XPM 2. Reflow Soldering / Curing Systems. Site Preparation & Installation

Transcription

1 XPM 2 Reflow Soldering / Curing Systems Site Preparation & Installation Site Preparation & Installation 1 Revision Date: May 2004

2 Table of Contents SITE PREPARATION CHECKLIST 3 ROOM PLANNING 4 Oven Clearances 4 XPM 2 Installation Drawing 5 FACILITY SERVICES & CONNECTIONS 6 Exhaust Specifications 6 Electrical Power 8 Nitrogen Supply (optional) 10 Compressed Air Supply 11 External Coolant Supply 11 OVEN RECEIPT & HANDLING 12 Receiving Inspection 12 Unpacking the Oven 13 Positioning & Pre-Leveling the Oven 14 Connect the Hood Interlock Switch 14 Connecting The Computer System 15 Site Preparation & Installation 2 Revision Date: May 2004

3 SITE PREPARATION CHECKLIST Prior to Vitronics Soltec installing / commissioning the solder reflow system (oven), the oven must be placed in line, pre-leveled, and connected to the required facilities by the customer. The checklist below should be reviewed and completed prior to requesting a site visit by a Vitronics Soltec Service Engineer. Reference the XPM 2 Installation Drawing and additional requirements herein for details. Exhaust system correctly sized and located? * Electrical power and main circuit breaker switch properly rated, installed and provided to the oven? * Nitrogen source correctly sized, located and plumbed to the oven? Compressed air supply correctly sized, located and plumbed to the oven? * External coolant supply available with proper hose lines and connections? Oven placed in position and pre-leveled? * Configuration dependent, consult purchase order and equipment specifications for details. Site Preparation & Installation 3 Revision Date: May 2004

4 ROOM PLANNING XPM 2 MODEL / / LENGTH (in/cm) 139 / / / / 630 WIDTH (in/cm) 52 / / / / 132 HEIGHT (in/cm) 57 / / / / 144 WEIGHT (lb/kg) 2800 / / / / 2770 Oven And Skid LENGTH (in/cm) 172 / / / / 617 WIDTH (in/cm) 67 / / / / 171 HEIGHT (in/cm) 65 / / / / 165 WEIGHT (lb/kg) 3000 / / / / 2885 Oven And Crate LENGTH (in/cm) 177 / / / / 724 WIDTH (in/cm) 67 / / / / 171 HEIGHT (in/cm) 76 / / / / 193 WEIGHT (lb/kg) 3425 / / / / 3125 Oven Clearances A full 36 clearance space should be provided around front and rear of the oven to allow for a safe working area. All applicable Codes and Regulations should be considered when providing service space. Oven Height listed is with the Hood down and does not include ductwork. Access Doors and other openings should be large enough to accommodate the personnel and equipment involved in moving and placing the oven. Allow approximately 6" (15 CM) of clearance above the oven for lifting. Floor The oven must be located on a level, dust free concrete floor not subject to vibration from other equipment or passing fork trucks. Vibration in the floor may cause problems with the oven 's conveyors and the printed circuit boards being processed. Air Conditioning Air Conditioning Load for all oven Models is not more than 35,000 BTU/ hour. The system is designed to operate within the following environmental conditions: Temperature: 55 to 90 o F (13 to 32 o C) Humidity: 20 to 90% Non Condensing Site Preparation & Installation 4 Revision Date: May 2004

5 Site Preparation & Installation 5 Revision Date: May 2004

6 FACILITY SERVICES & CONNECTIONS Exhaust Specifications Number of Connections per Oven 2 Oven Exhaust Duct Size 8 Facility Duct Material High Temperature Flexible Hose Rated For C Minimum Onload Stack ( Entrance ) Offload Stack ( Exit ) CFM IWC CFM IWC Standard Air or N to to With Polar Cooling or Controlled Cooling With Integrated Exhaust Stack Filter to to to to CFM = Cubic Feet Per Minute IWC = Inches of Water Column Note: On ovens equipped with the Exhaust Sensing System option, insufficient exhaust flow will cause an oven alarm condition if the exhaust flow is below the minimum setpoint. Exhaust Measurement Detail End View - Service Position Shown Site Preparation & Installation 6 Revision Date: May 2004

