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Amada UNIFLOW 4 REMOTE Operation Manual

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PULSED HEAT CONTROL
UNIFLOW 4 /
UNIFLOW 4 REMOTE
OPERATION MANUAL
 
 
990-908 REV K

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  • Page 1 PULSED HEAT CONTROL UNIFLOW 4 / UNIFLOW 4 REMOTE OPERATION MANUAL     990-908 REV K...

  • Page 2: Models Described In This Manual

    Models Described In This Manual STANDARD Versions (Control and Transformer in one unit) 2 kVA transformer 4 kVA transformer 4 kVA transformer 2 kVA transformer 2 kVA transformer (90 – 132 VAC (180-264 VAC (180-264 VAC (180-264 VAC (180-264 VAC input single phase) single phase input) single phase input)

  • Page 3: Revision Record

    Copyright © 2011, 2012, 2013, 2014 Amada Miyachi America The engineering designs, drawings and data contained herein are the proprietary work of Amada Miyachi America and may not be reproduced, copied, exhibited or otherwise used without the written authorization of Amada Miyachi America.

  • Page 4: Ship Kit Contents

    Ship Kit Contents Ship Kit Part Number 4-81203-01 PART NUMBER DESCRIPTION QUANTITY 160-116 Bolt, Cap, Hex Head, M6, 25,4l 160-117 Bolt, Cap, Hex Head, M8, 25mml 4-39005-01 Cord, 3x#14,8ft,1conn End 4-38703-01 Plug Set, Uniflow 4 4-38758-01 Thermocouple Cable Assembly, K Type 4-38771-01 CD ROM Manual, Uniflow 4 465-206...
  • Page 5 Ship Kit Part Number 4-81206-01 PART NUMBER DESCRIPTION QUANTITY 4-39005-01 Cord,3x#14,8ft,1conn End 4-38703-01 Plug Set, Uniflow 4 4-38758-01 Thermocouple Cable Assembly, K Type 4-38771-01 CD ROM Manual, Uniflow 4 4-38927-01 FAN 24VDC Power Cable Assy Ship Kit Part Number 4-81207-01 PART NUMBER DESCRIPTION QUANTITY...

  • Page 6: Table Of Contents

    CONTENTS Page Models Described In This Manual ......................ii Revision Record ............................iii Shipment Contents / Ship Kit Cross Reference ..................iii Ship Kit Contents ............................iv Contents .............................. vi Contact Us .............................. xi Safety Precautions ............................ xii Declaration of Conformity ........................xviii Chapter 1.
  • Page 7 Page Section III: Equipment Setup ....................... 2-10 Force Fired, Mechanically Actuated Head ..................2-10 Force Fired, Air Actuated Head ..................... 2-11 Chapter 3. Using Programming Functions Overview ............................3-1 Front Panel Display ..........................3-1 Screen Navigation and Menu Selection ....................3-1 Run Mode ............................

  • Page 8: Contents

    CONTENTS (Continued) Page Footswitch Response Mode ......................3-21 List of Hardware ..........................3-21 Backlight Operation ..........................3-21 Buzzer Loudness ..........................3-22 End of Cycle Buzzer ........................3-22 Set Output Relays .......................... 3-22 Baseheat ..........................3-23 Rise1 ............................3-23 Preheat On ..........................3-23 Reflow ............................
  • Page 9 Page Chapter 4. Operating Instructions Section I: Before You Start ........................4-1 Preparation ............................4-1 General Operator Safety ........................4-1 Section II: Power Up ..........................4-2 Section III: Graph and Data Screen Descriptions ................... 4-3 Graph Screen Description ........................ 4-3 Graph Schedule Profile ........................
  • Page 10 CONTENTS (Continued) Page Appendix C. System Timing .......................C-1 Appendix D. Communications ......................D-1 Appendix E. Guide to Reflow Soldering .................... E-1 ® UNIFLOW 4 PULSED HEAT CONTROL 990-908...

  • Page 11: Contact Us

    The contents of this manual are subject to change without notice. If you have any questions, or find any errors or omissions in this manual, please contact us. Amada Miyachi America is not responsible for any losses due to improper use of this product.

