isoperating.

When the Finger Cleaner is Off, Off isdisplayed in the text box under Actual.When the Finger Cleaner is On, On isdisplayed in the text box under Actual, theLED to the left illuminates green, and theStart button changes to a Stop button asthe next mode of operation.

Board -

Hole LengthThis parameter instructs the system toignore a hole smaller than the valueentered, in a board that is in-line with thephotocell. This prevents the system fromcounting multiple boards rather than asingle board.The value range for this parameter is 0.00 -508.0 mm (0.00 - 20.00 in.)For optional 24 in. machines the valuerange is 0.00 mm - 609.6 mm (0.00 - 24.00in.). (16, 18, and 20 in. options areavailable). Board spacing in the machinemust be greater than the hole length orthey will be ignored.PCB MultiplierIf running process using panels or palletsand there is more than one board, enter thenumber of boards in each panel or pallet.This will increment the “Number of Boards”by this value for each “board” that themachine detects.The value range for this parameter is 1 -100.Number Of Boards“Actual” represents the number of boardsprocessed through the system for the SetPoint is used to change the startingnumber for the “Number of Boards”processed.Total BoardsDisplays the total number of boards thatthe Electra™ has processed. Thisparameter is resettable under theMaintenance tab. The user must howeverhave machine configuration access.

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Maintenance Tab -

The Maintenance tab contains manual overrideStart buttons specifically for maintenancefunctions.

Figure 56: Conveyor Maintenance Tab

However, the machine must first be in the MANmode.

The S ta r t bu t tons l i s ted be low a l l owmaintenance personnel to perform what maynormally be automated functions:

Drive Motor

Conveyor On

• When the Start button is clicked, theLED associated with Conveyor Onilluminates green and the Start buttonchanges to Stop as the next mode ofoperation.

• The conveyor operates at the Set Pointentered next to Conveyor Speed in theConveyor Operation tab. Actual speedis displayed in the text box to the rightof the Conveyor On Start/ Stop button.

• All Start buttons except Conveyor Onbecome non-selectable.

• Click on the Conveyor On Stop

button to stop Conveyor On operation.

Jog In Reverse

• When the Jog In Reverse Start button isclicked, the LED to the left illuminatesgreen and the Start button changes toStop as the next mode of operation.

• The conveyor operates in reversedirection for approximately three (3)seconds.

• The text box to the right of the ConveyorOn Start button displays a speed of -0.3meters/ min. (-1.00 ft./min) during theJog In Reverse mode.

• All Start buttons except Jog In Reversebecome non-selectable while theconveyor operates in reverse mode.

Conveyor Width Motor

Move to Out Limit

• Click on the Move to Out Limit Startbutton to enable it.

• The LED to the left of Move to Out Limitilluminates green, and the Start buttonchanges to Stop as the next mode ofoperation.

• During the out to limit movement, allother Start button become non-selectable.

• The parameter value in the text boxnext to the Move to Width Start buttondisplays the width dimensions as theconveyor moves to the out limit.

• When the conveyor width reaches its

maximum width, a symbol appearsnext to the Move to Out Limit Startbutton — indicates the conveyor widthis at its limit.

• Move to In Limit and Move to WidthStart buttons are selectable when theconveyor width is at its widest position.

Move to In Limit

• Click on the Move to In Limit Startbutton to enable it.

• The LED to the left of Move to In Limitilluminates green, and the Start buttonchanges to Stop as the next mode ofoperation.

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• During the in to limit movement, allother Start button become non-selectable.

• The parameter value in the text boxnext to the Move to Width Start buttondisplays the width dimensions as theconveyor width decreases to theminimum width setting, 50.8 mm (2.00in.).

• When the conveyor width reaches its

minimum width, a symbol appearsnext to the Move to In Limit Start button— indicates the conveyor width is at itsnarrowest position.

• Move to Out Limit and Move to WidthStart buttons are selectable when theconveyor width reaches at itsnarrowest position.

Move to Width

• Click on the Move to Width Start buttonto enable it.

• The LED to the left of Move to Widthilluminates green, and the Start buttonchanges to Stop as the next mode ofoperation.

• The Move to Width Set Point is basedon the Conveyor Width Set Point in theOperation tab.

• If the conveyor width is at its out limitbefore starting the Move to Widthfunction, the Move to In Limit and Moveto Width LED’s illuminate green andthe Start buttons turn to Stop buttonsafter starting the Move to Widthfunction.

• If the conveyor width is at its in limitbefore starting the Move to Widthfunction, the Move to Out Limit andMove to Width LED’s illuminate greenan the Start buttons turn to Stopbuttons after starting the Move toWidth function.

• The parameter value in the text boxnext to the Move to Width Start buttondisplays the width dimensions as theconveyor width adjusts to Set Point.

• When the conveyor width reaches itsSet Point, all LED’s turn off, all buttons

revert to Start buttons, and the SetPoint value is displayed in the text boxassociated with Move to Width.

Drain Finger Cleaner

• Click on the Drain Finger Cleaner Startbutton to commence draining of thefinger cleaner tank.

W h e n d r a i n i n g t h e f i n g e rcleaner tank, the 3-way valvelocated near the tank must be

turned to the drain position to allow draining.

To avoid a chemical spill,ensure that the end ofhose to drain the finger

cleaner tank is placed into a containermarked for proper disposal prior to drainingthe tank.

• Once the Drain Finger Cleaner Startbutton is clicked, an Alert window isdisplayed indicating that the fingercleaner has started draining.

Figure 57: Finger cleaner draining alert

• Click on the OK button to acknowledge.• The Drain Finger Cleaner Start button

changes to Stop as the next mode ofoperation and the LED illuminatesgreen while draining.

• While the finger cleaner tank isdraining, the time elapsed is displayedin the text box associated with DrainFinger Cleaner.

• To stop draining the finger cleanertank, click on the Drain Finger Cleaner

Stop button.

• Once the Drain Finger Cleaner Stopbutton is clicked, an Alert window isdisplayed indicating that the fingercleaner has completed draining.

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Figure 58: Finger cleaner draining complete alert

• Click on the OK button to acknowledge.

To avoid a chemical spill,ensure that the f ingercleaner 3-way valve is

tu rned to the O f f o r Open pos i t i onimmediately after draining. This will preventchemicals from being inadvertently drainedto the floor.

Reset Board Count

• Resets the “PCB’s in Machine” countto zero (0).

Reset Total Boards

• Resets the “Total Boards to zero (0).This is displayed on the Operation Pagefor the Conveyor. This requiresConfiguration Access when security isactive.

Maintenance Timers -

The Maintenance Timers tab is designed for,and should be limited to use by, maintenancepersonnel. This tab contains timers which canbe set for specific intervals of maintenance forthe following conveyor components:

• Conveyor Level 1• Conveyor Level 2• Conveyor Level 3• Conveyor Level 4• Conveyor Level 5• Conveyor Speed• Conveyor Width• Finger Cleaner

• Click on the Maintenance Timers tab toaccess its features.

Figure 59: Conveyor Maintenance Timers tab

The eight (8) conveyor components listed in thelef t hand column are associated with aMaintenance Schedule found in the Electra™Maintenance manual. The different Levelsindicated refer to the frequency (Intervals) thatmaintenance is requi red for a speci f iccomponent, module, or series of maintenanceprocedures.

For Example:

Conveyor Level 1 is a series of Dailymaintenance procedures required at theend of each 24 hours. See the Sample chart

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Operation 2-9317-120-00-0 — Rev. 3 57

segment that follows.

Figure 60: Maintenance Level sample chart

Interval (hours)• Enter the expected interval time in

hours for maintenance to be performedon the module.

Time Remaining• The time displayed in the Time

Remaining text box indicates theamount of time remaining beforemaintenance is required for thismodule.

A T ime Exp i red message“Maintenance Required” isdisplayed in the Electra™ Status

Bar until maintenance is performed.

Total Run Time• This parameter displays the actual time

that the module has been “ON” sinceinstallation.

Complete• Click on the Complete button when the

maintenance task for this module hasbeen performed.A “Maintenance Note” windowappears. Notes for maintenance maybe entered in this window and storedas well. The note may be retrieved andviewed in the Log View MaintenanceScreen.

Restore Defaults Intervals• Click on the Restore Defaults Intervals

button to restore the system defaultinterval values.

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Troubleshooting Tab -

The Troubleshooting tab contains featuresspecifically for maintenance purposes.These features should be limited to use bymaintenance personnel only. This tabdisplays internal machine parameters thatthe computer is using, based on machineconfiguration and operation set points. Ifthere is a functionality problem related toany parameter pertaining to the Conveyor,the values provided here may provide theuser some indication as to what may becausing the problem.The machine must first be in the MANmode.

Figure 61: Conveyor Troubleshooting tab

Drive Motor

Alarm DelayReflects the time before the alarm isenabled. The timer counts down to zerowhen the conveyor speed is started.Motor SpeedThe actual present speed, in Hz, of theconveyor motor drive.

Conveyor Width Motor

ScalarFactors determined during calibration.OffsetThe correction value determined duringcalibration.Stall TimerThe time remaining for the conveyor toreach its programmed width or limitsbefore a stall alarm occurs.Motor SpeedThe actual present speed, in Hz, of theconveyor width motor drive.

Board Information

Board LengthDisplays the length of the board asdetermined by the incoming photocell.Hole LengthDisplays the length of any hole in the boardas determined by the incoming photocell.

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Conveyor Width Calibration Tab -

The Calibration tab contains features thatshould be limited to use by maintenancepersonnel only.

• Click on the MAN button icon at the topcenter of the graphic screen to place theElectra™ in the Manual Mode beforeutilizing the calibration features.

• Click anywhere on the conveyor module onthe graphic screen to open the Conveyordialog box.

• Click on the Conveyor Width Calibration tabto access the calibration functions.

When initialized, the Calibration tabcontains a single step — ConveyorWidth: Step 1.

Figure 62: Conveyor Width Calibration tab

Actual Width• Perform the calibration instructions as

they appear on-screen — Press theStart button to move width toward outlimit.

• The LED to the left of Actual Widthilluminates green while the calibrationof the outer limit takes place, and theStart button changes to Stop for thenext selection of operation.

• The value in the Actual Width text boxincreases until the conveyor widthreaches its maximum setting 510.5 mm(20.09 in.).

• For optional 24 in. machines themaximum width setting is 609.6 mm(24.0 in.). Optional widths of 16, 18, and20 in. are also available.Once the conveyor width reaches itslimit, the green LED turns off, the Startbutton becomes non-selectable, andan additional step appears in theConveyor Witdth Calibration tab —Conveyor Width: Step 2.

Figure 63: Conveyor Width: Step 2 field

Measured Out Width• Physically measure the width of the

conveyor adjustment performed by themachine in Conveyor Width: Step 1.

• Enter the measured conveyor width inthe text box next to Measured OutWidth, then press the Enter key on thekeyboard or click on the Apply button.

• Conveyor Width: Step 3 appears in thedialog box.


• Click on the Start button to move theconveyor width toward the limit.

• The LED for Conveyor Width: Step 3illuminates green while the conveyorwidth moves to the “In Limit”, and theStart button changes to a Stop buttonto cancel the operation.

• The value in the Actual Width text boxin Conveyor Width: Step 1 decreasesuntil the conveyor width reaches its “Inlimit”.

• Conveyor Width: Step 4 appears in thedialog box.

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Measured In Width• Physically measure the width of the

conveyor adjustment performed by themachine in Conveyor Width: Step 3.

• Enter the measured conveyor width inthe text box next to Measured In Widthin Conveyor Width: Step 4, then pressthe Enter key on the keyboard.

When the last step of the calibration iscompleted, a message is displayed underthe Calibration Status field…

… if everything is OK.

“Calibration Failed” is displayed ifsomething went wrong. The calibration isignored.• Troubleshoot the problem with the

conveyor width system, then repeat thecalibration procedure.

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FLUXER

The Electra™ machine may beconfigured for any one of thefluxer modules listed below.

H o w e v e r, t h e m a c h i n e s o f t w a r econfiguration must reflect actual hardwareinstalled on the machine. Fluxer dialog boxdisplays will vary in configuration from one tothe next. Refer to the fluxer operation sectionappliable to your machine configuration.

Fluxers Available

• Foam• Wave• Opti• Supa

The Opti and Supa spray typefluxers may also be configuredas External Fluxers.

Refer to the Electra OptionsManual for reference to the Opti-Flux spray fluxer features and

functions.

FOAM FLUXER

Foam Fluxer is a machine module dialog box.

To open the Foam Fluxer dialog box position thepointer device over any part of the fluxermodule on the graphic screen. Notice that thefluxer graphic highlights when the pointerdevice is placed over the graphic.

• Single click on the graphic to open theFoam Fluxer dialog box.

Figure 66: Foam Fluxer dialog box

The Foam Fluxer dialog box contains six (6)separate tabs:

• Operation• Maintenance• Maintenance Timers• Troubleshooting• Calibration• Timer

Operation Tab -

Within the Operation tab, specific parametersrelated to the Foam Fluxer module can beentered or changed to meet the requirementsof a specific recipe.

These entries may be saved in the existingrecipe or to a new recipe — or even applied to aspecific board without being saved.

The units appearing in eachdialog box is dependent onmachine configuration. Units

displayed in the graphic parts of this text aredepicted in imperial.

This section explains the operational featureswithin the Foam Fluxer Operation tab:

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62 2-9317-120-00-0 — Rev. 3 Operation

Fluxer

FluxerA check mark placed in the check boxassociated with Fluxer indicates it isselected for Auto Start mode. Whenselected for Atuto Start mode, the fluxerwill eventually start after the necessarymachine pareameters have been satisfiedfor Auto Start.• Click on the check box to either place

or remove the check mark in the box.• To start the fluxer manually click on the

MAN button icon to put the Electra™ inmanual mode. The Start button is non-selectable while in the Stop mode.

• When the fluxer is OFF, Off is displayedin the text box under Actual.

• When the fluxer is ON, On is displayedin the text box under Actual, the LED tothe left of Fluxer illuminates green, andthe Start button changes to a Stopbutton as the next mode of operation.

Auto-Start Delay• The value entered under Set Point

designates the amount of time (inseconds) the system waits before goingready after turning on the fluxer. Avalue range of 1 - 1800 seconds may beentered for this parameter.

Flux Level Control

High Level Drain PeriodAmount of time to run drain pump whenHigh level occurs. Should be set to lowerflux level to the midpoint between low andhigh level floats. A value range of 1 - 1800seconds may be entered for this parameter.Low Level Fill HysteresisAmount of time the Add pump continues torun after low level float is satisfied. This isto prevent cycling of the Add pump. A valuerange of 1 - 1800 seconds may be enteredfor this parameter.