7 Exhaust Specifications (continued) The oven requires one main facility exhaust connection branched into two sections and connected to the exhaust ducts/ vents on the oven. The main facility drop should be offset to the rear of the oven by approximately two feet. The connecting hose must be flexible and durable enough to allow for the opening and closing of the Hood / upper heat zone for servicing. The installation of adjustable dampers (as shown below) in the exhaust connection is required to allow flow adjustments as necessary. Flow dampers must be installed 40 inches above the top of the oven duct / vent. The Customer is responsible for supplying the main exhaust drop, the two branch sections, flow dampers and hose clamps to connect to the oven ducts/vents. Adjustable dampers located approximately 40 (102 cm) above the oven duct / vent in each branch. Examples of Acceptable Exhaust Configurations Site Preparation & Installation 7 Revision Date: May 2004

8 Electrical Power Vitronics Soltec electrical wiring design is based on the USA National Electrical Code (NFPA-70 & 79) from the National Fire Protection Association guidelines and European Standard EN Vitronics Soltec makes no claims or warranties for compliance to any other standard or any local, state, federal or country codes, expressed or implied. Unless purchased as an option, XPM 2 ovens are not equipped with a main circuit breaker disconnect switch. A properly rated fused disconnect or main circuit breaker switch, facility power cable and connection to the oven switch must be supplied by the customer and installed by a qualified electrician in accordance with applicable regulations and codes. Estimating Power Requirements Refer to the Electrical Configuration on the Purchase Order for the oven or the oven s Nameplate Data to determine the voltage. CAUTION: Incorrect voltage can result in extensive damage to the oven. The Electrical values in the data tables are based on Vitronics Standard Factory Settings for power management. Modification to the power management settings in the Oven Control Software may render these numbers invalid XPM 2 Current Draw at Start-up in Amperes (kva) MODEL / / vac, 3 ph 110 (38) 120 (42) 120 (42) 120 (42) 208 vac, 3 ph 120 (43) 120 (43) 120 (43) 120 (45) 220 vac, 3 ph 120 (46) 125 (48) 125 (48) 130 (50) 240 vac, 3 ph 125 (52) 130 (54) 135 (56) 140 (58) 380 vac, 3 ph 55 (36) 60 (39) 60 (39) 65 (43) 400 vac, 3 ph 60 (42) 65 (45) 65 (45) 65 (45) 415 vac, 3 ph 60 (43) 65 (47) 65 (47) 70 (50) 440 vac, 3 ph 60 (46) 65 (50) 65 (50) 70 (53) 480 vac, 3 ph 65 (54) 70 (58) 70 (58) 70 (58) Power Connections Connect the power and ground cables from the dedicated service (fused disconnect or circuit breaker) to the power connectors located inside equipment access door located at the front-right corner of the oven. Connect and secure the cables to the power and ground blocks. A hex wrench for socket head screws will be needed to tighten the power connections after inserting the supply conductors. The Circuit Breaker also uses socket head screws for securing the conductors. Site Preparation & Installation 8 Revision Date: May 2004

9 Grounding A dedicated equipment ground from the facility distribution panel for the oven is required to comply with Article 250 of the National Electrical Code. The equipment ground is necessary for the safety of personnel as well for safe and reliable oven operation. All grounding and service wiring should be installed and tested by a qualified licensed electrician. Power Quality The oven control systems do not condition the facility supplied power to the oven. For proper operation, the power must be maintained at a "cleanliness level" of less than 10% of High frequency (200V rise / microsecond) noise on the input voltage. The AC voltage supplied to the oven must be + 10% of the stated voltage. (For example 220 VAC must be between 198VAC and 242 VAC). The voltage frequency must be within + 1% limit of the stated frequency. For 3 Phase power, any line to neutral voltage must be within + 5% of the arithmetic mean of the three line to neutral voltages. Any and all damage, service and costs resulting from poorly conditioned facility power is solely the responsibility of the customer. Power Distribution A dedicated facility electrical distribution panel is recommended. Avoid powering heavy duty, electrically noisy equipment from the same panel as the oven; such as: Heavy air conditioners Elevators Heaters Office equipment Fluorescent lights Air ionizers High current motors such as electric drills or water pumps Welders Placement equipment Electromagnetic Fields As with all electronically controlled equipment, the oven should be installed in an area not affected by electromagnetic fields generated by other pieces of equipment. Uninterruptable Power Supply Systems Vitronics Soltec offers as and option, a UPS system for the oven which operates the oven conveyor, computer / control system and hood lifts for approximately five minutes after loss of facilities operating power. Consult the purchase order for configuration. It is important to note that neither UPS option will operate the oven heaters or cell fans. Site Preparation & Installation 9 Revision Date: May 2004