  • Page 12: Safety Precautions

    Use the appropriate tools for terminating the connecting cables, being careful not to nick the wire conductors. Do not modify the Control without prior written approval from Amada Miyachi America. HIGH VOLTAGE is used in the operation of this equipment.
  • Page 13 Before using this equipment, read the SAFETY PRECAUTIONS carefully to understand the correct usage of the equipment.  These precautions are given for safe use of the equipment and for prevention of injury to operators or others.  Be sure to read each of the instructions, as they are all important for safe operation.
  • Page 14 Stop operation if any trouble occurs. If you detect a burning smell, abnormal sounds, abnormal heat, smoke, etc., turn power OFF immediately to prevent fire or electric shock. Contact Amada Miyachi America or your distributor for help. People with pacemakers MUST stay away from the Control.
  • Page 15 CAUTION Apply the specified source voltage. Applying the wrong voltage can cause fire and electrical shock. Keep water and water containers away from the Control. Water spilled on the Control can cause a short circuit, electrical shock, or fire. Use proper tools (wire strippers, pressure wire connectors, etc.) for terminations of the connecting cables.
  • Page 16 Guide d'utilisation - Alimentation de électrique Amada Miyachi America. Bedienungsanleitung - Energieversorgung für Amada Miyachi America. Guida dell’operatore - Alimentazioni di corrente delle apparecchiature Amada Miyachi America. Guia do Operador - Componentes eléctricos da Amada Miyachi America. Guía del operador - Fuentes de alimentación de Amada Miyachi America.
  • Page 17 Use eye protection Oogbescherming dragen. Augenschutz verwenden. Använd skyddsglasögon. Usare occhiali di protezione. Käytä silmäsuojaimia. Use óculos de proteção. Porter une protection oculaire. Use protección para los ojos. Examine weld terminals Kijk de lasterminals na. Inspektera svetsterminalerna. Tarkista hitsausterminaalit. Examiner les bornes de soudure. Schweißverbindungen prüfen.
  • Page 18 ® UNIFLOW 4 PULSED HEAT CONTROL xviii 990-908...
  • Page 19 ® UNIFLOW 4 PULSED HEAT CONTROL 990-908...
  • Page 20 ® UNIFLOW 4 PULSED HEAT CONTROL 990-908...
  • Page 21 ® UNIFLOW 4 PULSED HEAT CONTROL 990-908...
  • Page 22 LIMITED WARRANTY 1. (a) Subject to the exceptions and upon the conditions set forth herein, Seller warrants to Buyer that for a period of one (1) year from the date of shipment (“Warranty Period”), that such Goods will be free from material defects in material and workmanship.
  • Page 23 (g) All expendables such as electrodes are warranted only for defect in material and workmanship which are apparent upon receipt by Buyer. The foregoing warranty is negated after the initial use. (h) Subject to Section 1(e) and Section 1(f) above, with respect to any such Goods during the Warranty Period, Seller shall, in its sole discretion, either: (i) repair or replace such Goods (or the defective part) or (ii) credit or refund the price of such Goods at the pro rata contract rate, provided that, if Seller so requests, Buyer shall, at Buyer’s expense, return such Goods to Seller.
  • Page 24 (6) months after the date of shipment, whichever occurs first. Acceptance Tests: Acceptance Tests (when required) shall be conducted at Amada Miyachi America, Inc., Monrovia, CA, USA (the “Testing Site”) unless otherwise mutually agreed in writing prior to issuance or acceptance of the Acknowledgement.
  • Page 25 Seller further warrants that all Services performed by Seller’s employees will be performed in a good and workmanlike manner. Seller’s sole liability under the foregoing warranty is limited to the obligation to re-perform, at Seller’s cost, any such Services not so performed, within a reasonable amount of time following receipt of written notice from Buyer of such breach, provided that Buyer must inform Seller of any such breach within ten (10) days of the date of performance of such Services.