Flux Density Control

Specific GravityRefer to the flux manufacturer’s materialdata sheet for the Specific Gravity Set Pointof the flux being used. Enter the SpecificGravity set point that the flux is to be

controlled to. A value range of 0.000 - 1.250g/cc (grams per cubic centimeter) may beentered for this parameter.Thinner Add PeriodEnter the amount of time in seconds thatthe thinner pump is to add thinner tocorrect the specific gravity of the flux. Setso that one (1) add period changes thespecific gravity by only 0.001. A value rangeof 1 - 1800 seconds may be entered for thisparameter.Thinner Sample RateEnter the amount of time the system waitsafter adding thinner to the flux beforechecking the specific gravity again. Thisvalue should be long enough to allow timefor the thinner to completely mix with theflux. Typical setting is 120 seconds. A valuerange of 1 - 1800 seconds may be enteredfor this parameter.Temperature ReferenceRefer to the flux manufacturer’s materialdata sheet of the flux being used for thebase temperature of the flux specific gravityspecification. Enter the base temperaturevalue in the text box under Set Point. Avalue range of 0 - 204 °C (0 - 400 °F) may beentered for this parameter.Temperature CoefficientRefer to the flux manufacturer’s data sheetof the flux being used. This parameterrepresents a correction factor for thespecific gravity if the actual temperature isdifferent than the reference temperature. Avalue range of 0.00000 - 0.100000 g/cc per°C may be entered for this parameter.

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Operation 2-9317-120-00-0 — Rev. 3 63

Maintenance Tab -

The Maintenance tab contains manual overrideStart buttons specifically for maintenancefunctions.

Figure 67: Foam Fluxer Maintenance tab

The machine must first be in MAN mode.


Manual

• Air• Circulating Pump*• Drain Pump*• Add Pump*• Thinner Pump*Level Control

• Drain Period• Fill Period

I tems wi th an* can not bestarted or stopped if the Timer isenabled. See Timer Tab for more

details.

When any of the listed Start buttons are clicked,the LED assoc ia ted w i th that funct ionilluminates green, and the Start button changesto Stop as the next selection of operation.

• Air

Click on the Air Start button to activate airto the aerator stones in the flux reservoir.

• Circulating PumpClick on the Circulating Pump Start buttonto enable the pump and circulate the flux.The Circulating Pump Start button will notbecome selectable if the flux level is low orempty.

• Drain PumpClick on the Drain Pump Start button todrain the flux reservoir.

• Add PumpClick on the Add Pump Start button to addflux to the flux reservoir.

• Thinner PumpClick on the Thinner Pump to add thinner tothe flux reservoir. The Thinner Pump Startbutton is not selectable when theCirculating Pump is not operating.

• Drain PeriodEnter the amount of Time in minutes todrain the fluxer; once this time expires thedrain pump stops. A value range of 1 - 30minutes may be entered for this parameter.

• Fill PeriodEnter the amount of Time in minutes to fillthe fluxer; once this time expires the lowliquid level alarm is armed. A value range of1 - 30 minutes may be entered for thisparameter.

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64 2-9317-120-00-0 — Rev. 3 Operation


The Maintenance Timers tab is designed for,and should be limited to use by operation andmaintenance personnel. This tab containstimers which can be set for specific intervals ofmaintenance for the following conveyorcomponents:

• Fluxer Level 1• Fluxer Level 2• Fluxer Level 3• Circulating Pump


Figure 68: Foam Fluxer Maintenance Timers tab

The four (4) fluxer components listed in the lefthand co lumn a re assoc ia ted w i th aMaintenance Schedule found in the Electra™Maintenance manual. The different Levelsindicated refer to the frequency (Intervals) thatmaintenance is requi red for a speci f iccomponent, module, or series of maintenanceprocedures.

For Example:

Fluxer Level 1 is a series of Dailymaintenance procedures required at theend of each 24 hours of operation. See theSample chart segment that follows.

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Operation 2-9317-120-00-0 — Rev. 3 65

Figure 69: Fluxer Maintenance Level 1 sample chart













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66 2-9317-120-00-0 — Rev. 3 Operation


The Troubleshooting tab contains featuresspecifically for maintenance purposes. Thesefea tu res shou ld be l im i ted to use bymaintenance personnel only. This tab displaysinternal machine parameters that the computeris using, based on machine configuration andoperation set points. If there is a functionalityproblem related to any parameter pertaining tothe Fluxer, the values provided here may givethe user some indication as to what may becausing the problem.

Figure 70: Fluxer Troubleshooting tab

Flux Level Control

High Level Delay TimerThe length of time that the high level mustremain high before the drain pump isstarted.Low Level Delay TimerThe length of time that is allowed,determined by the fill period, before armingthe low level alarm.High Level Alarm DelayThe time before the alarm is enabled;prevents false alarms.Low Level Alarm DelayThe time before the alarm is enabled;prevents false alarms.

Flux Density Control

Specific Gravity Alarm DelayThe time before the alarm is enabled;prevents false alarms.Specific Gravity Alarm TimerThe amount of time the flux density ispermitted to be out of tolerance before analarm occurs.Temperature OffsetThe correction value determined duringcalibration.

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Operation 2-9317-120-00-0 — Rev. 3 67

Calibration Tab -


• The Electra™ must first be in manual(MAN) mode before utilizing the calibrationfeatures.

• Click on the MAN button icon at the topcenter of the graphic screen to place theElectra™ in the manual mode.

• Click anywhere on the Fluxer module on thegraphic screen to open the Foam Fluxerdialog box.

• Click on the Calibration tab to access thecalibration functions.

When initialized, the Calibration tabcontains a single step — MeasuredTemperature.

• Perform the calibration instructions as theyappear on-screen — “To calibrate thetemperature, measure the currenttemperature of the fluxer and enter themeasured temperature in the field below”.

Figure 71: Foam Fluxer Calibration tab

• Using an accurate hand held thermometer,take a temperature reading of the flux asdirected, then enter the value in the textfield next to Measured Temperature.

• Click on the Apply button after entering themeasured temperature into the text box tocomplete the calibration of fluxtemperature.

The value in the Actual display next toMeasured Temperature displays themeasured temperature.

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Timer Tab -

The Timer tab only affects operation of the FDC(Flux Density Controller) and Level Control.

• Click on the Timer tab to access itsfeatures.

• Click on the check box next to Timer Enableto enable the timer. A check mark in thebox indicates it is enabled.

• To disable the timer, click on the check boxto remove the check mark.

Figure 72: Foam Fluxer Timer tab

To Set the Timer:

Using the pointer device and numberkeypad;

1. Set each day of the week starting time“On”, in military time, to enable operationof the FDC and Level Control.

2. Set each day of the week stop time “Off”that the FDC and Level control are to beturned off.

3. To allow the timer to skip non-operationaldays, enter 00:00:00 for time ON and00:00:01 for time OFF.

4. To allow the timer to always remain ON,enter 00:00:00 for time ON and 23:59:59 fortime OFF. This only allows the timer to turnoff for one (1) second (at midnight).

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Operation 2-9317-120-00-0 — Rev. 3 69

SOLDER POTSolder Pot is a machine module dialog box.

• Select Solder Pot by clicking on Moduleson the Menu Bar, then clicking on SolderPot in the drop-down list box.

Figure 73: Select Modules, Solder Pot

• Position the pointer device over any part ofthe solder module on the graphic screen.

Notice that the solder module graphichighlights and a text box pops up withthe Solder Pot parameters.

• Single click on the graphic to open theSolder Pot dialog box. Figure 74: Solder Pot dialog box

The Solder Pot dialog box contains eight (8)separate tabs:

• Operation• Standby• Maintenance• Maintenance Timers• Troubleshooting• Calibration• PID• Timer

Operation Tab -

Within the Operation tab, specific parametersre la ted to the so lde r modu le and i t scomponents can be entered or changed tomeet the requirements of a specific recipe.


The units appearing in eachdialog box is dependent onmachine configuration. Units

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70 2-9317-120-00-0 — Rev. 3 Operation

displayed in the graphic parts of this text isdepicted in imperial.

This section explains the operational featureswithin the Solder Pot Operation tab:

Solder Pot

Heater ElementWhile in Auto or Manual mode, and thesolder pot heaters are automatically ormanually activated, the Heater Elementindicator illuminates green, ONLY while .Whenever the solder pot heaters are turnedoff, the LED next to Heater Element turnsoff.Solder Temperature

• In the Set Point text box, enter thetemperature to which the solder pot is to beheated, either in imperial or metric units,whichever is applicable for your systemconfiguration.

• A Range Value of 221 - 287 °C (430 -550 °F)may be entered in the text box for thisparameter. If a value lower or higher thanthe specified range is entered, a ValueEntry Error pop-up window is displayed.

Figure 75: Value Entry Error window

• Actual represents the present temperatureof the solder in the pot. As the temperatureincreases, the value under Actual graduallyincreases — as the temperature decreases,so does the value under Actual.

• Note that while in the Auto or Stop mode,no buttons in the Operation tab areselectable. While in the Manual mode, thefollowing buttons are selectable foroperation:• Solder Temperature• Lambda Wave• Lead Clearance

If other Start buttons are visibleor selectable in your systemconfiguration that are not listed

on this page, refer to the Electra™ Optionmanual for that feature.

• Each of the listed features have either aStart or a Stop button available forselection as the next mode of operation.

Refer to the sect ion underManual or Auto Start for moredetails on these operations.

Solder Waves

Lambda™ Wave• The Lambda™ Wave can be started in

either the Manual or Auto Start mode.• First, the Set Point, in rpm’s, must be

entered in the text box for this feature. AValue Range of 425 - 1000 rpm’s may beentered for this variable.

• The Lambda™ Wave can not be starteduntil the solder temperature reaches theacceptable operating temperature 218 °C(425 °F).

• While the Start button is non-selectable,and the pointer device is positioned overthe Start button, a pop-up display messageappears stating …

Figure 76: Solder Temperature too low

• In Manual mode, after the soldertemperature reaches operatingtemperature, click on the Lambda™ WaveStart button. Note that the graphicrepresentation of the wave appearsoperating on the graphic screen.

• Actual rpm’s are visible in the Actual textbox across from Lambda™ Wave, and theLED associated with this featureilluminates green when the wave is active.

• When the start button is clicked, itimmediately changes to a Stop button astht next selection of operation.

• When starting the Electra™ in the AutoStart mode, once all preheat and conveyor

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Operation 2-9317-120-00-0 — Rev. 3 71

startup parameters have been satisfied, theLambda™ Wave and any other waveconfigured automatically start at the setpoints specified for that recipe.

Solder Options

Lead ClearanceThis feature allows product lead clearanceto be set, based on the length of the boards’components.

• Lead Clearance adjustment can be startedin either the Manual or Auto Start mode. Inthe Set Point text box, enter the requiredlead clearance to which the pot should beadjusted, either in imperial or metric units,whichever is applicable for your machineconfiguration.

• A Value Range of 6.3 - 101.6 mm (.25 - 4.00in.) may be entered for this variable.

• While in Manual mode Click on the LeadClearance button to adjust the clearance.

• When clicked, the solder pot adjusts itselfto the lead clearance designated in the SetPoint text box. The Actual value eitherincreases or decreases until the Set Pointvalue is reached.

• While the adjustment takes place, the LEDassociated with Lead Clearance illuminatesgreen, and the Start button changes to aStop button to cancel the operation.

• When the adjustment is complete, thegreen LED turns off and the Stop buttonreverts back to a Start button.

• When starting the machine in the AutoStart mode, the Lead Clearance functionautomatically adjusts to the parameterspecified for the recipe loaded.Wire/ Bar FeederWhen configured, the Wire/Bar Feederfeature appears in the Solder Pot dialog boxas an On or Off function.

• To enable the Wire/Bar Feeder for AutoStart, click on the box to the right this willplaces a check mark in the box. Clicking onthe box again removes the check mark.

• Under Actual, the text box displays Offwhen inactive and On when active.

• While in the Manual mode the Start buttonis available for manual start of the solder

feeder. When the feeder is started, the LEDto the left illuminates green. The Startbutton then changes to a Stop button tocancel the operation.

• Auto mode will start the solder feeder whenthe level of the solder in the pot is detectedas low level and the Wire/Bar Feeder barhas a check mark in it. The feeder thenactivates, adding solder until the properlevel within the pot is achieved, then shutsoff.

• Before the solder wire/bar feeder canbecome operational, the solder pot must berolled in to the in limit, the main wave mustbe “ON”, the solder temperature must beabove 218 °C (425 °F), and the solder levelremains low for 30 seconds or more.

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Standby Tab -

• Click on the Standby tab within the SolderPot dialog box to access it.

Figure 77: Solder Pot Standby tab

The Standby tab contains features to beused specifically for operation. Standbyallows the machine to decide when a boardis or is not present within a defined processparameter (window) — based on whetheror not a board is present, Standby willactivate and deactivate both the Lambda™/CoN2Tour and Rotary/Chip solder waves.

Standby Mode On• Click on the box to the right of Standby

Mode On to place a check mark in, orremove a check mark from the box.

• Placing a check mark in the boxenables Standby Mode On foractivation.

• When a check mark is placed in theStandby Mode On check box, theLambda/Contour Wave, Rotary/ChipWave, and Rotary speed LEDís in the

Solder Pot dialog box’s Operation tabfeatures, illuminate yellow. Thisindicates that the waves are presentlyoperating at Standby Speed until aboard is sensed within the definedwindow, then the waves operate at theSet Point speed defined in theOperation tab.

• No check mark in the box indicatesthat standby mode is not used and thewaves will operate at the set pointspeed defined in the operation tab.

Use Entire Conveyor• Click on the box to the right of Use

Entire Conveyor to place a check markin, or remove a check mark from thebox.

• Placing a check mark in the boxenables use of the entire conveyor asthe window in Standby Mode On,rather than a specific Start and End ofwindow.

• No check mark in the box indicates aspecific window range will be definedrather than using the entire conveyoras the window.

Lambda Wave

Standby SpeedThe value entered here will be the speed atwhich the Lambda/CoN2tour Wave will

operate until a board enters the definedwindow — the wave then operates at thespeed set for the recipe or set in theOperation tab.A Value Range of 425 - 1000 rpm’s may beentered for this parameter.Start of WindowEnter in inches (or millimeters), thedistance to engage the operations set pointfrom the center of the nozzle. A negativenumber engages the set point prior to thecenter and a positive number engages theset point after the center.A Value Range of –3,810.00 - 3,810.00 mm(–150.00 - 150.00 in.) may be entered for thisparameter.

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Operation 2-9317-120-00-0 — Rev. 3 73

Normal setpoint should be anegative number.

End of WindowEnter in inches (or millimeters), thedistance to dis-engage the operations setpoint from the center of the nozzle. Anegative number dis-engages the set pointprior to the center and a positive numberdis-engages the set point after the center.A Value Range of –3,810.00 - 3,810.00 mm(–150.00 - 150.00 in.) may be entered for thisparameter.

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74 2-9317-120-00-0 — Rev. 3 Operation

Maintenance Tab -

The Maintenance tab contains manual overrideStart buttons, specifically for maintenancefunctions. These features should be limited touse by maintenance personnel only.

Figure 78: Solder Pot Maintenance tab

The machine must first be in the MAN mode.


Solder Pot

• Solder Temperature Bypass

Damage to solder pumps,motors and belts couldresult if the solder pump

drive belts are not removed prior to startingthe pump motors using Solder Temperaturebypass. Remove the belts before turning onmotors. Proceed with CAUTION whenutilizing this function.

When the Start button is clicked, theLED illuminates green and a timerstarts counting down from 00:10:00 to

00:00:00 (10 minutes).The Start button changes to a Stopbutton — if clicked, revert back to aStart button again. Starting againstarts the timer over from 00:10:00.This allows the user to start the pumpmotors if the solder temperature isbelow (219 °C) 426 °F.

