Southern Machinery

SMT & THT PCB Assembly Automation for EMS Factories

Reflow profile measurement method

Reflow profile specification

Figure 1. Illustration of critical reflow process parameters.

Recommended reflow oven settings

The following settings shall verified for each oven using oven calibration method (section 6.2) and settings shall be adjusted if necessary to achieve a profile within the specification in section 6.3.

ERSA Hotflow 7

ETA and Southern Machinery will attend the USA IPC APEX EXPO 2016 exhibition to share the industry’s top feast.

You are warmly welcome to visit our booth No. :#2930 in USA IPC APEX EXPO (Mar. 15th-Mar17, 2016)

As the industry's leading manufacturers, ETA would show our latest T-series lead-free reflow oven together with Southern Machinery in USA IPC APEX EXPO 2016 exhibition.This is unique machine in China now. It refreshes the traditional perception of reflow oven. T-series lead-free reflow oven could ensure the lead-free process optimization under the condition of the smallest footprint and the lowest power consumption. It could meet all customer’s demand. Meanwhile, Many new special equipment will also be displayed at this show.

ETA is the professional manufacturer of reflow oven and offer full SMT solutions for customers. We have more than 20 years experience and technology in SMT filed. The most professional term and the best service are waiting for you. Our goal is to provide the reliable full SMT solutions to all the customers around the world. Southern Machinery is our good global partner. We would provide the high-value technical support to our customers together.

www.smt11.com,

smthelp.org/

You are warmly welcome to visit our booth No. :#2930.

Southern Machinery:Provide SMT whole line solution.

All PCBs will be designed with the following preference guidelines for choice of components, placement, and track size. This strategy is intended to make maximum use of Design and Manufacturing capabilities and to minimize overall manufacturing costs:

Full SMT. Component side only
Full SMT. on both Component and solder sides
Mixed SMT. and pth. on component side only
mixed smt. and pth. with active smds on the component side and passive components on solder side

Clinch Tooling to SMT Clearance (Bottom side)

BrushedMotorX-YPositioningSystemMotionFaultDiagnosticProcedure

The following procedure is intended to be used as a diagnostic tool for determining general causes for X Y Positioning System Motor failures and Motion Faults. Using a known good motor, an attempt will be made to isolate the problem between there motor, or the other system issues. UsethisprocedureonlyonGeneration8,SingleHeadMachinesequippedwithBrushedMotors(referencepartnumber42418104).

Note:
Ifyouhavetoreplacea Motor, pleasereturnittoBinghamtonintheboxthereplacementcomesin.

EQUIPMENT NEEDED:
Good Motor, Blue Kendall grease (40833810) for leadscrew, 10W (40833827) oil for ball bushings & axis shafts, Phillips head screw driver, Allen wrenches

F/E SKILLS REQUIRED:

IM Diagnostics
X-Y Home Zero Set-up
Installing X-Y Positioning system motors

ESTIMATED TIME TO PERFORM PROCEDURE:
30 minutes if no problems found
3 hours if motor is found to be defective
5 + hours if other system problems are found INFORMATION (please fill out)

STEP1(PerformonXaxisfirst,thenrepeatonYaxis)

In this step, you will be running a single axis at reduced speed & acceleration while observing the Max DAC output, which is proportional to the torque. If the torque is too high, this may indicate motor or positioning system problems.

LAUNCH IM DIAGNOSTICS

Run “Quick Start” Select #1 “Set-up BEC”
When macro is done zeroing (quit don’t save) to exit “set-up BEC” screen

Select: DIAGNOSTICS, MANUAL DIAGNOSTICS
On the LEFT side, click the pull down menu of the “SECTION” box. Select “UIMC 1 AXIS INPUTS”
Click the BLUE “MOVE” button & edit the following parameters: Speed from 116 to 10
Acceleration from 2400 to 500

Click the Auto Cycle & Continuous Run check boxes Cycle the axis from 0” to 18” or 0 count to 144,000 count
Observe the “Maximum DAC Output During Move” number for approximately 5 minutes and fill out the STEP 1 CHART below.
If the number ever gets above 340 maximum, the system has too much friction. It could be the motor or other system problems.
If the “Maximum DAC output during move” is less than 340. Stop. No further steps are required for this Axis.
This Axis appears to be functioning correctly.

STEP1CHART
Proceed to STEP 2
STEP 2
In this step you will perform specific PM activities that have a large impact on the amount of torque required to
operate the positioning system.

Grease the lead screw, oil the shafts & re-tension the belt.

Cycle at normal speed and acceleration for ½ hour, check the appropriate box below.