  • Page 27: Chapter 1. Description Section I: Features

    Consult Amada Miyachi America if custom lengths of connecting cables are required. For the rest of this manual, both models of Uniflow will simply be referred to as “the Control,” except in specific instances where unique descriptions are required such as specifications, connections, etc.
  • Page 28 CHAPTER 1: DESCRIPTION The operator is coached by visual displays on a Liquid Crystal Display (LCD) screen if out-of-range entries are made, or when out of limits or alarm/error conditions occur. Up to 63 heat profiles (the records containing the joining parameters to be used during the joining cycles) can be programmed, stored, and recalled for use.

  • Page 29: Section Ii. Control Models

    CHAPTER 1: DESCRIPTION Section II. Control Models The standard and remote versions of the Control have a front panel with controls and a display for operator control of the Control. Amada Miyachi AC Input Output Heating Type of Operation America Part #...

  • Page 30: Heads, Thermodes And Accessories

    CHAPTER 1: DESCRIPTION Heads, Thermodes and Accessories For details of solder reflow and heat seal heads, thermodes and accessories available from Amada Miyachi America, please contact Amada Miyachi America using the phone, e-mail, or mailing information in the Foreword of this manual.

  • Page 31: Section Iii: Controls And Indicators

    CHAPTER 1: DESCRIPTION Section III: Controls and Indicators Front Panel Display (LCD) The LCD on the front panel displays both graphic and alphanumeric data depending on the function chosen by the Operator. NOTE: These screens, their functions and displays are described in Chapter 3, Using Programming Functions and Chapter 4, Operation.

  • Page 32: Numerical Keypad

    CHAPTER 1: DESCRIPTION Numerical Keypad The keypad allows you to edit the numeric values of the display screens. The keypad also allows you to enter in the alphanumeric schedule reference which is displayed on the graphic screen Cursor Keys The cursor keys allow you to move the editing cursor up, down and sideways. You use the ▲...

  • Page 33: Data Key

    CHAPTER 1: DESCRIPTION DATA Key key brings up the data screen to the display. DATA The data screen reports the most recent heat cycle parameters in numerical format: time, temperature, duty cycle, and counter status (when enabled). You may initiate the cycle while the HEAT screen (rather than the graphic...

  • Page 34: Schedule Edit Keys

    CHAPTER 1: DESCRIPTION Schedule Edit Keys The Schedule Edit Keys allow you to edit the time and temperature parameters of the heat profile on the graphic display. The keys BASE RISE1 PREHEAT RISE2 REFLOW, COOL1, POSTHEAT COOL2 are vertically aligned with the profile heating states as displayed on the graphic screen. When these keys are repeatedly pressed, the input capability switches back and forth between time and temperature.

  • Page 35: Setup Key

    CHAPTER 1: DESCRIPTION SETUP Key This key brings up the screen. SETUP MENU screen provides a menu of SETUP MENU < SETUP MENU > operating characteristics for the Control. HARDWARE SETUP COMMUNICATIONS REFLOW SETUP SYSTEM SECURITY COPY PROFILE SET TO DEFAULTS LANGUAGE I/O STATUS Number...

  • Page 37: Chapter 2. Installation And Setup Section I: Planning For Installation

    CHAPTER 2 INSTALLATION AND SETUP Section I: Planning for Installation Space Requirements Dimensions (including all projections from the housing, but excluding cabling): Uniflow 4 Uniflow 4R 2KV Transformer 4KV Transformer Weight: ® UNIFLOW 4 PULSED HEAT CONTROL 990-908...

  • Page 38: Utilities

    CHAPTER 2: INSTALLATION AND SETUP 2 KVA models: 48 pounds (21.8 kg) ● 4 KVA models: 60 pounds (27.2 kg) ● Install the Control in a well-ventilated area that is free from excessive dust, acids, corrosive gases, salt and moisture. ●...

  • Page 39: Section Ii: Connections To External Equipment

    CHAPTER 2: INSTALLATION AND SETUP Section II: Connections To External Equipment Overview All connections, other than the transformer cable connections, between the Control and external equipment are made through the rear panel. The transformer cable connections from the reflow soldering or heat seal head are made at the transformer cable terminals on the front panel. NOTE: If you require compressed air, cover gas, and cooling water service for the reflow soldering or heat seal head, please refer to the head manufacturer’s user’s manual for service specifications.