Roll Out

• Solder Pot In

• If the solder pot is already rolled in atits maximum position, the Start buttonis not available, and an in limit symbol

is displayed next to the Start button.• Once the pot is rolled out to any

position away from the in limit, thesymbol disappears, indicating that thepot is not completely rolled in.

• The Start button only becomesavailable when the pot has been rolledout, and the roll out function hasstopped.

• Click on the Start button to roll the potback to its in limit.

• The LED illuminates green. The SolderPot In function automatically stopswhen the in limit is reached.

• While the solder pot is rolled in, theJacking features; Solder Pot Up, SolderPot Down, and Lead Clearance areavailable for selection.

• Solder Pot Out

• If the solder pot is already rolled out toits maximum position, the Start buttonis not available, and an out limit symbol

is displayed next to the Start button.• If the solder pot is rolled in, click on the

Solder pot Out Start button to roll thepot out.

• The LED illuminates green, and theStart button changes to a Stop buttonto cancel the operation. The Solder PotOut function automatically stops whenthe out limit is reached. The pot may bestopped at any out position by clickingon the Stop button any time while thepot is being rolled out.

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Operation 2-9317-120-00-0 — Rev. 3 75

• While the solder pot is rolled out to anyposition, other than all the way out tolimit, only the Solder Pot Down Jackingfeature is available.

Jacking

• Solder Pot Up

• The Solder Pot Up Start button may notbe selected while the pot is eitherrolling in or rolling out.

• Once the pot is rolled all the way in orall the way out, the Solder Pot Up Startbutton may be selected.

• When the Start button is clicked, theLED illuminates green.

• The Lead Clearance text box displaysthe adjustment as it is beingperformed.

• When the pot reaches the up limit, thefunction automatically stops and thegreen LED that was illuminated turnsoff, and an up limit symbol appearsnext to the solder pot up start button.

• Solder Pot Down

• The Solder Pot Down Start button maynot be selected while the pot is eitherrolling in or rolling out.

• The Solder Pot Down Start button is notavailable for selection if the pot isalready at its down limit position.

• The Solder Pot Down function may beapplied to the pot while it is anywherein the out or in position.

• When the Solder Pot Down Start buttonis clicked, the Solder Pot Down LEDilluminates green.

• The Lead Clearance text box displaysthe adjustment as it is beingperformed.

• When the solder pot reaches its downlimit position, a down limit symbolappears next to the Solder Pot DownStart button.

• Lead Clearance

• Clicking on the Lead Clearance Startbutton manually forces the leadclearance adjustment to the setting inthe Operation tab.

• The LED illuminates green when theStart button is clicked, and the Startbutton changes to a Stop button tocancel the operation.

• The Solder Pot Up, Solder Pot In, SolderPot Down LED illuminates green,dependent upon direction of travelrequired.

• The adjustment is displayed in the textbox associated with this feature.

• When the adjustment is complete, theStop button reverts back to Start andthe LED’s turn off.

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76 2-9317-120-00-0 — Rev. 3 Operation


The Maintenance Timers tab is designed for,and should be limited to use by operation andmaintenance personnel. This tab containstimers which can be set for specific intervals ofmaintenance for the following Solder Potcomponents (depend ing on sys temconfiguration — there may be more or fewercomponents):

• Solder Level 1• Solder Level 2• Solder Level 3• Solder Level 4• Solder Heater• Lambda Wave• Chip Wave• Rotary Speed• Jacking Stand• Roll Out• Solder Feeder


Figure 79: Solder Pot Maintenance Timers tab

The Solder Pot components listed in the lefthand co lumn a re assoc ia ted w i th aMaintenance Schedule found in the Electra™Maintenance manual. The different Levels

indicated refer to the frequency (Intervals) thatmaintenance is requi red for a speci f iccomponent, module, or series of maintenanceprocedures.

For Example:

Solder Level 1 is a series of Dailymaintenance procedures required at theend of each 24 hours. See the Sample chartsegment that follows.

NOTE All level 1, 2, 3, and 4 timers are freerunning. All specific timers, i.e., SolderHeater, are based on their function beingactive (ON).

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Operation 2-9317-120-00-0 — Rev. 3 77

Figure 80: Solder Module Maintenance Level 1 sample chart













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78 2-9317-120-00-0 — Rev. 3 Operation


The Troubleshooting tab contains featuresspecifically for maintenance functions. Thesefea tu res shou ld be l im i ted to use bymaintenance personnel only.

This is a display of internal machine parametersthat the computer is using, based on machineconfiguration and operation set points.

If there is a functionality problem related to anyparameter pertaining to the Solder Pot, thevalues provided here may give the user someindication as to what may be causing theproblem.

Figure 81: Solder Pot Troubleshooting tab

The machine must first be in the Manual (MAN)mode.

Solder Temperature

Temperature OffsetThe correction value determined duringcalibration.Alarm DelayDisplays the time remaining before thealarm is enabled.

Lead Clearance

ScalarA correction value determined duringcalibration.OffsetA correction value determined duringcalibration.Stall TimerThe time remaining for the Solder pot toreach it’s programmed Lead Clearancebefore a stall alarm occurs.Motor SpeedThe actual current speed, in Hz, of theJacking motor drive.

Roll Out

Stall TimerDisplays the time remaining for the Solderpot to reach it’s limits of Roll Out or Roll In,before a stall alarm occurs.Motor SpeedThe actual current speed, in Hz, of the RollOut motor drive.

Wave Motor Speeds

Lambda/Contour WaveDisplays the actual present speed, in Hz, ofthe Lambda™/CoN2tour™ Wave motor

drive.

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Operation 2-9317-120-00-0 — Rev. 3 79

Calibration Tab -


The machine must first be in the MAN mode.

Click on the Calibration tab within the SolderPot dialog box to access its features.

Figure 82: Solder Pot Calibration tab

The Calibration tab displays two (2) separatecategories when initialized — MeasuredTemperature and Lead Clearance:

Measured Temperature

• Allow the actual solder pot temperature tostabilize or reach set point temperature.Refer to the Operation tab for the Set Pointtemperature.

• Follow the on-screen instructions under theSolder Temperature category, MeasuredTemperature.

Figure 83: Measured Temperature field

“To calibrate the solder pot temperature,measure the current temperature at thesolder pot and enter the measuredtemperature in the field below”.

• This is caluclated by using a hand held,accurate thermometer, and submergingthe probe into the solder near the solderpot thermocouple, or 25 mm (1.0 in.) intothe solder wave.

• Click on the Apply button in the lowersection of the dialog box to accept the valueentered.

Lead Clearance: Step 1

Actual Height

Figure 84: Lead Clearance Step 1

• Click on the button next to Actual Height tomove the solder pot toward the up limit.

• As the adjustment takes place, the LEDilluminates green, and the Start buttonchanges to a Stop button to cancel theoperation.

• When the up limit for the Lead Clearancehas completed positioning, the LED turnsoff and a Lead Clearance: Step 2 category isdisplayed in the Calibration tab.


Measured Height


• Follow the on-screen instruction under theLead Clearance: Step 2 category, MeasuredHeight…“Enter the measured solder pot height”.

• This is calculated by physically measuring

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80 2-9317-120-00-0 — Rev. 3 Operation

the solder pot height distance from thebottom of a PCB to the top of the incomingcurved plate on the main wave.

• Enter the measured height in the text boxnext to Measured Height, then press theEnter key on the keyboard to accept thevalue entered.

• Lead Clearance: Step 3 appears in theCalibration tab.



• Step 3 prompts the user to click on theStart button to move the solder pot towardthe down limit.

• When clicked, the Actual Height in theLead Clearance: Step1 section changes tothe down limit, the LED in Step 3illuminates green while the calibration ofthe down limit takes place, and the Startbutton changes to a Stop button to cancelthe operation.

• Lead Clearance: Step 4 appears in thedialog box.


Measured Height


• Follow the instructions under LeadClearance: Step 4…“Enter the measured solder pot height”.

• This value is calculated by physicallymeasuring the solder pot heightadjustment performed by the machine inLead Clearance: Step 3.

• Enter the measured distance in the text boxnext to Measured Height, then press theEnter key on the keyboard to accept thevalue entered.

• Step 4 completes the calibration for thesolder pot.

Calibration Status

When the last step of the calibration iscompleted, a message is displayed underthe Calibration Status field…

Figure 88: Calibration Status field

… if everything is OK.“Calibration Failed” is displayed ifsomething went wrong — the calibration isignored.

• Troubleshoot the problem with the leadclearance system, then repeat thecalibration procedure.

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PID Tab -

The P ID fea tures are des igned for usespecifically by Process Engineers or personnelexperienced in PID calculations.

In an attempt to improve heater performancefor unusual load conditions, experiencedpersonnel may modify parameters using thePID features.

Click on the PID tab within the Solder Pot dialogbox to access its features.

Figure 89: Solder Pot PID tab

• ProportionalSet proportional band in %. A Value Rangeof 1 - 100% may be entered for thisparameter.

• IntegralEnter a time value in seconds to calculateError for integral purpose. A Value Range of0.0 - 60.0 seconds may be entered for thisparameter.

• Output MaximumLimit Duty Cycle to prevent eruption andstress in the Solder Pot.Reducing the Output Maximum reduces

the occurrence of solder eruptions,however, increases the solder heat up time.

• Duty CycleDisplays the value of output in %; may varyfrom 0 to Output Maximum.

• ErrorDisplays the difference between setpointand actual temperature.

• Accumulated IntegralDisplays the integral or reset value tocompensate for an offset condition.

• Restore DefaultsTo restore default values for the PIDfeatures, click on the Restore Defaultsbutton.

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Timer Tab -

The Timer tab affects operation of the SolderPot heaters.

• Click on the Timer tab to access itsfeatures.

• Click on the check box next to Timer Enableto enable the timer. A check mark in thebox indicates it is enabled.

• To disable the timer, click on the check boxto remove the check mark.

Figure 90: Foam Fluxer Timer tab

To Set the Timer:

Using the pointer device and numberkeypad;

1. Set each day of the week start time “On”,in military time, to enable operation of thesolder pot heaters. It is recommended toenable the heaters at least three (3) hoursprior to running process.

2. Set each day of the week stop time “Off”that the soler pot heaters are to be turnedoff — usually at the end of each day ofoperation.

3. To allow the timer to skip non-operationaldays, enter 00:00:00 for time ON and

00:00:01 for time OFF. This will only allowthe timer to enable functions for one (1)second.

4. To allow the timer to always remain ON,enter 00:00:00 for time ON and 23:59:59 fortime OFF. This only allows the timer to turnoff for one (1) second.

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Operation 2-9317-120-00-0 — Rev. 3 83

HOT KNIFERefer to the Electra™ Options Manual — seeand CoN2Tour Plus TM options.

LOWER PREHEAT 1 (CONVECTION)Refer to the Electra™ Options Manual — seeOptional Vectaheat™ Preheaters.

LOWER PREHEAT 1 (RADIANT)Lower Preheater 1 is a machine module dialogbox.

Lower Preheater 1 is the lowerpreheat module closest to thesolder pot.

To open the Preheater 1 dialog box, position thepointer device over any part of Lower Preheater1 module on the graphic screen. Notice that thepreheat module highlights when the pointerdevice is placed over the graphic.

• Single click on the graphic to open LowerPreheater 1 dialog box.

Figure 91: Lower Preheater 1 dialog box

The Preheater 1 dialog box contains five (5)separate tabs:

• Operation• Maintenance Timers• Troubleshooting• Calibration• PID

Operation Tab -

Within the Operation tab, specific parametersrelated to the Preheater module and itscomponents can be entered or changed tomeet the requirements of a specific recipe.


Heater

Heater ElementWhen power is applied to the heaterelement the LED next to Heater Elementilluminates green.TemperatureWhile in the Auto or Manual mode, and thepreheaters are automatically or manuallyactivated, the Heater Temperature indicatorLED illuminates green. Whenever thepreheater is turned off, the LED next toTemperature turns off.

• In the Set Point text box, enter thetemperature the Preheater will control to,either in imperial or metric units, whicheveris applicable for your system configuration,then click on the Apply button or press theEnter key on the keyboard.

• When Closed Loop Control is NOTactivated, Actual temperature is displayedin a text box in the Actual column acrossfrom Temperature. As temperatureincreases, the value under Actual graduallyincreases — as the temperature decreases,so does the value under Actual.

Whi le in an Auto mode, nobuttons are available. While int h e M a n u a l m o d e , t h e

Temperature Start button is available.

• Click on the Start button while in Manualmode to activate the preheater.

• The LED illuminates green, the Start buttonchanges to a Stop button as the nextselection of operation, the temperaturestarts increasing to the Set Point, and theHeater Element indicator illuminatesgreen.

• As temperature increases, approaching SetPoint, the Heater Element indicator willcycle OFF and ON as the temperature of thepreheater fluctuates up and down. As thepreheater cools between fluctuations theLED turns ON indicating it is heating again.As the temperature nears Set Point againthe heaters will cycle OFF again.Auto Start Delay

• Displays the time remaining beforepreheats will display as complete in the

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Auto-Startup Status screen.• This value is set in Preheaters

Configuration. Refer to the section in thismanual under Module Configuration,Preheaters tab for more details.

Closed Loop

This feature is displayed only if aPyrometer is configured on theElectra™.

Closed Loop On• Click in box to enable the Closed Loop

control.TemperatureThe Set Point text box displays the Setpointcorrected by Closed Loop Control as setupin the Optional Pyrometer Module. Refer tothe Electra™ Options Manual for moredetails pertaining to the OptionalPyrometer.The Actual text box displays the Actualtemperature of the preheater, when ClosedLoop Control is activated.


The Maintenance Timers tab is designed for,and should be limited to use by operation andmaintenance personnel. This tab containstimers which can be set for specific intervals ofmaintenance for the following Lower Preheatercomponents:

• Heater Level 1• Heater Level 2• Heater


Figure 92: Lower Preheater 1 Maintenance Timers

The Lower Preheater components listed in thelef t hand column are associated with aMaintenance Schedule found in the Electra™Maintenance manual. The different Levelsindicated refer to the frequency (Intervals) thatmaintenance is requi red for a speci f iccomponent, module, or series of maintenanceprocedures.

For Example:

Heater Level 1 is a series of Weeklymaintenance procedures required at theend of each 168 hours. See the Samplechart segment that follows.

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Operation 2-9317-120-00-0 — Rev. 3 85

Figure 93: Preheat Module Maintenance Level 1 sample chart













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The Troubleshooting tab contains featuresspecifically for maintenance purposes. Thesefea tu res shou ld be l im i ted to use bymaintenance personnel only.

Click on the Troubleshooting tab within theLower Preheater 1 dialog box to access itsfeatures.

Figure 94: Lower Preheater 1 Troubleshooting tab

The Troubleshooting tab displays internalmachine parameters that the computer isusing, based on machine configuration andoperation set points.

If there is a a functionality problem related toany parameter pertaining to Preheater, thevalues provided here may provide the usersome indication as to what may be causing theproblem.

Temperature Offset

A correction value determined duringcalibration.

Closed-Loop Offset

A correction value determined by theclosed loop mode for correction.

Alarm Delay

Displays the amount of time remainingbefore the alarm is enabled; allows forstabilizing the temperature.

Conveyor Interlock Timer

Displays the amount of time remaining beforethe Preheater is to be turned off by the Electra™software, if the conveyor is not running.