Speed…………116 Acceleration….2400

Was theleadscrewdry?	YESĀ	NOĀ
Was theShaftdry?	YESĀ	NOĀ
Was thebeltloose?	YESĀ	NOĀ

Cycle at the reduced Speed & Acceleration per STEP 1 and fill out the STEP 2 CHART below. If it gets considerably better (Max DAC below 340) you’re done. If not, go on to STEP 3.

STEP2CHART

STEP 3

In this step you are removing the motor in preparation for Step 4 and making further investigation into possible sources of high positioning system friction.

Remove the motor and move axis by hand.
Feel and listen for binds, hesitations or noises in the lead screw and/or ball bearing/shafts.

Whatwasfound?

Check axial play/gap in the lead screw by grabbing it by hand & pushing in both directions. There should be no perceivable axial play in the leadscrew.

MaxDACOutputDuringMove

Was thereanyplay?		YESĀ	NOĀ
Replace any parts that you think it has problem.
Whatwasreplaced?
PartNo Description	Symptom

Purpose:

The purpose of this document is to describe how to maintain the “Gold” series motors, PMI type U12M4, and U12M4H (UIC part number 11467000, 13570000, 40051001, and 40051002, sold before November 1995) This procedure should be performed every six months, or more frequently if found to be necessary.

Tools Required:

Allen wrenches
Screw driver (5 to 6 mm wide)
Screw driver, small blade (2,5 to 3 mm wide)
Adjustable wrench

Prerequisite:

Push in the machine’s Emergency Stop button
Turn off the machine’s power

Procedure:

1. Note which wires are attached to which motor terminal. Using an adjustable wrench, remove the wires from the motor’s terminals.

2. Remove the motor from the machine

3. Remove the brushes from the motor

4. The minimum usable length of the carbon part of the brushes is .240 inches ( 6,1 mm) long. If the brushes wear shorter than .240 inches, the motor’s commutator wires can be damaged by electrical arcing.

So that the brushes will not wear to less than .240 inches, we recommend that they be replaced when they become .300 inches long ( 7,62mm). Universal’s part number for a set of four (4) brushes for these motors is B26100021.

5. Check that the motor’s shaft turns smoothly. If not, then the bearings are damaged, and the motor should be discarded.

6. Using clean, dry, compressed air, blow the carbon dust out of the motor.

7. Look through the brush holes and examine the condition of the commutator wires, while turning the motor shaft. If there are any burned or damaged wires, the motor must be discarded.

8. To install the brushes into the motor, place the carbon block in the brush hole.

9. Using a small screwdriver, gently push the spring down into the brush hole. It will be necessary to reposition the blade of the screw driver several times into the coils of the spring, to make the spring go into the hole.

10. It may be necessary to push the metal tab on the side of the brush contact to make it go into the brush hole.

11. After the metal tabs have gone into the hole, use the screw driver to hold the brush contact down in the brush hole.

12. Pull the small screw driver blade out while moving the screw into place. Be sure that the brush contact’s tabs do not come completely out of the brush hole when doing this. Start the screw in the threaded hole by turning it clockwise with your fingers. If it will not turn easily, remove it, and repeat step 11. Then tighten the screw gently using the large screw driver.

13. Install all (4) brushes into the motor. Mount the motor on the machine again. Reattach the wires on to the proper motor terminals.

Machine Axis Control IM-Diagnostics Mode Overview *

*This is a generic overview for training purposes. Actual axes on the machine may differ slightly from this overview.

Purpose:

Tools Required:

Allen wrenches
Screw driver (5 to 6 mm wide)
Screw driver, small blade (2,5 to 3 mm wide)
Adjustable wrench

Prerequisite:

Push in the machine’s Emergency Stop button
Turn off the machine’s power

Procedure:

1. Note which wires are attached to which motor terminal. Using an adjustable wrench, remove the wires from the motor’s terminals.

2. Remove the motor from the machine

3. Remove the brushes from the motor

5. Check that the motor’s shaft turns smoothly. If not, then the bearings are damaged, and the motor should be discarded.

6. Using clean, dry, compressed air, blow the carbon dust out of the motor.

7. Look through the brush holes and examine the condition of the commutator wires, while turning the motor shaft. If there are any burned or damaged wires, the motor must be discarded.

8. To install the brushes into the motor, place the carbon block in the brush hole.

10. It may be necessary to push the metal tab on the side of the brush contact to make it go into the brush hole.

11. After the metal tabs have gone into the hole, use the screw driver to hold the brush contact down in the brush hole.

13. Install all (4) brushes into the motor. Mount the motor on the machine again. Reattach the wires on to the proper motor terminals.

Machine Axis Control IM-Diagnostics Mode Overview *

*This is a generic overview for training purposes. Actual axes on the machine may differ slightly from this overview.