  • Page 40: Uniflow 4 Rear Panel Without Initiate Connector

    CHAPTER 2: INSTALLATION AND SETUP UNIFLOW 4 Rear Panel ( Without INITIATE Connector UNIFLOW ® 4 PULSED HEAT CONTROL 990-908...

  • Page 41: Uniflow 4R Rear Panel With Initiate Connector

    CHAPTER 2: INSTALLATION AND SETUP UNIFLOW 4R Rear Panel ( With INITIATE Connector UNIFLOW 4R Rear Panel ( Without INITIATE Connector UNIFLOW ® 4 PULSED HEAT CONTROL 990-908...

  • Page 42: Input Power Connections

    CHAPTER 2: INSTALLATION AND SETUP Input Power Connections CAUTION Be sure that the source power is appropriate for your Control model. Attach an electrical plug to the power cable supplied in the Ship Kit. Connect the Control power cable to a single-phase, 50/60Hz power source. The nominal voltage range for each model is set at the factory: either 100 to 120 VAC, or 200 to 240 VAC.
  • Page 43 CHAPTER 2: INSTALLATION AND SETUP 1. Locate the TRANSFORMER at the bottom of the CONNECTOR Control's rear panel. 2. Align the dot on the TRANSFORMER CABLE CONNECTOR dot on the TRANSFORMER CONNECTOR 3. Once the dots are aligned, push the cable into the transformer connector until it stops, then twist slightly counterclockwise until the connectors...

  • Page 44: Control To Head Connections

    CHAPTER 2: INSTALLATION AND SETUP Control to Head Connections To connect the Control to the reflow soldering or heat seal head, refer to the head manufacturer’s manual as you follow the instructions below. Connect the reflow soldering or heat seal head thermocouple cable, referenced in this manual thermocouple, to terminal block on the rear panel.

  • Page 45: Transformer Terminal Dimensions

    CHAPTER 2: INSTALLATION AND SETUP 6. Connect the two transformer cables from the head to the transformer terminals on the Control front panel for the standard version or to the transformer terminals on the remote transformer for the remote version. Transformer Terminal Dimensions UNIFLOW ®...

  • Page 46: Section Iii: Equipment Setup

    CHAPTER 2: INSTALLATION AND SETUP Section III: Equipment Setup Force Fired, Mechanically Actuated Head NOTE: If you are using an Air Actuated Head, skip this section and go the next page for the Force Fired Air Actuated Head instructions. Adjust the reflow soldering head force adjustment knob to produce 5 units of force, as displayed on the force indicator index.

  • Page 47: Force Fired, Air Actuated Head

    CHAPTER 2: INSTALLATION AND SETUP 4. Set the circuit breaker on the rear panel of the Control to the ON position. The default graphic screen will display. You will use this screen to enter heating parameters. Force Fired, Air Actuated Head Adjust the head force adjustment knob to produce 5 units of force, as displayed on the force indicator index.
  • Page 48 CHAPTER 2: INSTALLATION AND SETUP 4. Using the air-head manufacturer’s user manual for reference, connect the head air valve solenoid cable connector to the Control connector. HEAD VALVE NOTE: This connector supplies 24 VDC or 24VAC power for the standard version, or 24VDC only for the remote version.
  • Page 49 CHAPTER 2: INSTALLATION AND SETUP 15. Press the foot switch to actuate the first level and set the thermode on the parts. Release the foot switch and verify that thermode does not impact during retraction. If it does impact during retraction, go to Step 17. 16.

  • Page 51: Overview

    CHAPTER 3 USING PROGRAMMING FUNCTIONS Overview To ensure accurate, consistent soldering, the Control delivers extremely precise pulses of energy to the reflow head. Each pulse is comprised of time and energy values that you pre-program. Chapter 1, Description told you where the Controls and Indicators are located. This chapter describes how to use them in order to program the precise temperature profiles needed for reflow soldering, heat sealing or other processes.