Calibration Tab -


This procedure requires the use of theThermocouple Test and Calibration Cableassembly p/n 3-0954-077-01-6. This assembly isincluded in the Electra™ tool kit, shipped withthe sys tem. In add i t i on , the use o f a“Thermocouple Simulator” is required. Thisitem is NOT included in the Electra™ tool kit.

1. At the operator console, click on the MANbutton icon at the top center of the screento place the Electra™ in the Manual Mode.

2. Click on Lower Preheater 1 on the graphicscreen to open the Preheater dialog boxassociated with that particular preheater.

3. Click on the Calibration tab

4. Follow the instructions as they appear inthe Calibration tab. “To calibrate thepreheater, measure the currenttemperature at the preheater and enter themeasured temperature in the field below”.

Figure 95: Lower Preheater 1 Calibration tab

5. There are two (2) methods to performingthis calibration.

Method 1 (Preferred)

A. The first method utilizes connectors P1,P5, and the shield ground connector onthe Thermocouple Test and calibrationcable assembly and a thermocouplesimulator.

B. Unplug the thermocouple from under thePreheater assembly.

C. Plug P1 into the thermocouple simulator.

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Operation 2-9317-120-00-0 — Rev. 3 87

D. Plug P5 into the thermocouple receptacleon the Preheater.

E. Plug the ground plug into any groundedconnector on the Electra™.

F. Set the simulator for 700 °F. If the system isset up for degrees C set the simulator to371 °C.

G. If the actual field gets the same responseas set in by the simulator, it is notnecessary to enter a value into theMeasured Temperature field.

If the reading is higher or lower, enter that valuein the Measured Temperature field.

Method 2 (Alternate)

A. The second method utilizes connectorsP1, P2, and the shield ground connectoron the Thermocouple Test and CalibrationCable, and a Thermocouple Simulator.

B. Open the rear electrical enclosure.

C. Plug P1 of the test cable into thethermocouple simulator.

D. Plug P2 of the test cable into the P2, P3,P4 or P5 connector on Analog I/OInterface Board #5 or P2 or P3 connectoron Analog I/O Interface Board #6.

The P connector depends onwhich Prehea te r i s be ingcalibrated.

E. Plug the ground plug into any groundedconnector on the Electra™.

F. Set the simulator for 700 °F. If the system isset up for degrees C set the simulator to371 °C.

G. If the actual field gets the same responseas set in by the simulator, it is notnecessary to enter a value into theMeasured Temperature field.

If the reading is higher or lower, enter that valuein the Measured Temperature field.

Figure 96: Thermocouple Test and Calibration Cable Assembly

6. After completing the calibration be sure tore-connect the thermocouple plugs backinto their respective receptacles at eitherthe heater or the I/O interface board.

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PID Tab -

The P ID fea tures are des igned for usespecifically by Process Engineers or personnelexperienced in PID calculations.

In an attempt to improve heater performancefor unusual load conditions, experiencedpersonnel may modify parameters using thePID features.

Click on the PID tab within the Lower Preheater1 dialog box to access it.

Figure 97: Lower Preheater 1 PID tab

• ProportionalSet proportional band in %. A Value Rangeof 1 - 100% may be entered for thisparameter.

• IntegralEnter a time value in seconds to calculateError for integral purpose. A Value Range of0.0 - 60.0 seconds may be entered for thisparameter.

• DerivativeEnter a time value in seconds to calculaterate or slope for derivative purpose. A ValueRange of 0.0 - 60.0 seconds may be enteredfor this parameter.

• Duty CycleDisplays the value of output in %; may varyfrom 0 to 100%.

• ErrorDisplays the difference between setpointand actual temperature.

• Accumulated IntegralDisplays the integral or reset value tocompensate for an offset condition.

• Derivative ChangeDisplays the derivative or rate value used toprevent any fast change in systemconditions.

• Restore DefaultsTo restore default values for the PIDfeatures, click on the Restore Defaultsbutton. Any previous changes made to PIDparameters are lost when defaults arerestored.

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LOWER PREHEAT 2 & 3

The features of Lower Preheater2 & 3 dialog boxes are identicalto the f ea tu res o f Lower

Preheater 1 dialog box. Refer to the sectionon Lower Preheat 1 for all informationregarding Lower Preheat 2 & 3.

UPPER PREHEAT 1 - 3The features of Upper Preheater 1 -3 dialog boxes are identical to thefeatures of Lower Preheater 1

dialog box. Refer to the section on LowerPreheat 1 for all information regarding UpperPreheat 1 - 3.

PYROMETERRefer to the Electra™ Options Manual — seePyrometer option.

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ANALOG I/OAnalog I/O is a machine module dialog box.

The Analog I/O module dialog box can beopened by clicking on Modules on the MenuBar, then clicking on Analog I/O in the drop-down list box.

Figure 98: Select Modules, Analog I/O

The Analog I/O dialog box is displayed with allthe Analog related I/O’s listed.

Figure 99: Analog I/O dialog box

The features within the Analog I/O dialog boxare des igne d fo r use b y ma in te nancepersonnel.

The data provided is strictly for viewing,intended for use in troubleshooting proceduressuch as the confirming of input and output (I/O)signals and determining the validity of the data.

The data within the dialog box lists the I/OName, with the Type being an Input or Outputsignal.

The Board, I/O Number represents which I/Oboard and channel is associated with the Typeand I/O Name listed.

The Value represents a DC voltage reading,ranging from 0 - 10 VDC, associated with theinput or output being generated.

To view the remaining data on the list, simplyclick and hold the lower right arrow on the rightside scroll bar unti l the data required isviewable.

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Operation 2-9317-120-00-0 — Rev. 3 91

DIGITAL I/ODigital I/O is a machine module dialog box.

The Digital I/O module dialog box can beopened by clicking on Modules on the MenuBar, then clicking on Digital I/O in the drop-down list box.

Figure 100: Select Modules, Digital I/O

The Digital I/O dialog box is displayed with allthe Digital related I/Oís listed.

Figure 101: Digital I/O dialog box

The features within the Digital I/O dialog boxare d e s ig ne d fo r use b y ma i n tenancepersonnel.

The data provided is strictly for viewing,intended for use in troubleshooting proceduressuch as the confirming of input and output (I/O)signals and determining the validity of the data.

The data within the dialog box lists the I/OName, with the Type being an Input or Outputsignal.

The Board, I/O Number represents which I/Oboard and channel is associated with the Typeand I/O Name listed.

The Value represents the status for a digital I/O,either On or Off.

To view the remaining data on the list, simplyclick and hold the lower right arrow on the rightside scroll bar until the data required isviewable.

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4.3 CONFIGURATION FEATURESFeatures that appear in the drop-down list boxunder Configuration are all configurablemodules within the Electra™ software.

The fol lowing modules are l isted underConfiguration from the Menu Bar:

• Alarms• Data Log• Modules• Quick View• Security• Specials• Units

ALARMS• Click on Configuration on the Menu Bar,

then click on Alarms in the drop-down listbox to open the Alarms Configurationdialog box.

Figure 102: Select Configuration, Alarms

Figure 103: Configure Alarms dialog box

There are six (6) fields associated with alarmconfiguration:

1. Alarm Name

2. Action

3. % Alarm

4. Repeat

5. % Process

6. Repeat Time

Alarm Name -

is the name of the actual alarm associated witha specific condition that may occur.

Action -

allows the user to define what type of alarm isto presented by the software. There are three (3)basic choices of action, of which only one (1)may be selected for a specific Alarm Name:

• Ignore - ignores all alarm conditions.• Warning - sounds an audible alarm and

displays a message on the screen.• Soft Stop - stops all modules of the

machine except the conveyor. After allremaining PCB’s have exited themachine, the machine shuts down.

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Operation 2-9317-120-00-0 — Rev. 3 93

% Alarm -

Alarms are entered, in a percentage value, totell the software what range from set point themachine will be allowed to deviate beforealarming.

For Example:The conveyor speed’s set point is at 10FPM.Alarm Name - Conveyor Speed Out ofTolerance; % Alarm - 10.00By setting the % Alarm to 10, the speed ofthe conveyor is allowed to deviate from setpoint by 10 %, in the + or – range (min.speed = 9 FPM; max. speed = 11 FPM)before an alarm occurs.

Repeat -

some alarms may be repeated if an alarmcondition is not corrected.

% Process -

For some alarm features, color codedindication for visual representation of thedeviation from the % Process value entered isprovided. The colors used are RED, BLUE,and BLACK.

• RED - If actual exceeds the set pointvalue by the amount entered for thedeviation value (% Process), the Actualvalue is displayed RED.

• BLUE - If actual falls below the set pointvalue by the amount entered for thedeviation value (% Process), the Actualvalue is displayed

• BLACK - The actual value is displayedin BLACK text when the value displayedis within tolerance of the % Process, orif the feature is off.

Repeat Time -

The value entered in the text box field (inminutes) tells the software how often to Repeatan alarm that has not been cleared.

DATA LOG• Click on Configuration on the Menu Bar,

then click on Data Log in the drop-down listbox to open the Data Log Configurationdialog box.

Figure 104: Select Configuration, Data Log

The Electra™ must be in manual(MAN) or auto (GO) mode torecord data.

Figure 105: Configure Data Log dialog box

Logging Interval

A single selection must be made in thiscategory.

• Noneno DataLog in Action.

• Board BasedDepending on the parameter to logselected, the data will be collected for theselected parameter(s) each time thesystem has processed this many boards.

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• Time BasedData will be collected for the selectedparameter(s) every X number of seconds.

File Format

Select one category

• Comma DelimitedUtilizes commas between fields todifferentiate the fields in a data base.

• Tab DelimitedUtilizes tabs between fields to differentiatethe fields in a data base.

Maximum File Size

• No LimitUsed for storing on the Hard Disk or aNetwork

• 1.44 MegabytesUsed for storing on a Floppy Disk.

Current File

• FileFile name where data will be store.

• PathPath where the file is located.

• Select Data Log PathTo change the Path to the file name.

• Parameters To LogSelect as many items as you want to collectdata for this particular file.

The output is in ASCII formatwith the first line of the outputindicating the order of the items

being logged.

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Operation 2-9317-120-00-0 — Rev. 3 95

MODULES

The machine must be in theAUTO-STOP mode to enable theModule Configuration function.

Access to any configuration function of theElectra™ must be defined by the ProcessAdministrator within the Configure Securitydialog box. Configuration access must belimited to use by the Process Administratoronly.

Once specific modules have been configuredinto the module configuration (factory set), thisfeature should not require additional access.Access may be required, only if a specificmodule of the Electra™ has been removed orreplaced with a different module, or if anotheroption has been added to the Electra™ tochange its original configuration.

Do not attempt to add,remove, or change anyse lect ions wi th in the

module tabs that have not f i rs t beenphysically installed, removed or changed onthe machine. This could result in eroneousalarms and messages.

• Click on Configuration on the Menu Bar,then click on Modules in the drop-down listbox to open the Module Configurationdialog box.

Figure 106: Select Configuration, Modules

Figure 107: Module Configuration dialog box

The Module Configuration dialog box displaysall Modules, standard and optional, which areconfigurable.

There are twelve (12) individual module tabswithin the Module Configuration dialog box:

1. Conveyor

2. Fluxers

3. Preheaters

4. Pyrometer

5. Solder Pot

6. Light Tower

7. Custom Inputs

8. Custom Outputs

9. Communications

10. Barcode Reader

11. GEM

12. Miscellaneous

Each module’s tab contains features or optionspertinent to the components built into themachine.

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Conveyor Tab -

• Click on the Conveyor tab within theModule Configuration dialog box to accessConveyor configuration options.

Figure 108: Module Configuration Conveyor tab


Conveyor module tab that has not first beenphysically installed, removed or changed onthe machine. This could result in eroneousalarms and messages.

Conveyor Direction

Selection of only one (1) item is permittedwithin this category.

To select features within the ConveyorDirection and Conveyor Type categories, usethe pointing device and click on the bulletbox that it is associated with. A bullet presentin the bullet box indicates it is selected.

• Left To RightSelect this conveyor direction if theconveyor installed in your machinetransports PCB’s at an incline from left toright.

• Right To LeftSelect this conveyor direction if theconveyor installed in your machinetransports PCB’s at an incline from right toleft.

Conveyor Type


• FingerThis selection indicates the presence of aFinger type conveyor.

• PalletThis selection indicates the presence of aPallet type conveyor.

• LugThis selection indicates the presence of aLug type conveyor.

Conveyor Width


• 16 inchesThis selection indicates the presence of a16 inch width capacity conveyor.

• 18 inchesThis selection indicates the presence of an18 inch width capacity conveyor.


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Conveyor Options

Selection of the following options is made usingthe pointing device and clicking on the checkbox associated with it. A check mark present inthe box indicates it is selected.

• Cooling FansSelection of this option indicates thatCooling Fans are installed at the exit end ofthe conveyor system.

• Motorized PCB SupportThis selection indicates the presence of amotorized board support system on theconveyor. Ensure this feature is installedprior to selecting it. Selection of this item isindicated by a check mark in the boxassociated with this feature.

• SMEMAClick to enable SMEMA (Surface MountEquipment Manufacturing Association).

Conveyor Board Exit Sensor

• Board Exit Sensor Click on the check box to the left of thisoption to place or remove a check mark inthe box. A check mark in the check boxindicates that it is selected. The exit sensoris located at the unload end of themachine.

• Distance from input sensor Distance from incoming photocell and exitphotocell in mm or inches.

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Fluxers Tab -

• Click on the Fluxers tab within the ModuleConfiguration dialog box to access Fluxerconfiguration options.

Figure 109: Module Configuration Fluxer tab

Do not a t tempt to add,remove , o r change anyselections within the Fluxers

module tab that has not first been physicallyinstalled, removed or changed on the machine.This could result in eroneous alarms ormessages.

Selection of an option is made using thepointing device and clicking on the bullet boxthat it is associated with.

A bullet present in the bullet box indicates it isselected.

Only one (1) selection may be made within theexternal “Fluxer Type” field.

When selecting an External orInternal Opti or Supa spray typefluxer, the operating parameters

should be entered in the configuration tabscreen as well. Refer to the Electra™ Optionsmanual for parameter setup information.

External Fluxer

• NoneWhen selected indicates that NO fluxer isinstalled on the outside of the mainmachine cabinet.

• FoamIndicates the presence of a Foam fluxer.

• WaveIndicates the presence of a Wave fluxer.

• OptiIndicates the presence of an ultrasonic,reciprocating spray head type fluxer.

• SupaIndicates the presence of a traversing headtype spray type fluxer.

• JetFluxIndicates the presence of a stationary,programmable jet nozzle type spray fluxer.

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Internal Fluxer

Only one (1) selection may be made within theinternal “Fluxer Type” field.

• NoneWhen selected indicates that NO fluxer isinstalled in the machine.

• FoamIndicates the presence of a Foam fluxer.

• WaveIndicates the presence of a Wave fluxer.

• OptiIndicates the presence of an ultrasonic,reciprocating spray head type fluxer.

• SupaIndicates the presence of a traversing headtype spray type fluxer.

When selecting Foam or Wavea s t h e t y p e o f f l u x e r, thefollowing selections associated

with this type of fluxer are also available. Ifany of these options are installed, theyshould be selected.