PLACEMENT PROCESS SPECIFICATIONS
Nozzles

Recommended nozzle sizes for some package types:

Feeders

NC-Programs

Part Data / Vision processing

Placement process management data compatibility table

Reflow soldering process specification
Profile measurement equipment

Reflow profile shall be measured using a temperature measurement equipment specifically designed for pass-through reflow profile measurements.

The profiling equipment shall be calibrated regularly according to the maintenance instructions by the supplier.

Only the thermocouples recommended and approved by the measurement equipment supplier shall be used.

Reflow profile measurement method

Reflow profile specification

Figure 1. Illustration of critical reflow process parameters.

Recommended reflow oven settings

ERSA Hotflow 7

BTU VIP98

MANUAL SOLDERING PROCESS AND WORKMANSHIP CRITERIA

Manual and semi-automatic hot gas soldering and rework

Warning! A visual change in PWB surface characteristics during heating is a sign of too high a temperature and/or too long exposure time and must result in rejection of module.

Product Description

This solder paste special for SMT production process. It is made from the special solder paste and sphere tin power with little oxide content. It has the excellent performance in continuous printing. It has very little residue after reflow and very good insulation impedance. With various alloy composition, different diameter of tin powder, and metal content to meet the customer need in products and process requirement.

Product Feature and Selling points

1. Good rollability in printing, excellent performance in printing even for 0.3mm part spacing in steel plate.
2. Little changes for the viscosity for continuous printing, longer life time for the stencil, and good printing performance even for continuous 8 hours printing.
3. No slump electron migration several hours after printing.
4. Excellent welding performance and proper wettability in different parts.
5. Adaptable to different level of welding equipments, finish welding with no nitrogenization, good performance in welding even in wide range reform temperature.
6. Very little residue, light in color, and good insulation impedance and no corrosion to PCB, no need clean.
7. Good testing performance in ICT.
8. Workable for paste in Hole process

Printing process parameters (stencil printing)

Parameter	Setting
Print speed	100mm/s recommended, min 70mm/s, max 120mm/s Note: Under non-conforming situations caused by technical problems, lower than specified speeds are temporarily accepted.
Squeegee pressure for 200mm wide squeegee** in constant force mode (force automatically adjusted, print head floating)	minimum pressure that will wipe stencil surface clean +5N as safety margin, normally between 40 50 N
Squeegee adjustment for MPM printers (constant squeegee distance (negative) from PWB surface, force against down stops)	Minimal adjustment that will wipe stencil surface clean +0.5mm as safety margin
Snap-off distance	-0.5 – 0.0mm on whole panel area (negative snap-off recommended to give margin against machine misadjustments)
Separation speed	Max. 20 mm/sec until stencil has released, then maximum speed.
Automatic wipe rate	After every 10 ± 5 prints Note: Under non-conforming situations caused by temporary technical problems more frequent wipe may be applied.
Wipe cycle recommendation	1 dry with vacuum or 1 dam followed by 1 dry for printers without vacuum option
Recommended cleaning fluid for printer automatic wiping	Multicore Prozone SC-01 or equivalent high flash point solvent officially accepted by printer manufacturer. Use of isopropanol (IPA) or equivalent solvents is not recommended due to fire safety.
Recommended cleaning fluid for cleaning of misprinted boards	Multicore Prozone SC-02 is preferred (SC-02 will attack slightly acrylics and some rubbers used in protective gloves) Use of isopropanol (IPA) is allowed but not recommended. Waste must be handled properly. Note! Components that are not designed for liquid cleaning process, have to be removed and changed after cleaning. PWB with laser (micro) vias, OSP plating or which are totally or partly Aramid based, ARE NOT ALLOWED TO BE WASHED! Cleaning solvent traps into PWB structures and reduces esp. CSP components joint reliability.

Support table vacuum	OFF while printing, unless dedicated workholder is of such construction that no vacuum is created between PWB and stencil OR vacuum is limited to 100-200mbar. Vacuum ON during loading and table movements (activate special 1043 in AP-25 SW 6.1 or later).
Kneading1	8 kneads after every 20min or longer pause in printing process and recommended after addition of paste. Otherwise not needed.
Solder paste amount on stencil	150 160 g + paste attached to squeeze (200mm )
Printing accuracy	+/- 0.05 mm

*) Sometimes referred as ”squeegee pressure” and force given in KGs, 1kg=9.81N

**) Depends linearly on squeegee width

1) Automatic procedure to soften paste and dissolve partly dried paste residues at stencil aperture opening edges instead of stencil manual cleaning. The panel used for kneading can be fed to production line as normally printed board. After pauses beyond 120min careful stencil cleaning in dedicated cleaner is recommended.