  • Page 52: Run Mode

    CHAPTER 3: USING PROGRAMMING FUNCTIONS In general, there are three kinds of instructions on the bottom line of the screen. For and example, refer to the screen: Schedule Setup Page 1 of 5 The instruction on the left side of the screen briefly describes the appropriate response for the options on the current screen.

  • Page 53: Graph Key

    CHAPTER 3: USING PROGRAMMING FUNCTIONS Graph Key Pressing the key when any screen is displayed except for the Graph and GRAPH Schedule Setup Screens, will change the display to the screen. Pressing GRAPH key when the Graph or Schedule Setup Screens are displayed will GRAPH rotate the screen display through the and two...

  • Page 54: Base

    CHAPTER 3: USING PROGRAMMING FUNCTIONS You can include a process cycle in a Profile by assigning the desired process cycle a time of greater than 0 seconds. The Control requires that every Profile has at least one process cycle, Reflow, with a time of at least 0.1 seconds.

  • Page 55: Cool1

    CHAPTER 3: USING PROGRAMMING FUNCTIONS NOTE: The temperature will always be higher than the actual melting point of the solder or heat Reflow seal adhesives due to heat losses in both the thermode and parts. is shown as having a time length of 3.0 seconds and a set-point temperature of 350C. Time can Reflow be set for 0.1 to 99.9 seconds.

  • Page 56: Schedule Setup Parameters

    CHAPTER 3: USING PROGRAMMING FUNCTIONS Schedule Setup Parameters screens are accessed Schedule Setup < SCHEDULE SETUP, Page 1 of 5 > by pressing the key. GRAPH ENABLE PEAK AND AVG LIMITS PREHT PEAK TIME DELAY 00.0 Pressing the key when the Graph GRAPH PREHT AVG TIME DELAY 00.0...
  • Page 57 CHAPTER 3: USING PROGRAMMING FUNCTIONS Press the through keys to edit the high PREHT PEAK HI TEMP LIMIT +030 < and low limits for the peak and average temperatures. The number entered will be the difference between the profile set After edit Page to accept new value temperature and the limit.
  • Page 58 CHAPTER 3: USING PROGRAMMING FUNCTIONS Press the key to toggle to between . If set to then the REFLOW ENVELOPE LIMITS Control will monitor temperatures and trigger an if the temperature at any point is outside Out of Limits the user-set Reflow Envelope Limits. If set to the Control will not monitor or display any OFF, temperature envelopes for Reflow.
  • Page 59 CHAPTER 3: USING PROGRAMMING FUNCTIONS Press the key to set the time length of the x axis of the Graph. The GRAPH GRAPH TIME SPAN can be set from 0 to 600 TIME SPAN seconds and can be changed after a After edit Page to accept new value reflow if an expanded or close-up view is...
  • Page 60 CHAPTER 3: USING PROGRAMMING FUNCTIONS > Press the key to enter the REFERENCE TEXT This field will accept any alphanumeric character, “-“, or space. The numbers and letters are entered via the numeric keypad. One press will enter a number, a second, third or fourth press of the same key will enter a letter in the sequence printed on the key for each number.
  • Page 61 CHAPTER 3: USING PROGRAMMING FUNCTIONS Item 4 on the menu, , allows < PID CONTROL > PID CONTROL the operator to fine tune the temperature PID CONTROL control. A PID CONTROL number in the range of can be selected from After edit Page to accept new value ...
  • Page 62 CHAPTER 3: USING PROGRAMMING FUNCTIONS There is a big change in performance when jumping from Row has roughly control performance similar to Row and Row has roughly similar control performance to Row Performance is optimized within rows through or within rows through When trying different numbers, move up from...
  • Page 63 CHAPTER 3: USING PROGRAMMING FUNCTIONS Pressing the key when the GRAPH < SCHEDULE SETUP, Page 5 of 5 > , screen is AUXILIARY THERMOCOUPLE Schedule Setup, Page 4 of 5 displayed will change the display to the PREHEAT ENVELOPE LIMITS REFLOW ENVELOPE LIMITS .