• FDC (PAAR - Flux Density Controller)• Options

FDC

• NoneSelect this item if there is not an FDC (FluxDensity Control) installed.

• PaarSelection of this option indicates thepresence of an FDC with the Foam or Wavefluxer.

Options

• Level Control Select this item if the Level Control featureof the FDC unit is installed.Selection of this item is indicated by acheck mark in the box associated with thisfeature. Clicking on the box using thepointing device will either place or removethe check mark in the box.

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Preheaters Tab -

• Click on the Preheaters tab within theModule Configuration dialog box to accessPreheater configuration options.

Figure 110: Module Configuration Preheaters tab


Preheaters module tab that has not first beenphysically installed, removed or changed onthe machine. This could result in eroneousalarms or messages.

Selection of an option is made using thepointing device and clicking on the arrow in thescrol l bar of the drop-down l ist box andhighlighting the option. The selected optionappears in the drop-down l ist box whenreleasing the pointing device.

The following describes each of the optionalselections listed within the Preheaters tab:

Lower 1

Lower 2

Lower 3

Each may be configured as one (1) of three (3)choices:

• NoneWhen selected indicates NO preheaterinstalled in the designated preheaterlocation.

• RadiantWhen selected indicates this type ofpreheater is installed in the designatedpreheater location.

• ConvectionWhen selected indicates a Vectaheat™ typepreheater is installed in the designatedlocation.

Upper 1

Upper 2

Upper 3

Each may be configured as one (1) of two (2)choices:

• NoneWhen selected indicates NO preheaterinstalled in the designated preheaterlocation.

• RadiantWhen selected indicates this type ofpreheater is installed in the designatedpreheater location.

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Auto Start Delay

Enter a value in this field to stipulate theamount of time the software will delaybefore going to Ready after the preheat hasreached setpoint. This is to provide thepreheaters time to stabilize the machine’sinternal temperature before starting theprocess. A Value Range of 1 - 1800 secondsmay be entered for this parameter.

Pyrometer Tab -

Click on the Pyrometer tab within the ModuleConfiguration dialog box to access the OptionalPyrometer configuration features.

Figure 111: Module Configuration Pyrometer tab


Pyrometer module tab that has not first beenphysically installed, removed or changed onthe machine. This could result in eroneousalarms or messages.

• Pyrometer PresentClick on the check box to the right of thisoption to place or remove a check mark inthe box. A check mark in the box indicatesa Pyrometer is installed in the machine. Anempty check box indicates a Pyrometer isnot installed or is not being utilized.

• Distance from Input sensorThe Starting Position refers to the distancefrom the photocell at the load end of theElectra™, to the leading edge of thepyrometer, where it actually begins readingwhen a board approaches. A Value Rangeof 0.00 - 3810 mm (0.00 - 150 in.) may beentered for this parameter.

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Solder Pot Tab -

• Click on the Solder Pot tab within theModule Configuration dialog box to accessSolder Pot configuration options.

Figure 112: Module Configuration Solder Pot tab


Solder Pot module tab that has not first beenphysically installed, removed or changed onthe machine.

It is possible for all featureslisted under the Options field, tobe selected, if all the options are

installed on the machine.

Selection of an option is made using thepointing device and clicking on the check boxthat it is associated with. A check mark presentin the box indicates it is selected.

Options

• Omega WaveSelection of this option indicates thepresence of a Lambda™ nozzle and Omegavibrator.

• Chip WaveSelection of this option indicates a ChipWave nozzle is installed in the solder pot.

• Rotary Chip WaveThis option is only available if the ChipWave has been selected. Selection of this

option indicates that the Rotary Chip Wavefeature for the Chip Wave is installed.

• Wave Height ControlSelection of this option indicates thepresence of a sensor used to maintainspecific wave heights as the solder level inthe solder pot changes.

• Finger MasksSelection of this option indicates thatFinger Masks are installed on the fixed ormoveable rail at the fluxer and solder pot.

• Solder Level SensorSelection of this option indicates thepresence of a Solder Level Sensor used todetect the level of solder in the pot. Thesensor is used in conjuction with a solderfeeder, to maintain solder level in the pot.

• Hot KnifeSelection of the Hot Knife option indicatesthat a Hot Knife debridging system isinstalled immediately after the solderwaves.

• Manual Wave ControlA special option to allow the user to turnon/off solder waves from the rear of the

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machine; used for maintenance & setuponly.

Nitrogen Options

• TunnelSelection of this option indicates that acomplete nitrogen tunnel, for inerting thepreheater and solder pot sections, isinstalled on the machine.

• ContourSelection of this option indicates thepresence of an “A” Wave nozzle in lieu ofthe Lambda™ nozzle, with an inertboundary system. If the Chip Wave option isselected, it too is inerted. If the Hot Knifeoption is selected, the knife blows hotnitrogen for debridging.

• Oxygen MonitorSelect this item if the Oxygen Monitorfeature for Nitrogen Options is installed.This feature is only available if a NitrogenOption is selected. The oxygen monitor isused with the tunnel selection, to monitorthe level of oxygen/nitrogen in the tunnel.

Feeder Options

Only one (1) selection in this category ispermitted.

• NoneSelect “None” if no solder feeder optionsare installed.

• Bar FeederSelection of the Bar Feeder option indicatesthat a solder Bar Feeder, for automaticloading of solder, is installed on the solderpot.

• Wire FeederSelection of the Wire Feeder optionindicates that a wire type solder feeder, forautomatic loading of solder, is installed onthe solder pot.

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Light Tower Tab -

• Click on the Light Tower tab within theModule Configuration dialog box to accessthe Optional Light Tower configurationsetup.

Figure 113: Module Configuration Light Tower tab

Light Tower

The Light Tower may be configured as one ofthree (3) choices:

• NoneSelect “None” when NO Light Tower isinstalled.

• Red-Amber-GreenWhen selected, indicates a Light Tower withthis color combination for machine statusis installed on the external cabinet of theElectra™.

• Red-Amber-BlueWhen selected, indicates a Light Tower withthis color combination for machine statusis installed on the external cabinet of theElectra™.

Name

A list of specific machine conditions thatcan be configured for Light Towerindication is displayed under the fieldheading Name.

• Color IndicationAcross from the Name field are four (4)

fields, of which one (1) or two (2) selectionsmay be made to represent the machinecondition. It is possible that no selectionmay be made for specific machinecondition names.For Example: The user wants to know when the machineis in Manual Mode. Find the machinecondition Manual Mode under the namefield. Across from Manual Mode, a redcheck mark is in the Green and Blink checkboxes. This indicates that when themachine is in Manual Mode, the LightTower will Blink on Green.

• Make the appropriate selections for lighttower configuration to represent themachine conditions required by clicking onthe check box in the color field or blink fielddesired. Clicking on the check box places ared check mark in it. Clicking on the boxagain will remove the check mark from thecheck box. A red check mark in the boxindicates it is selected.

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Custom Inputs Tab -

• Click on the Custom Inputs tab within theModule Configuration dialog box to accessthe Optional Custom Inputs configurationsetup.

Figure 114: Module Configuration Custom Inputs tab

If your machine is configuredwith the SMEMA Option, Inputs1 & 2 are utilized for SMEMA;

otherwise the Four (4) User ProgrammableInputs can be used. The Custom Inputsfeature must be selected to uti l ize i tsfunctions.

Custom Inputs

• Click on the check box to the left of thisoption to place or remove a check mark inthe box. A check mark in the check boxindicates that it is selected.

Custom Inputs utilizes signals from an externalpiece of equipment entering the Electra™. Thesignal is processed through Electra’s softwarethrough a selected input channel, for a specificalarm indication. By communicating thissignal, the external equipment utilizes theselected Electra™ alarm.

There are three (3) fields associated withCustom Inputs:

• Name• Action• Active Low

• NameThe user may enter the name you want forthe input. This is the text that will displaywhen its alarm occurs.

• Action• Ignore - ignores all alarm conditions.• Warning - sounds an audible alarm and

displays a message on the screen.• Soft Stop - stops all modules of the

machine except the conveyor. After allremaining PCB’s have exited themachine, the conveyor will shut down.

• Hard Stop - same as an EmergencyStop switch being activated.

• Active LowA check mark in the box indicates that thisentry is active low otherwise this entry isactive high.

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Custom Outputs Tab -

• Click on the Custom Outputs tab within theModule Configuration dialog box to accessthe Optional Custom Outputs configurationsetup.

Figure 115: Module Configuration Custom Outputs tab

If your machine is configuredwi th the SMEMA Opt ion ,outputs 1 & 2 are utilized for

SMEMA; o therwise the four (4 ) UserProgrammable Outputs can be used. TheCustom Outputs feature must be selected toutilize its functions.

Custom Outputs

• Click on the check box to the left of thisoption to place or remove a check mark inthe box. A check mark in the check boxindicates that it is selected.

Custom Outputs sends signals from theElectra™ to a piece of equipment external of theElectra™. Signals are processed throughElectra’s software via selected output channelsfor specific machine conditions. The outputsignal is then generated and sent to theexternal equipment.

Outputs can be customized by choosing theoutput number associated with the machinecondition to be triggered — the machinecondition listed in the Name column. It ispossible to have several machine conditionstrigger the same output number, or the same

machine condition to trigger more than oneoutput number.

To select an output number for the machinecondition listed under Name, click on the checkbox under the output number associated withthe name. A red check mark appears in thecheck box when it is selected.

Electra™

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Communications Tab -

• Click on the Communications tab withinthe Module Configuration dialog box toaccess the Optional Communicationsfeatures.

Figure 116: Module Configuration Communications tab

This feature is utilized strictly in the event thatcommunications via serial port is terminated; asecondary configuration can be assigned. Thisconfiguration utility should be limited to accessby personnel knowledgeable in troubleshootingserial port conflicts.

The fo l l ow ing tab le rep resen ts theCommunications default configuration:

The information provided here isfor troubleshooting purposesonly. The baud, bit word, parity,

and stop bits configuration is coded in thesoftware and can not be changed. Refer tot h e E l e c t r a ™ M a i n t e n a n c e m a n u a lTroubleshooting section, on how to re-configure COM Ports for.

PORT NAME COM PORT BAUD BIT WORD PARITY STOP BITS

Barcode Reader COM 7 9600 7 bit Even 1

GEM Port COM 2 19,200 8 bit Even 1

External Fluxer Port COM 8 9600 7 bit Even 1

Internal Fluxer Port COM 6 9600 7 bit Even 1

Motor Port(Poll interval 1 sec)

COM 5 19,200 8 bit Even 1

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Barcode Reader Tab -

• Click on the Barcode Reader tab within theModule Configuration dialog box to accessthe Optional Barcode Reader configurationsetup.

Figure 117: Module Configuration Barcode Reader tab

Type

Selection of one (1) item is permitted within thiscategory.

• None• Datalogic• Standard• Symbol Technologies

Code Type

When the Datalogic Type Barcode Reader isselected, one (1) of the following Code typesmust be selected within this category:

Figure 118: Datalogic Code Types

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When the Standard Type Barcode Reader isselected, one (1) of the following Code Typesmust be selected within this category:

Figure 119: Standard Code Types

Options

• Quick Load ParametersWhen selected, the only recipe parametersread in on the barcode is flux pressure andhot knife pressure. Thes are changed onthe fly as soon as the board exits the fluxeror hot knife modules. As the board exits thefluxer or hot knife, the parameters changeto whatever the next new recipe (barcode)was read in. Any other parameters on thebarcode recipe are ignored. If Quick LoadParameters is not selected, the softwarereads and resets everything on the newrecipe (barcode).

• DefaultsTo reset the default values for Quick LoadParameters, click on the Defaults button.

Message Prefix Character

Select “None” or 1-255

As the name states, a prefix character at thebeginning to indicate the starting of the string.

Message Suffix Character

Select 1-254

As the name states, the suffix characterselected to indicate the end of the string.

Defaults

To reset the default values, click on the Defaultsbutton.

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GEM Tab -

GEM (General Equipment Model) standard,published by SEMI (Semiconductor Equipmentand Materials International), is a specificationthat provides methods for implementing SECS(SEMI Equipment Communication Sandard), acomputer - to -computer communicat ionprotocol, designed to communicate with factoyautomation (host) computers. The GEM optionprovides a software link between a personalcomputer and the Electra™.

• Click on the GEM tab within the ModuleConfiguration dialog box to access theOptional GEM (General Equipment Model)configuration setup.

Figure 120: Module Configuration GEM tab

GEM

Selection of one (1) item is permitted within thiscategory.

Figure 121: GEM Selections

• None selected — GEM is off

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• Select Serial when a Serial Card is used forcommunication.

Figure 122: Serial GEM Configuration

When Serial is selected, a bullet is present inthe bullet box and the Serial parmeters areavailable for selection.

General

• Device IDIndicates the Device Identification Number.This parameter has a Value Range of 0 -32,767. The default value is 1.

• Establish Communications DelayThe Equipment ConstantGemEstabCommDelay determines the timeinterval, in seconds, GWGEM waits afterone (1) GWGEM-Initiated Connect Requestfails before GWGEM tries again.

Set the value to zero to disable Equipment-Initiated Connect Request; the Equipmentnever initiates Connect Request — theHost must initiate Connect Request.

This option useful when connecting to non-GEM Hosts.

Serial

• Inter-Character Timeout (T1)Detects an interruption between characters. A Value Range of 0.5 - 25.5seconds may be entered for thisparameter. Default value is 1.0seconds.

• Block Protocol Timeout (T2)Detects a lack of protocol response. AValue Range of 0.1 - 25.5 seconds maybe entered for this parameter. Defaultvalue is 3.0 seconds.

• Reply Timeout (T3)Detects a lack of reply message. AValue Range of 1.0 - 120 seconds maybe entered for this parameter. Defaultvalue is 30.0 seconds.

• Inter-Block Timeout (T4)Detects an interruption in a multiple-block message. A value Range of 1.0 -120 seconds may be entered for thisparameter. Default value is 10.0seconds.

• RetriesThe maximum number of send retriesallowed. The Value Range for thisparameter is 0 - 31. The Default is 3Retries.

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• Select HSMS to utilize HSMS (High-Speed SECS Message Services)transmission mode.

Figure 123: Serial GEM Configuration

When HSMS is selected, a bullet is present inthe bullet box and the HSMS parmeters areavailable for selection.

General

• Device IDIndicates the Device Identification Number.This parameter has a Value Range of 0 -32,767. The default value is 1.

• Establish Communications DelayThe Equipment ConstantGemEstabCommDelay determines the timeinterval, in seconds, GWGEM waits afterone (1) GWGEM-Initiated Connect Requestfails before GWGEM tries again.

Set the value to zero to disable Equipment-Initiated Connect Request; the Equipmentnever initiates Connect Request — theHost must initiate Connect Request.

This option useful when connecting to non-GEM Hosts.

HSMS

• Port5000

• IP AddressFour(4) Characters 0-255

• Reply Timeout (T3)Detects a lack of reply message. AValue Range of 0 - 30 seconds may beentered for this parameter. Defaultvalue is 30.0 seconds.

• Control Message Reply Timeout (T6)Detects an interruption in a multiple-block message. A value Range of 0 - 30seconds may be entered for thisparameter. Default value is 10.0seconds.