10 Nitrogen Supply (optional) Oven Model / / N 2 Process volume [low] CFH (M 3 /hr) 400 (12) 600 (17) 800 (23) 1000 (28) N 2 Process volume [high] CFH (M 3 /hr) 1400 (40) 1600 (45) 1800 (51) 2000 (57) N 2 volume [w/quick atmosphere purge] 2500 CFH (71 M 3 /hr) Pressure regulated to PSI ( Bar) Fitting size 1/2" Female National Pipe Thread (FNPT) Supply pipe size 1/2" Nitrogen purity [typical] * % Moisture content Oxygen content [typical] * < 1 Volume Parts per Million 70 o C < 5 Parts per Million (PPM) * Multiple grades of Nitrogen are available. The following table is provided for reference to the incoming Nitrogen supply. The actual atmosphere within the tunnel will vary depending on oven configuration and process parameters. Typical atmosphere performance will yield O 2 levels greater than the source N 2 purity. %N2 Purity N 2 PPM O 2 PPM % % % % % % % % % The oven is equipped with a pressure regulator and gauge for control of the nitrogen supply. Site Preparation & Installation 10 Revision Date: May 2004

11 Compressed Air Supply Pressure [Basic] regulated to PSI ( Bar) Pressure [N 2 /Air Switching option] regulated to PSI ( Bar) Volume CFH, ( M 3 /hr ) Fitting size 1/2" National Pipe Thread (NPT) Supply pipe size 1/2" The oven is equipped with a pressure regulator and gauge for control of the compressed air supply. External Coolant Supply For N2 ovens not equipped with Polar Cooling or Controlled Cooling options, must have a facility coolant supply to the oven. Temperature Flow rate Pressure (minimum) sensor trips at 50 psig Fitting size / type Coolant medium Alternative Coolant medium PH Particulate 20 C +/- 5 C gpm ( liter/min) minimum flow sensor trips at 0.5 gpm 2 Cooling zones 20 PSI (1.4 Bar) 3 Cooling zones 30 PSI (2.1 Bar) 4 Cooling zones 40 PSI (2.8 Bar) 3/8 FPT (Supply must be 3/8 MPT) Supercool (Inhibited Propylene Glycol and distilled water mixture) Pure distilled water Note: flushing frequency increases 2-6X that of Supercool. Caution: De-ionized water is NOT to be used (attacks brass and copper) Neutral Filtered to at least 100microns Site Preparation & Installation 11 Revision Date: May 2004

12 OVEN RECEIPT & HANDLING Receiving Inspection A complete inspection of the oven should be conducted and any discrepancies noted. Shipping indicators, (see examples below), are mounted to the inside of the oven before shipping from the factory. These indicators should be checked and the as received condition recorded as part of the receiving inspection process. If the oven shipping crate/packaging shows any signs of damage or rough handling, a notice should be filed with the shipper at the time of receipt. Tip Indicator Example Shock Indicator Example Site Preparation & Installation 12 Revision Date: May 2004