  • Page 64: Data Key

    CHAPTER 3: USING PROGRAMMING FUNCTIONS Sample Auxiliary Thermocouple Temperature and Envelope Setup: This is based on the following Control settings:  = 25° C (schedule setup page 5 of 5) AUX START TEMPERATURE  = 75° C (schedule setup page 5 of 5) AUX PREHEAT TEMPERTURE ...

  • Page 65: Profile Number Keys

    CHAPTER 3: USING PROGRAMMING FUNCTIONS You may initiate the cycle while HEAT screen (rather than the DATA GRAPH screen) is displayed. PROFILE NUMBER Keys With the graphics screen on the display, these keys will increment/decrement the heat profile number on the graphics screen. With the data screen on the display, pressing either key returns the graphics screen to the display;...

  • Page 66: Good Reflow Counter

    CHAPTER 3: USING PROGRAMMING FUNCTIONS Good Reflow Counter Press the key to edit the good reflow counter. This option is the same as the total usage counter except that only good reflows are counted. A good reflow occurs when the actual temperature is within all enabled peak temperature, average temperature and envelope limits.

  • Page 67: Schedule Edit Keys

    CHAPTER 3: USING PROGRAMMING FUNCTIONS < REPLACE COUNTER SETUP > Pressing will toggle REPLACE REPLACE COUNTER between will COUNTER REPLACE COUNTER ACTION STOP activate this feature and will de- EDIT CLEAN COUNTER +000008 activate it. Pressing will toggle REPLACE between COUNTER ACTION STOP Number...

  • Page 68: Saving Changed Values

    CHAPTER 3: USING PROGRAMMING FUNCTIONS 3. Enter 500 with the keypad. Press the key to store GRAPH the new temperature Reflow value to . The Heating Profile 1 graph will now display shown on the right. Saving Changed Values When you change values, they are saved in the Control’s flash memory (“flash” for short) when the , or screens are used.
  • Page 69 CHAPTER 3: USING PROGRAMMING FUNCTIONS The default value is . The progression from provides more energy to heat the Medium Very Slow Fast thermode. Use the table below as a guide to optimizing the coarse heating rate. Select the recommended coarse heating rate by pressing keys through .

  • Page 70: Setup Key

    CHAPTER 3: USING PROGRAMMING FUNCTIONS SETUP Key This key brings up the screen. SETUP MENU screen provides a SETUP MENU < SETUP MENU > menu of operating characteristics for the HARDWARE SETUP Control. COMMUNICATIONS REFLOW SETUP SYSTEM SECURITY COPY PROFILE SET TO DEFAULTS LANGUAGE I/O STATUS...

  • Page 71: Footswitch Response Mode

    CHAPTER 3: USING PROGRAMMING FUNCTIONS The solder cool valve will also activate at the end of and de-activate when the thermode POSTHEAT temperature reaches either the temperature which ever is lower. The COOL2, PREHEAT, or BASE solder cool valve is used to direct the cool air onto the thermode to force it to cool faster. The solder cool valve supplies a connector-selectable 24 VAC or +24 VDC signal for controlling a user supplied air solenoid valve.

  • Page 72: Buzzer Loudness

    CHAPTER 3: USING PROGRAMMING FUNCTIONS BUZZER LOUDNESS Press the key to bring up the BUZZER <BUZZER LOUDNESS > adjustment screen. With this LOUDNESS BUZZER LOUDNESS : 50 % screen, you may adjust the loudness of the end of cycle buzzer so that it may be heard reliably against background noise.

  • Page 73: Baseheat

    CHAPTER 3: USING PROGRAMMING FUNCTIONS key will bring up the RELAY 1 < RELAY 1 > status option screen. BASEHEAT RISE1 through keys on the keypad set PREHEAT ON status options. RELAY 1 RISE2 REFLOW : Relay is BASEHEAT COOL1 during baseheat OPEN/CLOSED END OF REFLOW...
  • Page 74 CHAPTER 3: USING PROGRAMMING FUNCTIONS switches to active at end of the Head Up Delay time. The relay remains active until the Control receives the fire signal for the next process. : Relay is for any alarm condition. This relay state is reset as referenced in ALARM OPEN/CLOSED the following table.