• Connect Timeout (T7)Detects a lack of connection response.The Value Range for this parameter is 0- 30 seconds. The Default is 5 seconds.

• Inter-Character Timeout (T8)Detects an interruption betweencharacters. The Value Range for thisparameter is 0 - 30 seconds. TheDefault is 6 seconds

• Connection EstablishmentThe amount of time the software waitsbefore trying to reconnect after aconnection failure.

• Circuit AssuranceEnter a parameter value in seconds.This parameter specifies the frequency atwhich SDR (SECS Driver) initiates theHSMS Linktest control transaction to verifythat the link remains functional.

A smaller value means more frequentcontrol messages.

SDR sends Linktest transactions onlyduring idle periods, when there is nonormal Data Message traffic whichindicates that the connection remainsfunctional.

If you specify the value 0, SDR initiates nolinktest transactions, and does not verifythat the link remains active.

A typical value is 15 or 0.

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Operation 2-9317-120-00-0 — Rev. 3 113

Miscellaneous Tab -

• Click on the Miscellaneous tab within theModule Configuration dialog box to accessthe Miscellaneous features.

Figure 124: Module Configuration Miscellaneous tab

Recipe Location

• PathLocation where recipe files will beautomatically saved and retrieved.

• Select PathClick on the Select Path button to Modifythe Path — when clicked, a Browse forFolder window pops up to allow the user toselect a folder.

Figure 125: Browse for Folder window

Select the Folder where the recipe files areto be saved by double clicking using thepointer device, then click on the OK button.

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QUICK VIEWThe Configuration Quick View dialog box can beopened by clicking on Configuration on theMenu Bar, then clicking on Quick View in thedrop-down list box.

Figure 126: Select Configuration, Quick View

Figure 127: Module Configuration Quick View dialog box

The Quick View dialog box lists all machineparameter names and allows the user to selector deselect which items will be displayed whenutilizing the Quick View utility.

• Click on the check box next to the item oritems to be included for display in theQuick View utility.

• Clicking on the check box places a checkmark in the check box. Clicking on thecheck box again removes the check markfrom the box.

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SECURITY

Prior to setting up parametersfor the machine, the ProcessAdministrator must set the

security limits of Electra’s software featuresto ensure restricted access to specificfunctions.

The user setting up Securitym u s t b e L o g g e d o n a s“Supervisor” or a user with

“Modify Security” Rights must be logged onbefore Security can accessed.

The Configure Security dialog box is designedto permit the Process Administrator to set upsecurity rights for specific users.

When configuring security, it is important totake in to account the use rs and the i rresponsibilities, to determine which functionsor features the users will access.

The Configuration Security dialog box can beopened by clicking on Configuration on theMenu Bar, then click on Security in the drop-down list box.

Figure 128: Select Configuration, Security

Figure 129: Configure Security dialog box

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If Security is grayed out or no selectionavailable, it is possible that Security has beenmade INACTIVE. To re-activate Security, dothe following:

1. Single click on the open lock icon

button just below the Menu bar.

Figure 130: Icon button bar

2. A Logon dialog box is displayed promptingthe user to enter the user name andpassword — enter Name and Password,then press the Enter key on the keyboardor click on the OK button.

The selection “Security” is nowavailable for selection underConfiguration.

CONFIGURING RIGHTS

• Click on the User Name so that it appearshighlighted prior to selecting Rights.

• Under the field labeled “Rights”, Click oneach check box that the designated user isallowed to access.

Figure 131: Configure Rights

• Clicking on the check box places a checkmark in the check box — clicking on thecheck box again removes the check markfrom the box.

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Operation 2-9317-120-00-0 — Rev. 3 117

TIMEOUT SETTING

In the text box under Time-Out, enter thenumber of minutes allowed to pass before theuser is required to log back onto the machine toperform any changes.

A value range of 0 - 60 minutes may be enteredfor this value; “0” indicating that the securitywill always remain active.

CHANGE PASSWORD

• Click on the user name requiring apassword change so that it appearshighlighted.

• Click on the Change Password

button.

A Change Password dialog box isdisplayed with the selected user’sname displayed.

Figure 132: Change Password dialog box

Refe r to the passwordrestrictions described under“Adding a User”.

• Next to the heading “Old Password”, enterthe user’s previous password exactly as itwas originally. If no password was entered,leave this text box blank.

• Enter the user’s new password next to theheading “New Password”.

• Next to the heading “Confirm NewPassword”, enter the password again,exactly as typed in the New Password textbox, to confirm the password entry.

• Click on the OK button to accept thechanges and close the dialog box,

OR

• Click on the Cancel button if an incorrectchange has been made — cancels thechanges.

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ADD USER

• Click on the Add User

button. An Add User dialog box opens.

Figure 133: Add User dialog box

• The minimum size for the User Name isone (1) character — maximum size is 32characters. There is no restriction on thecharacters that can be used.

• Enter the new user’s name in the text boxnext to User Name, then press the tab keyon the keyboard, or position the cursor inthe New Password text box using thepointing device.

To reduce the risk of violatingsecurity, it is recommended thateach user be responsible for

remembering their own password ratherthan making a written list. In the event thatusers forget their password, i t wil l benecessary to delete that user’s name, thenre-enter a new User Name and password.

• When adding a user, a New Password isoptional. For no password, leave the text box empty.When selecting a password, up to eight (8)characters can be used.

• Enter a password for the user in the textbox next to New Password:, then press thetab key on the keyboard, or position thecursor in the Confirm New Password textbox using the pointing device.

It is important to rememberwhen using upper or lower casecharacters in the User Name

and Password text boxes, the program willonly recognize characters exactly as theywere originally entered.

• Before the password will be accepted, theuser must enter the New Password again inthe text box next to Confirm NewPassword:. Remember that both the UserName and Password are case sensitive.

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DELETE USER

• In the User Name column, click on theuser’s name to be deleted.

When clicked, the user’s namebecomes highlighted and the DeleteUser button becomes available forselection.

Figure 134: Select user to be deleted

Deleting a User Namefrom the list permanentlyr e m o v e s a l l s e c u r i t y

related rights along with the user’s name. Besure the correct User Name is selectedbefore clicking the Delete User button.

• Click on the Delete User

button to remove the user name from thelist.

A Delete User dialog box appearsdisplaying “Continue to Delete User?”

• Click on the Yes button to delete theselected user name — click on the Nobutton to cancel the deletion.

Figure 135: Delete User dialog box

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SECURITY ACTIVE

ATTENTION PROCESSADMINISTRATOR

In order maintain systemintegrity, it is important to restrict access toElectra’s machine software configuration,and the accessibility to specific machinefunctions. Without Security Active enabled,access to machine configuration or othermachine functions is not restricted.

• Click on the check box next to SecurityActive to place a check mark in the box. Acheck mark in the box indicates thatsecurity for machine access is active. Nocheck mark in the box indicates SECURITYIS INACTIVE.

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Operation 2-9317-120-00-0 — Rev. 3 121

SPECIALS• Click on Specials under Configuration on

the Menu Bar to access its features.

Figure 136: Select Configuration, Specials

A Specia ls Conf igurat ion d ia log box isdisplayed.

Figure 137: Specials Configuration dialog box

The Specials Configuration mayonly be modified if a BarcodeReader is selected under the

Module Configuration dialog box.

• Click on the check box next to “Barcodeused to find Recipe from COM server”, toplace a check mark in the box.

• A check mark in the box indicates it isselected to utilize this feature. Whenselected, the configuration buttons “SelectCOM Server” and “Update COM Server”,become active.

Figure 138: Buttons are active when check box is selected

Select COM Server

• Click on the Select COM Server button toaccess a barcode recipe from the COMServer.

• A Select COM Server window opens,displaying the drive’s folders. Double clickon the folder containing the file required, orenter the File name in the “File name:” textbox.

Figure 139: Select COM Server display window

• Click on the OK button when the requiredfile is displayed next to File name:.

Update COM Server

• Click on the Update COM Server button tore-establish the COM Server connection.

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UNITS• Click on Units under Configuration on the

Menu Bar to access its features.

Figure 140: Select Configuration, Security

A Units Configuration dialog box isdisplayed.

Figure 141: Units Configuration tab

There are three (3) possible selections for Unitswithin the Type field.

Type

• ImperialSelect this unit of measurement to displayall parameters in Imperial format (inches,°F, PSI, inches/second, and feet/ minute).

• MetricSelect this unit of measurement to displayall parameters in Metric format(millimeters, °C, kPa, meters/second, andmeters/minute).

• MixedSelect this unit of measurement to displayall parameters in Mixed format — alltemperatures displayed in Metric and allother units of measurement in Imperial.

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Operation 2-9317-120-00-0 — Rev. 3 123

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4.4 USING ON-LINE HELPElectra™ software offers immediate assistanceto most of the software features using the on-line help. On-line Help can be accessed at anytime by pressing the F1 key on the keyboard.The following Help Topics further describe theOn-line Help feature.

HELP TOPICSTo access Help press F1 on the keyboard — listsan Electra™ Help Index.

Figure 142: Electra™ Help Index

or, click on Help on the Menu Bar, then click onHelp Topics in the drop-down list box.

Figure 143: Select Help, Help Topics

Figure 144: Help Topics: Electra™ Help; Contents

Content

• Displays Help topics organized by category.

Double-click a book icon to see what

topics are in that category. To see a topic,double-click it.

• Close a book by double-clicking it.Index

• Click on the Index tab to access the Indexfeatures.

• Displays the Help Index. Type a topic youwant to find, or scroll through the list ofindex entries. Click the index entry youwant — then click the Display button.

Figure 145: Help Topics: Electra™ Help; Index

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Operation 2-9317-120-00-0 — Rev. 3 125

Find

• Click on the Find tab to access its searchfeatures.

• Find provides the user a text block to type aword(s) or a phrase to find in the HelpTopics. Type a few characters and use theword list below to see if any words matchwhat has been typed into the text block.

Figure 146: Help Topics: Electra™ Help; Find

• To specify more than one word, use a spaceto separate them. If uppercase charactersare specified, then only words that areuppercase will be found. However, iflowercase characters are specified, bothupper and lowercase words will be found.

• To change the search options, click theOptions button.

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Operation 2-9317-120-00-0 — Rev. 3 127

SECTION 5: THEORY OF OPERATION

5.1 GENERAL MACHINE OPERATIONOnce Electra’s main disconnect switch isac t i va ted , the mach ine powers up thecomputer, running under Windows NT® — theElectra™ software starts up and is ready foropera t ion . The E lec t ra™ modu les andparameters are set via the user interface at themoveable console, prior to processing product.

Af ter a l l system parameters have beensatisf ied, PCB’s can be placed onto theconveyor system at the load end of themachine. The conveyor system transports thePCB’s th rough E lec t ra ’ s subsys temcomponents.

A photocell sensor at the load end of theconveyor detects product entering the system.When product passes the photocell , thephotocell sends a signal to the Electra™software to start counting the PCB’s beingprocessed.

When operating in Standby mode, the photocellcommunicates to the software when boards areno longer present in the machine within ade f ined w indow. S t a n d b y a c t i v a t e s o rdeactivates the solder wave(s) to run at reducedspeeds until boards are detected entering thesystem again. Standby feature may also beconfigured for the optional hot knife.

As product passes over the fluxer, flux is appliedto the bottom side of the board. Flux applicationis available in sevaral types of flux modules —foam, wave, or spray. Foam and Wave typefluxers operate continuously after activationuntil manually deactivated through systemsoftware. Other optional spray type fluxers areconfigured with separate photocells whichactivate the flux unit as product pass thefluxer’s photocell. Each type of flux modulecontains a separate exhaust hood above thef lux unit to extract f lux fumes from theElectra™.

When the PCB’s exit the flux module, theybegin entering the preheat zone. Preheat isapplied to product after fluxing to activate anddry the flux. Preheat also is important inheating the PCB’s up to a specific temperatureto prevent thermal shock upon entering thesolder wave, as well as ensuring proper solderflow to components and circuitry.

Preheater temperatures are monitored throughE l e c t r a ’ s s o f t w a r e . Tempera ture i s

automatical ly adjusted as necessary tomaintain set point temperatures according tothe parameters defined in the recipe loaded. Itis important that operators determine preheatparameters required for each preheat moduleto achieve optimum soldering results for eachproduct being processed.

Next the PCB’s are conveyed accross the solderwave(s). Solder is pumped from the solder potthrough the solder nozzle(s). As solder is beingpumped it forms a wave of solder (available ind i f f e r e n t c o n f i g u r a t i o n s f o r v a r i o u sapplications) which is applied to the bottomside of the board as it is conveyed accross.

The Electra™ main exhaust system extracts andvents fumes out of the machine v ia thecustomer supplied exhaust ventilation system.

PCB’s exit the Electra™ at the unload end of thecabinet via the conveyor system.

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SECTION 6: SETUP

6.1 CONVEYOR

SYSTEM LEVELING 1. Place a level on the underside of the

machine's frame along its length, frontand rear.

2. Adjust the leveling feet to bring themachine into level, making sure not tochange its set height.

3. Place a level on the underside of themachine's frame along its width, load andunload ends.

4. Adjust the leveling feet to bring themachine into level, making sure not tochange its set height.

When interfacing with otherconveyors, it is important toadjust the machine height to

allow for smooth transition. Note that theconnection height is dependent on theconveyor incline angle for wave soldering.The distance from the floor to either end ofthe conveyor varies with the angle of theconveyor. The Electra™ conveyor angle isfactory set at a six (6) degree incline.

Figure 147: System Leveling

Adjust the six (6) Leveling Feet (TYP) to bring the machine into level

Place a level on the underside of the machine along its length, front and rear, to verify leveling

Turn the leveling foot clockwise to decrease height and counterclockwise to increase height

Place a level on the underside of the machine along its width at either end to verify leveling

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Operation 2-9317-120-00-0 — Rev. 3 129

CONVEYOR LEVELING

1. Perform the System Leveling procedurebefore performing the Conveyor Levelingprocedure.

2. Place a Lev-chek™ in the conveyor fingersbetween the conveyor rails at the unloadend of the coveyor. Ensure the glass isseated all the way in the fingers so that it islevel in the fingers.

3. Place a level on the Lev-chek™ across theconveyor width, and verify that the levelreads level.

4. Repeat steps 2 and 3 at the load end of theconveyor.

5. If the conveyor is level, DO NOT proceed tothe next step.

If the conveyor is NOT level, proceed to thenext step to level the conveyor.

6. If the conveyor is out of level at the unloadend, but not the load end of the conveyor:

A. Locate the conveyor heightadjustment nuts inside the cabinetat the unload end, directly underthe conveyor rails.

B. Determine which rail needs to beadjusted up or down, then, using a13 mm open end wrench, loosenthe M8 x 16 locking bolt securingthe adjustment nut under the railrequiring adjustment.

C. Once the locking nut is loosened,while the level is placed across theconveyor rails, using a 15.0 in.Crescent™ wrench, slowly turn thenut in the proper direction to raiseor lower the conveyor rail — turnthe nut clockwise to lower andcounterclockwise to raise theconveyor.

D. When the proper height isachieved, re-tighten the M8 x 16locking bolt using a 13 mm openend wrench.

7. If the coveyor is only out of level at the loadend of the conveyor, re-check and adjust

the System Leveling, then re-check theconveyor rails as performed in step 3 ofthis procedure.