13 Unpacking the Oven The XPM2 is a piece of large industrial equipment. Only qualified fork lift operators or riggers should unpack, move, and position the oven. Keep fingers, hands and feet clear at all times while lifting and positioning the oven. CAUTION: Failure to follow the sequence described may result in injury or damage to the oven. Ovens are shipped secured to a wooden pallet (skid) and plastic wrapped. Where required the oven may be crated and foil bagged. If crated, remove the top section of the crate first, the shorter end panels next and the longer side sections last. Cut open and remove the barrier bag and plastic wrapping material. Remove the auxiliary equipment boxes from the skid - be sure to save the original packing material and boxes in the event a return shipment may be necessary for any reason. Unbolt and remove the shipping brackets (as shown), located at the each end the skid/ oven before lifting the oven Once the shipping brackets are unbolted and removed from the oven and the area is cleared of shipping material the oven may be lifted with a fork truck and placed on movable wheeled dollies capable of supporting the oven's weight. Make sure the lifting forks are at least 6 feet (1.8 cm) long and enter from the rear of the oven only. Forks should be positioned to lift from the measured center of the oven. Raise the oven high enough to allow the skid to be removed from under the oven. Make sure the oven is balanced properly on the dollies before removing the fork truck. On 7 and 10 zones oven s use two dollies, one under each end. On 13 and 16 zone ovens use three dollies, one under each end and one under a middle crossmember to evenly support the oven weight. Site Preparation & Installation 13 Revision Date: May 2004

14 Positioning & Pre-Leveling the Oven Once the oven has been lifted from the shipping skid and placed securely on wheeled dollies, it may be moved to the designated location. The leveling feet are not casters or wheels and may be damaged if the oven is pushed or slid along the floor. The oven must be lifted and placed in position. Once in place, adjust all of the feet down to an equal setting before the oven is removed from the dollies. This preliminary adjustment assumes that the oven will be placed on a level floor surface. The oven may then be lifted with a fork truck and set carefully in place. Make sure to position the lifting forks at the measured center of the oven. For pre-leveling, the oven does not need to be lifted to adjust the height. The adjustable leveling feet are designed and should be used as a jacking mechanism. The locking nut on each foot can be loosened and the foot turned clockwise or counter-clockwise to raise or lower the oven. The preliminary or pre-leveling operation requires a 2 foot level and tape measure. 1. Measure the transport height of the up / down stream conveyors. 2. Start at the Onload (in-feed) end, adjust the oven leveling foot at the front corner legs until the conveyor height agrees with the transport height of the up / down stream conveyors. 3. Place the level across the conveyor at the Onload end of the oven and adjust the leveling feet to level the conveyor across the Onload end. 4. Do the same for the Offload (out-feed) end of the oven. 5. Once the Onload and Offload ends of the aligned and leveled to the up / down stream conveyors, adjust the center leveling feet until pressure is felt with the floor surface. When finished, all leveling feet must be firmly placed against the floor equally supporting the oven weight. 6. The Vitronics Soltec Service Engineer will perform a final leveling procedure to ensure that the oven is straight, flat, and free of twist Connect the Hood Interlock Switch The switch which detects if the hood position is down is removed from its mounting location to avoid damage during shipping. This switch is located behind the corner door located below the post for the monitor. Remove the tape from the switch, remove the locking nut and insert the switch through the hold shown. Replace the locking nut on top of the cabinet to hold the switch into position. The switch is already pre-wired. Site Preparation & Installation 14 Revision Date: May 2004

15 Connecting The Computer System The computer system must be set up and connected to the oven. Unpack the computer, monitor, and keyboard and place them on the tower as shown. A B C A. The computer case is installed behind the corner door located below the post for the monitor. All of the cables to be connected to the rear of the computer are pre-wired to that location. B. Connect the cables for the power, monitor, data connection, keyboard and mouse. Be sure cables are secured and will not come in contact with any chains or belts inside of the oven. C. Install the monitor and keyboard tray as shown. There is a cover included for the bottom of the keyboard tray to enclose the wiring. D. The cables needed are prewired to the post. Make all connections as shown. If a light tower was ordered (as an option) install and connect it to the top of the post at this time. D This completes the setup of the oven. You are now ready for a site visit by a Vitronics Soltec Service Engineer to start up the equipment. Site Preparation & Installation 15 Revision Date: May 2004