  • Page 75: Communications

    CHAPTER 3: USING PROGRAMMING FUNCTIONS : Relay is for any out of limits condition. OUT OF LIMITS OPEN/CLOSED OUT OF LIMITS temperature conditions that are outside any active Limits. PEAK, AVERAGE, ENVELOPE NOTES: If an Out of Limits is triggered, this relay state will continue to remain active until you perform one of the following actions: a) You apply a signal at J4A-7 on the Control back panel b) You press the Up Arrow Key on the front panel.

  • Page 76: I.d. Number

    CHAPTER 3: USING PROGRAMMING FUNCTIONS Pressing the 3 key will alternately select either RS232 or RS485 communications. Default value is RS232. BAUD RATE key on the menu COMMUNICATION < BAUD RATE > brings up the screen. Use BAUD RATE 1200 19.2K the keypad to select the required data 2400...

  • Page 77: Reflow Setup

    CHAPTER 3: USING PROGRAMMING FUNCTIONS REFLOW SETUP With the screen displayed, SETUP MENU < SETUP MENU > press the key to bring up the REFLOW HARDWARE SETUP screen. SETUP COMMUNICATIONS REFLOW SETUP SYSTEM SECURITY COPY PROFILE SET TO DEFAULTS LANGUAGE I/O STATUS Number Select an item,...

  • Page 78: Set Release Timer

    CHAPTER 3: USING PROGRAMMING FUNCTIONS SET RELEASE TIMER Press the 3 key to bring up the < SET RELEASE TIMER > screen. You can use the RELEASE TIMER SET RELEASE TIMER release timer to delay the initiation of a new heating cycle after the thermode has cooled down to the Cool temperature and the release timer has expired.

  • Page 79: Max. Idle Temperature Limit

    CHAPTER 3: USING PROGRAMMING FUNCTIONS MAX. IDLE TEMPERATURE LIMIT Press the 6 key to bring up the MAX IDLE < MAX IDLE TEMPERATURE LIMIT > screen. With this TEMPERATURE LIMIT MAX AUX TEMPERATURE LIMIT screen, you set the maximum temperature that can be entered into a Profile for the Idle Temperature.

  • Page 80: Profile Lock

    CHAPTER 3: USING PROGRAMMING FUNCTIONS Enter a user-selected seven-digit (or less) < CHANGE PASSWORD > password, using the keypad. When you PASSWORD ******* enter the password, followed by pressing cursor key, the indication on screen will SYSTEM SECURITY change to Enter NUMBERS followed by the arrow If you press the...

  • Page 81: Set To Defaults

    CHAPTER 3: USING PROGRAMMING FUNCTIONS SET TO DEFAULTS Press the key to bring up the RESET TO < RESET TO DEFAULTS MENU > screen. With this screen, you DEFAULTS DO YOU WISH TO RESET ALL PARAMETERS TO may reset all user-settable parameters THEIR SYSTEM DEFAULT VALUES? including all the settings in all 15 profiles to the default settings.

  • Page 82: I/O Status

    CHAPTER 3: USING PROGRAMMING FUNCTIONS I/O STATUS Press the key to bring up the < I/O STATUS SCREEN > screen. This screen STATUS SCREEN INPUTS OUTPUTS J4A-3 NOHEAT J6A-1,2 RELAY1 displays the current status of the Control J4A-6 AIRHEAD : J6A-3,4 RELAY2 inputs and outputs.

  • Page 83: Chapter 4. Operating Instructions Section I: Before You Start

    CHAPTER 4 OPERATING INSTRUCTIONS Section I: Before You Start Preparation Before operating the Control:  You must be familiar with the principles of reflow soldering and/or heat sealing.  You must be familiar with the location and function of Controls and Indicators. For more information, see Chapter 1, Description.

  • Page 84: Section Ii: Power Up

    CHAPTER 4: OPERATING INSTRUCTIONS Section II: Power Up Powering Up To turn the Control power ON, set the circuit breaker/power switch on the rear panel to the ON position. After one introductory screen is displayed, the GRAPH screen will display with the message.