RAIL PARALLELISM

To check for Rail Parallelism:

1. Check the distance between the blocksdepicted in the photograph in Figure 148at the unload end width adjust shaft. Thedistance must be 2.54 cm (1.0 in.).

Figure 148: Check distance between blocks

2. If the distance between the blocks iscorrect, it is not necessary to make anyadjustments on the block.

If the distance between the blocks isincorrect, use an M6 hex wrench to loosenthe two (2) M8 x 30 socket head screws onthe inner block — reposition the block to2.54 cm (1.0 in.) distance, then re-tightenthe hardware.Repeat this step for all three (3) widthadjust shafts.

Since it is necessary to checkthree (3) reference points for railparallelism, take measurements

in the vicinity of the three (3) width adjustshafts. Repeat the following steps at eachlocation.

Tools Required: Lev-chek™

Level

13 mm Open end Wrench

15.0 in. Crescent™ WrenchTools Required: Tape Measure

M6 Hex Wrench

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130 2-9317-120-00-0 — Rev. 3 Operation

3. Pick a common reference point and use atape measure to measure the distancebetween the conveyor rails — note themeasured distance.

FOR EXAMPLE: From the center of theadjustable (rear) rail, to the inside edgeof the fixed (front) rail. (Refer to thefollowing figure).

Figure 149: Measure distance between rails

4. If the distance measured at any of thethree (3) points is within 1.524 mm (.060in.) toleranace, adjustment is notnecessary. Distances over tolerancerequire adjustment.

Pinch Point

The chain tensioner isspring loaded and under

high pressure. Take caution not to pinchfingers between the chain and sprocket.Severe injury or finger dismemberment canresult if not handled safely.

5. Adjustment is made at the exit end chaindrive mechanism. Using a pry bar asdepicted in the following photograph,release tension on the chain tensioner.

One person should re l ievepressure on the chain tensionerwhile another makes adjustment

on the chain links.

Figure 150: Use a prybar to releive tension on conveyor tension device

6. While the tension is relieved, move thechain one link at a time over the sprocketin the proper direction. Move the chain in aclockwise direction to move the railinward. Move the chain in thecounterclockwise direction to move therail outward.

Figure 151: Adjust Rail Parallelism

7. Release the prybar slowly after adjustingthe chain on the sprocket — re-checkdistance between rails after adjustment.Repeat the previous steps until the railsare parallel within tolerance.

End of prybar ontension device

tensiondevice

PrybarPull back onprybar to releasetension on tensiondevice

Lift Chain upover sprocket Advance Chain links in

one direction or the other

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Operation 2-9317-120-00-0 — Rev. 3 131

6.2 FINGER CLEANER

FILLING THE RESERVOIRPerform the following procedure to inspect orfill the finger cleaner reservoir prior to systemstartup:

1. The reservoir for the finger cleaner islocated at the exit end of the system’scabinet at the lower right hand corner ofthe Electra™. Use a 5/16 in. Allen wrenchto unlatch the slide drawer that houses thefinger cleaner unit.

Figure 152: Accessing the finger cleaner reservoir

2. Slide the reservoir out using the drawer'shandle.

3. Remove the finger cleaner cover from thetop of the reservoir.

Figure 153: Remove finger cleaner cover

4. Verify that the drain valve for the reservoiris in the closed or Operate position prior tofilling the reservoir.

• Note that the label for the fingercleaner valve is labeled for properpositioning.

Figure 154: Finger cleaner 3-position valve

5. Fill the reservoir with solvent or watersoluble solution that is compatible withyour systems process chemistry. If unsureas to what chemical to use, contact theProcess Engineer responsible for thisequipment.

Figure 155: Filling the reservoir

• The finger cleaner reservoir capacity isapproximately 14 liters (4 gallons).

• Fill the reservoir to a level

6. Re-install the reservoir cover, then,carefully slide the reservoir back into thecabinet.

Use a 5/16 in.Allen wrench

FingerCleanerDrawer

Liquid LevelFloat Switch

Reservoir

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AIR PRESSURE SETTINGAdjust the finger cleaner airknife pressure viathe front pneumatics panel. Adjust the airpressure based on the process chemistry foroptimum performance.

6.3 FLUXER (FOAM)

INSTALLING THE AERATORS 1. Slide the fluxer out from the rear then,

remove the fluxer nozzle from the fluxreservoir.

Figure 156: Removing fluxer nozzle

2. Locate the Aerator Cleaning Reservoirmounted on the left rear wall near thefluxer module.

Figure 157: Aerator reservoir

3. Remove the Aerators from the reservoirthen, connect the air line tubing in thefluxer reservoir to each of the ends of thebarbed fittings on the aerators. Tightensecurely using the hose clamps.

4. Install the aerators in the bracket providedin the flux reservoir.

5. Re-install the fluxer nozzle removed in stepone of this procedure.

Fluxer Nozzle

Aerators

Barbed fittings,Hose clamps,and tubingconnections

Aerator Brackets

Air Tubing

AirTubing

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Operation 2-9317-120-00-0 — Rev. 3 133

Figure 158: Foam Fluxer Components

Fluxer Nozzle

Air Line Tubing connectionw/ hose clamp




Bracket

Bracket

Aerator

Aerator

FluxReservoir

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FILLING THE RESERVOIR (FOAM) 1. Access the fluxer via the rear of the system

cabinet.

Figure 159: Accessing the Foam Fluxer, closing the drain valves, and filling the reservoir

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

3. Slide the fluxer out unitl it stops.

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

5. Verify that the drain valve for the fluxerrecirculation reservoir is closed.

6. Obtain the flux to be used — to beapproved by the Process Engineerresponsible for this equipment; fluxcapacity depends on systemconfiguration.

• Refer to the Fluxer Capacity tablebelow.

Capacity is based on the normal flux level inthe reservoir; 2.54 cm (1.0 in.) above theaerators.

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

• If configured with the FDC (PAAR FluxDensity Control) option, the flux andsolvent pumps automatically maintain

Rear of Fluxer

Flux Reservoir

Flux RecirculationReservoir

Aerators

Fluxer NozzleRecirculation ReservoirDrain Valve

LatchFlux ReservoirDrain Valve

Foam Fluxer Capacity Table

14.6 Liters (3.85 U.S. Gal)

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Operation 2-9317-120-00-0 — Rev. 3 135

the flux level as well as monitoring andadjusting the density level of the flux inthe reservoir, after the reservoir hasbeen initially filled, and while power tothe system remains on.

FLUX DENSITY CHECKPrior to operation each day, it is recommendedto manually verify the density of the flux in thereservoir to ensure qual i ty and to veri fyaccuracy. Use the conventional hydrometermethod to verify flux density, or for moreaccuracy, utilize a titration kit which can beacquired from most flux manufacturers.

AIRKNIFE AIR ADJUSTMENTAdjust the airknife incoming air pressure viathe regulator on the front pneumatics panel.For optimum performance, adjust the airpressure based on process chemistry andproduct configuration .

Figure 160: Pneumatics panel

AERATOR AIR ADJUSTMENTAdjust the incoming air pressure for theaerators via the front pneumatics panel. Adjustthe individual flow rates for each aerator. Forbes t foaming resu l ts , re fe r to the f luxmanuafacurers data for recommended airpressure and air flow settings.

FILLING THE RESERVOIR (WAVE)Refer to the Electra™ Option Manual, 9.4,Setup.

OPTI-FLUX® SPRAY FLUXERRefer to the Electra™ Option Manual, 7.9,Setup.

Aerator Air Regulator

Airknife Air Regulator

Finger Cleaner Air Regulator

Flow Controls for Aerators

Electra™

136 2-9317-120-00-0 — Rev. 3 Operation

6.4 SOLDER MODULE

INSPECTING THE SOLDER LEVELWhen starting each shift of operation, a visualinspection of the solder level in the pot shouldbe performed. With the solder pumps off, thesolder level should be no more than 12.7 mm(1/2 in.) from the top edge of the solder pot. Ifdross is present on the solder surface, be sureto remove the dross before verifying the solderlevel for an accurate measurement from thesolder’s surface.

Dedrossing the pot prior to each shift ofoperation should also be performed. Refer tothe Electra™ Maintenance manual, Dedrossingthe Solder Pot Surface.

Adding Solder to the Solder Pot:

If the solder level is low, add bar, pellet or ingot,63/37 (unless your process requires a different

type of solder) virgin solder to the pot to bringthe level of the solder to at least 12.7 mm (1/2in.) from the top edge of the solder pot.

LAMBDA™ AIR NOZZLE SETUPTo Level the Exit Wing Dam:

1. Using an 8 mm nut driver, loosen theadjusting bolts that secure the exit wingdam to the nozzle.

2. The exit wing dam should be 3.1 mm - 4.7mm (1/8 - 3/16 in.) above the surface of theexit wing.

3. While the wave is running, level the dam toensure the solder flows evenly off the exitwing.

4. Tighten the screws when level.

Figure 161: Lambda™ Air Nozzle Cut-away view

Dross Gate Adjustment:

To minimize dross production, the unload drossgate must be adjusted. Using an 8 mm nutdriver, make adjustments to the Dross Gateadjusting bolts to bring the solder level withinthe dross gate as depicted in Figure 161.

Front Dross Gate Adjustment:

1. Locate the front and rear dross gateadjustment pivot plates.

2. Loosen the M5 hardware using an 8 mmwrench to allow the pivot plate to be

Front Dross Gate

Entrance Curve Plate

Pivot Plate

Exit WingExit DamAdjusting Bolts

Exit Dam

Dross GateAdjusting Bolts

UnloadDross

= Solder Flow

= Solder Wave

= Solder Level

Gate

Electra™

Operation 2-9317-120-00-0 — Rev. 3 137

adjusted — loosen at both ends of thenozzle.

3. Slide the pivot plate toward the dross gateto open or away from the dros gate toclose the gap.

Figure 162: Front end of Lambda™ Nozzle

Exit Wing Adjust Setting:

1. While the wave is operating, raise the exitdam by turning the exit dam adjustingbolts until the solder stops flowing over theexit dam.

2. Adjust the bolts slowly to lower the exitdam until the solder starts to flow over theexit dam.

3. Using a stainless steel spatula, scrape thelip of the exit dam to break the solder flow.Gently push the solder as though a boardis passing through the wave.

4. Raise the solder pot to a height that allowsthe bottom of the conveyor fingers tobarely touch the solder wave.

5. Set the conveyor to about two (2) feet perminute and verify that the fingers on bothconveyor rails pass through the wave atequal depths. If the fingers on one rail aredeeper in the wave than the other, verifythat the nozzle is level in the pot and thatthe machine is level. Adjust the solder potor machine so that they are level and bothsets of fingers are at equal depths in thesolder wave.

Unload Dross Gate Adjustment:

Make adjustments while the wave is operating.

1. Using an 8 mm nut driver loosen theunload gate by turning the two (2) drossgate adjusting bolts counterclockwise.

2. Gently tap on the gate using a bluntinstrument until the plated movesdownward. Solder should overflow the

dross gate. If it does not, then tap on thegate until it moves freely.

3. Adjust the unload dross gate by turningthe dross gate adjusting bolts using the 8mm nut driver. Adjust the bolts until aheight of 37.5 mm (1.5 in.) from the soldersurface at the top of the exit wing to thesolder surface within the unload drossgate can be maintained.

Lead Clearance Setting:

1. Determine the longest lead length on thePCB’s being processed. Adjust theLambda™ wave height via the Electra™software at the operator interface to awave depth for a lead length of actual leadlength plus two (2) mm.

2. Raise the solder pot until the “V” Groove or“L” of the fingers is at a height equal to thelead clearance determined in step 1 of thisprocedure.

3. Run a test PCB across the wave verify thatthe solder does not flow over the top of thePCB.

Wave Characteristics:

A Lambda™ Wave that is flowing correctly hasthree (3) characteristics:

• The flattest portion of the wave (Exit Wingarea) should be as close to a mirror-likesmoothness as possible. There is little or noturbulence or rippling on the flattestportion of the wave. If dross is beingpumped up through the wave, remove andclean the pump, nozzle, vane element, andflow duct assemblies — dedross the solderpot.

• The solder wave appears to be stagnantuntil a PCB comes in contact with theleading edge of the wave. A stagnant areais usually characterized by a cloudy area onthe solder wave’s shiny surface. The cloudyareas indicate oxidation — dross formation.Oxidation may occur if the exit wing orsolder nozzle is not level, or if the drosscontrol gates are not adjusted properly.

• The volume of solder flowing from the exitdam is at a minimum, and the back-flow iseven and uniform across the full width ofthe exit dam. If not, check the level of theexit dam and nozzle.

Front Dross Gate Pivot Plate

M5 BoltM5 Bolt

Electra™

138 2-9317-120-00-0 — Rev. 3 Operation

TURBULENT CHIP NOZZLE SETUPThe Turbulent Chip wave has adjustments forthe load and unload dross plates in order tocontrol dross production. Both gates each havetwo (2) adjusting bolts. Adjusting the bolts upor down, adjusts the dross gates up or down,controlling the speed at which the solder flowsback in to the so lder pot . For opt imumperformance, the dross gates should be leveledabout 12 mm (.50 in.) from the top of the nozzle.Always adjust the load side dross plate first.

Figure 163: Turbulent Chip Air Nozzle Cut-Away view

Lead Clearance:

Lead clearance for the turbulent chip waveshould be set at the same t ime that theLambda™ lead clearance is set. Use the samelead length parameters to set the chip wave asperformed on the Lambda™ wave.

Wave Height Verification:

The wave height must be set so that the crest ofthe chip wave ripples do not overflow the PCBbeing processed.

Increase the Chip Wave rpm via the Electra™software at the operator interface to increasewave height. Decrease rpm’s to decrease waveheight.

A t itanium PCB stiffener orpallet can be used to preventso lder over f low dur ing the

soldering process on boards that are notrigid enough.

The Chip wave should be turned off (set tozero) when not needed for process.

Dross GateAdjusting Bolt

Dross GateAdjustingBolt

Unload

Dross GateLoad SideDross

= Solder Flow

= Solder Wave

= Solder Level

Gate

Side

Electra™

Operation 2-9317-120-00-0 — Rev. 3 139

ROTARY CHIP NOZZLE (AIR) SETUPThe Rotary Chip wave adjustments are thesame as the Turbulent Chip, with the exceptionof adjusting the rotary speed. The Rotary Chipnozzle has adjustments for the load and unloaddross p la tes in o rder to cont ro l d rossproduction. Both gates each have two (2)adjusting bolts. Adjusting the bolts up or down,adjusts the dross gates up or down, controllingthe speed at which the solder flows back intothe solder pot. For optimum performance, thedross gates should be leveled about 12 mm (.50in.) from the top of the nozzle. Always adjust theload side dross plate first.

Figure 164: Rotary Chip Air Nozzle Cut-Away View

Lead Clearance:

Lead clearance for the Rotary Chip wave shouldbe set at the same time that the Lambda™ leadclearance is set. Use the same lead lengthparameters to set the Rotary Chip wave asperformed on the Lambda™ wave.


The wave height must be set so that the crest ofthe Rotary Chip wave ripples do not overflowthe PCB being processed.

Increase the Rotary Chip Wave rpm via theElectra™ software at the operator interface toincrease wave height. Decrease rpm’s todecrease wave height.

A t i tanium PCB stif fener orpallet can be used to preventso lder over f low dur ing the


Rotary Speed Setting:

The Rotary Speed is set via the Electra™software at the operator interface.

Once the Rotary Chip wave is started andoperating at a minimum of 300 rpm’s theRotary Speed can be set. Minimum rotary is75 rpm’s.

The Chip wave should be turnedoff (set to zero) when not neededfor process.


Unload SideDross Gate


Load SideDross Gate

= Solder Flow

= Solder Wave

= Solder Level

= Rotary Chip Rotation

Electra™

140 2-9317-120-00-0 — Rev. 3 Operation

CON2TOUR AND CON2TOUR PLUS WAVE SETUPFor optimum performance and to achieve thebest soldering results using the CoN2Tour™system, it is important to set up the nozzle ornozzles (if configured with an inerted chip orRotary Chip) and flow ducts in the sameconfigurat ion each and every t ime. Thefollowing list of points, i l lustrated in thephotograph in Figure ?, illustrates the referencepoints of contact required to contact a singleplane (straight edge) on a six (6°) degree inclinewhile maintaining an operating height of 1/8 in.(1/4 in. max.) in the solder pot. The 1/8 in. (1/4in. max.) distance is measured with the straightedge place across al l points of contactillustrated, with the extended edge over theentrance edge of the solder pot. The distancebetween the bottom edge of the straight edgeand the lip of the solder pot is the measuringpoint.

The figure below illustrates thepo in ts o f con tac t f o r theCoN2TourPlus™ as well as the

optional interted Rotary Chip™ nozzle. Thisfigure may be used as reference for setup forthose configurations as well.

Figure 165: Verifying the height and angle of the nozzles in relation to the solder pot

This setup is with the Hot Knifeset at a 90° angle. The inclineshould be set in this fashion,

allowing the knife to lay flat, to permit thefront and exit slider plates for the Hot Knife toproperly contact the straight edge.

If all points of reference do not contact thestraight edge, adjustment is required.

1. Verify that the flow ducts that the nozzlesset in are level. If they are not, adjust theleveling nuts, two (2) front and two (2) rear,at either end of the flow duct to adjust theheight of the assembly up or down in thesolder pot. See Figure 166 - Leveling Nuts.

Con2TourPlus™ Setup Points of Contact for 6° Incline

POINT DESCRIPTION

A Hot Knife Exit Slider Plate

B Hot Knife Front Slider Plate

C A-Wave Exit Curve Plate

D A-Wave Front Curve Plate

E A-Wave Load Slider Plate

F Rotary Chip Exit Plate

G R-Chip Baffle Plate Leading Edge

H Rotary Chip Front Plate

Hot Knife

A-Wave

Rotary Chip

Leading Edge of Pot

Electra™

Operation 2-9317-120-00-0 — Rev. 3 141

Figure 166: Leveling Nuts

2. Now place a level across the nozzle toensure that the nozzle remains level in thepot from front to back.

Figure 167: Check the level across the nozzles

3. Once adjusted to the proper height inrelation to the front lip of the solder pot,tighten the lock nuts below the levelingnuts to secure the nozzle in position.

4. If all nozzles are at the proper height inrelation to the leading edge of the solderpot, and the nozzles are at a 6° incline, butnot all designated points are in contactwith the straight edge, additional fineadjustment can be made by adjusting thecurbe and slider plates accordingly. Thecurve plates can be adjusted up or downby loosening the bolts, adjusting the plateup or down, and then re-tightening thebolts. Slider plates may be adjusted in orout from the applicable nozzles.

5. If all designated points are in contact withthe straight edge but the hot knife sliderplates, verify that the angle of the HotKnife has been adjusted to 90° so that itlays flat. Otherwise, the point of contactmay be touching the hot knife itself. Onceadjustment is made so all points arecontacting the straight edge, the hot knifeangle can then be re-adjusted to therequired angle for operation.

Electra™

142 2-9317-120-00-0 — Rev. 3 Operation

Nitrogen Setup:

At the nitrogen control panel, set the nitrogento 304 kPa (44 psi) using the pressure regulator,and set the flow rates according to the valuesshown in the Flow Rate table that follows.

Figure 168: Nitrogen Controls

Allow the flow meters and nitrogen pressure tostabilize; re-check the readings again on theflow meters and on the pressure gauge. If thepressure and flows have increased or dropped,adjust again to the specified settings until theys tab i l i ze as c lose as poss ib le to therecommended settings.

Lead Clearance Setting:

1. Determine the longest lead length on thePCB’s being processed. Start theCoN2Tour™ wave (if configured, also startthe interted chip or rotary chip wave) viathe Electra™ software at the operatorinterface. Adjust the CoN2Tour™ wavespeed to achieve a wave depth equal to theactual lead length plus two (2) mm.

2. Raise the solder pot until the “V” Groove or“L” of the fingers is at a height equal to thelead clearance determined in step 1 of thisprocedure (inspect both waves ifapplicable).

3. Run a test PCB across the wave to verifythat the solder does not flow over the topof the PCB.

Flow Meters (From Left to Right)

Load End Chip N2 Unload End Chip N2 Load End CoN2Tour N2 Unload End CoN2Tour N2

4.2 M3/Hr. (150 Ft3/Hr.) 4.2 M3/Hr. (150 Ft3/Hr.) 4.2 M3/Hr. (150 Ft3/Hr.) 8.5 M3/Hr. (300 Ft3/Hr.)

Electra™

Operation 2-9317-120-00-0 — Rev. 3 143

Entrance Slide Plate Adjustment:

1. While the wave is operating, use an 8 mmnut driver to loosen the Entrance SlidePlate Adjusting Bolts — loosen each of thebolts just enough to allow the Slide Plateto be slid in one direction or the other.

2. Adjust the Slide Plate to achieve an evengap across the front edge of the wave,about 0.318 mm (1/8 in.) from the surfaceof the solder.

3. Re-tighten the adjusting bolts loosened instep 1.

4. This sets the inert boundary at the leadingedge of the solder wave.

Exit Slide Plate Adjustment:

1. While the wave is operating, use an 8 mmnut driver to loosen the Exit Slide Plate

Adjusting Bolts — loosen each of the boltsjust enough to allow the Slide Plate to beslid in one direction or the other.

2. Adjust the Slide Plate to achieve an evengap across the exit edge of the wave, about0.318 mm (1/8 in.) from the surface of thesolder.

3. Re-tighten the adjusting bolts loosened instep 1.

4. This sets the inert boundary at the exitedge of the solder wave.

Refer to the applicable chipw a v e s e t u p p r o c e d u r e s i fconfigured with Turbulent or

Rotary Chip nozzles.

Figure 169: CoN2Tour™ Nozzle Cut-Away View

= Solder Flow

= Solder Wave

= Solder Level

Entrance Slide Plate

Exit Slide Plate

Adjusting Screws

Adjusting ScrewsExit Curve Plate


Electra™

144 2-9317-120-00-0 — Rev. 3 Operation

Figure 170: CoN2TourPlus™ Nozzle Cut-Away View

To Adjust the Hot Knife Angle:

• Using a flat head screwdriver, turn the hotknife to the operating angle desired. Thefactory default setting is 70°.

Figure 171: Set the Hot Knife Angle

To Adjust the Hot Knife Height:

• The factory default setting of the hot knifeheight is set to 1/16 in. above the 6° plane ofthe solder nozzles.

• To raise or lower the height of the hot knife,loosen the locking screws at either end of

the knife’s height adjustment plates.• Once at the desired height, verify the nozzle

is level along its length, then tighten thelocking screws.

Figure 172: Adjust the Hot Knife Height

= Solder Flow

= Solder Wave

= Solder Level

Entrance Slide Plate Adjusting Screws

Adjusting Screws Exit Curve Plate


Exit Slide Plate

InsertScrewdriverHere

Hot Knife

AngleIndicator

Scale

Height AdjustLockingScrew

Hot Knife

Height AdjustLocking Screw

Electra™

Operation 2-9317-120-00-0 — Rev. 3 145

ROTARY CHIP NOZZLE (N2) SETUP

The only adjustments available for the RotaryChip nitrogen nozzle is Wave Height for leadlength, Rotary Speed, and the Nitrogen Setup.

Figure 173: Rotary Chip N2 Nozzle Cut-Away View

Lead Clearance:

Lead clearance for the Rotary Chip wave shouldbe set at the same time that the Lambda™ leadclearance is set. Use the same lead lengthparameters to set the Rotary Chip wave asperformed on the Lambda™ wave.


The wave height must be set so that the crest ofthe Rotary Chip wave ripples do not overflowthe PCB being processed.

Increase the Rotary Chip Wave rpm via theElectra™ software at the operator interface toincrease wave height. Decrease rpm’s todecrease wave height.

A t itanium PCB stiffener orpallet can be used to preventso lder over f low dur ing the


Rotary Speed Setting:

The Rotary Speed is set via the Electra™software at the operator interface.

Once the Rotary Chip wave is started andoperating at a minimum of 300 rpm’s the

Rotary Speed can be set. Minimum rotary is75 rpm’s.

The Chip wave should be turnedoff (set to zero) when not neededfor process.

Nitrogen Setup:

Refer to the Nitrogen Setup table on page 142.

= Solder Flow

= Solder Wave

= Solder Level

= Rotary Chip Rotation

Electra™

146 2-9317-120-00-0 — Rev. 3 Operation

IR PREHEAT SETUPSetup for the IR Preheat involves adjusting theheight of each of the preheaters. Perform thethe steps that follow to adjust the height of thepreheaters to accomodate the process ofproduct through the Electra™.


The preheaters, solderpot, rail guards, parts of the conveyor andother exposed metal and glass surfaces arepotent ia l burn hazards to personne lperforming maintenenace or operation setupprocedures. Components and surfaces canreach temperatures in excess of 66 °C (150°F), which may cause serious burns. Allowhot comonents to cool whenever possibleprior to performing maintenance. Alwayswear safety garments or equipment whenworking with or around hot components. It isrecommended to perform this procedurewhile the preheaters are cool.

1. Open the Electra™ cabinet overheaddoors.

Figure 174: Electra™ overhead doors and tailgate open (shown with Vectaheat™ preheaters

2. Open the tailgate door to allow access to the preheaters.

Electra™

Operation 2-9317-120-00-0 — Rev. 3 147

3. Starting with lower preheater #1, using atape measure, measure the distance fromthe V-groove on the conveyor fingers to thesurface of the IR preheater glass at eachof the four (4) corners of the preheater.Each corner has an adjustment bolt on theunderside of each corner.

4. Slide the preheater out until it stops.

Unless process lead lengthsexceed 1 /2 in . , i t i srecommended to set the default

operating height of the preheaters to 1/2 in.clearance. For lead lengths exceeding 1/2 in.,adjust the preheater height accordingly. Theadjustment range is from 1/2 in. (adjusted allthe way up) to two (2) in. (adjusted all the waydown).

5. Using a 10 mm nut driver, adjust each ofthe four (4) M6 x 60 hex head bolts evenly,so that when measured at each corner ofthe preaheater, there is 1/2 in. clearancefrom the V-groove on the finger to thesurface of the IR preheater glass.

6. Slide the preheater back into operatingposition and re-check the clearance ateach of the four (4) corners of thepreheater.

7. Repeat steps 4 thru 6 until the preheatheight is properly adjusted for clearance.

8. Repeat steps 3 thru 7 for the remaininglower preheaters.

Electra™

148 2-9317-120-00-0 — Rev. 3 Operation

VECTAHEAT™ SETUPSetup for the Vectaheat™ preheater involvesadjusting the height of each of the preheaters.Perform the the steps that follow to adjust theheight of the preheaters to accomodate theprocess of product through the Electra™.


The preheaters, solder pot,rail guards, parts of the conveyor and otherexposed metal and glass surfaces are potentialburn hazards to personne l per formingmaintenenace or operation setup procedures.C o m p o n e n t s a n d s u r f a c e s c a n r e a c htemperatures in excess of 66 °C (150 °F), whichmay cause serious burns. Allow hot comonentsto cool whenever possible prior to performingmaintenance. Always wear safety garments orequipment when working with or around hotcomponents. It is recommended to performthis procedure while the preheaters are cool

1. Open the Electra™ cabinet overheaddoors.

Figure 175: Electra™ overhead doors and tailgate open (shown with Vectaheat™ preheaters

2. Open the tailgate door to allow access to the preheaters.

Electra™

Operation 2-9317-120-00-0 — Rev. 3 149

3. Starting with lower preheater #1, using atape measure, measure the distance fromthe V-groove on the conveyor fingers to thetip of the bolt at the center of theVectaheater. Verify the height at each of

the four (4) corners of the preheater. Eachcorner has an adjustment bolt at the top ofeach corner.

4. Slide the preheater out until it stops.

Figure 176: Vectaheat preheater slid out for adjustment

Unless process lead lengthsexceed 1 /2 in . , i t i srecommended to set the default

operating height of the preheaters to 1/2 in.clearance. For lead lengths exceeding 1/2 in.,adjust the preheater height accordingly. Theadjustment range is from 1/2 in. (adjusted allthe way up) to two (2) in. (adjusted all the waydown).

5. Using a 10 mm nut driver, adjust each ofthe four (4) M6 x 60 hex head bolts evenly,so that when measured at each corner ofthe preaheater, there is 1/2 in. clearancefrom the V-groove on the finger to thesurface of the IR preheater glass.

Height Adjustment Bolts TYP

Height Reference Point

Electra™

150 2-9317-120-00-0 — Rev. 3 Operation

Figure 177: Measure from center of V-groove to top of Bolt

6. Slide the preheater back into operatingposition and re-check the clearance ateach of the four (4) corners of thepreheater.

7. Repeat steps 4 thru 6 until the preheatheight is properly adjusted for clearance.

8. Repeat steps 3 thru 7 for the remaininglower preheaters.

Height Reference Point

Height Adjustment BoltMeasure from Center ofV-groove on Fingers

Electra™

Operation 2-9317-120-00-0 — Rev. 3 151

SECTION 7: STARTUP

7.1 EXHAUST• Activate the facility exhaust system for the

Electra™.• The Electra™ is configured with two (2)

exhaust sensors; one for each exhaust port— fluxer and solder pot. Without the facilityexhaust system activated, the Electra™ willnot go into the Auto mode, nor can the

nitrogen be enabled. An alarm is generatedin the event that the exhaust sensors arenot satisfied.

• If the system exhaust is on but, the systemwill not operate, refer to the Technical Datasection in this manual for the correctexhaust requirements.

Figure 178: Electra™ exhaust sensors

7.2 SYSTEM ACTIVATION• Turn on power to the Electra™ via the

system disconnect at the rear of themachine.

Figure 179: System Disconnect

• The Electra™ powers up with the computer

running under Windows NT® — theElectra™ software starts up and is ready foroperation, and the interior hood lightsilluminate.

Figure 180: Electra™ open with lights on and operator interface screeen

Fluxer End Exhaust Sensor

Solder Pot End Exhaust Sensor

Electra™

152 2-9317-120-00-0 — Rev. 3 Operation

7.3 RECIPE SELECTIONSee Load Rec ipe in the Opera t ion andDescription section of this manual.

7.4 CREATING A NEW RECIPERefer to the Save Recipe As New … function inthe Operation and Description section of thismanual.

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