  • Page 85: Section Iii: Graph And Data Screen Descriptions

    CHAPTER 4: OPERATING INSTRUCTIONS Section III: Graph and Data Screen Descriptions Graph Screen Description Graph Schedule Profile A graphical representation of the programmed temperature profile is displayed in the upper left section of the Screen. GRAPH A thin solid line represents the programmed temperature profile with temperature on the Y axis and time on the X axis.

  • Page 86: Graph Screen Detail #1

    CHAPTER 4: OPERATING INSTRUCTIONS GRAPH Screen Detail #1 The six lines of information in the upper right corner are:  Profile Number  10 alpha-numeric character user-settable reference for selected profile will be displayed is IDLE ON the Idle temperature was set to on in Reflow Setup schedule.

  • Page 87: Graph Screen Detail #3

    CHAPTER 4: OPERATING INSTRUCTIONS GRAPH Screen Detail #3 The three lines at the bottom of the screen are:  The lowest line indicates the time length of each process cycle of the current Profile.  The second line from the bottom of the screen indicates the temperature for each process cycle of the current...

  • Page 88: Data Screen Description

    CHAPTER 4: OPERATING INSTRUCTIONS DATA Screen Description The far right and bottom three lines of the screen contain the same DATA information as on the screen. GRAPH The information specific to the DATA screen is as follows:  The table in the upper section displays the peak, average, and final temperatures for the process...

  • Page 89: Preheat And Reflow Control

    CHAPTER 4: OPERATING INSTRUCTIONS Abbreviation Time Calculation Baseheat Initiation of to end of process Baseheat time. End of to when the actual temperature reaches the temperature setting less Base Preheat Rise1 the user-set in the Profile. Preheat Temperature Delta From the point where reached the temperature setting less the Rise1...
  • Page 90 CHAPTER 4: OPERATING INSTRUCTIONS The Control begins to ramp the temperature during the period at the ramp rate you set. RISE1 As soon as the temperature in reaches 140° C, will end and will start. The Rise1 Rise1 Preheat Control will immediately control temperature to the temperature and there could be a Preheat fast rise to...
  • Page 91 CHAPTER 4: OPERATING INSTRUCTIONS If you select for Preheat and Reflow Control, the Control will abort if the Temperature Preheat Reflow temperature has not reached the Delta temperature within the length of the programmed RISE1 time, or the time. The Control will display the message PREHEAT RISE2 REFLOW...

  • Page 92: Section Iv: Process Cycle Parameters

    CHAPTER 4: OPERATING INSTRUCTIONS Section IV: Process Cycle Parameters Temperature Setting Ranges: Idle ...................... 25° to 300°C Base ....................25° to 300°C Preheat ....................60° to 500°C Reflow (default) ................. 60° to 600°C Reflow (extended mode operation) ........... 60° to 999°C Cool1 ....................

  • Page 93: Section V: Operating Instructions

    CHAPTER 4: OPERATING INSTRUCTIONS Section V: Operating Instructions When the message displays after Power Up, the Control is ready for operation using SYSTEM READY either of the following options:  Pre-Defined Reflow Profiles. For your convenience, you may quickly select a profile stored in the Control that has been pre-defined for your most common reflow applications.
  • Page 94 CHAPTER 4: OPERATING INSTRUCTIONS 2. Press the key to select the temperature value for editing. BASE  BASE NOTE: The temperature BASE value will be highlighted when it is selected. In this example the temperature value is BASE as shown in the bottom left corner of the screen on the right.

  • Page 95: Display Backlight On/Auto

    CHAPTER 4: OPERATING INSTRUCTIONS 10. Press the key to select the temperature value for editing. Use the keypad to COOL1 COOL1 enter a temperature of , then press the key. COOL1 100C ▲ 11. If using a Postheat process cycle, press the key to select the temperature POSTHEAT...

  • Page 97: Chapter 5. Maintenance Section I. Before You Start

     Do not modify the Control without prior written approval from Amada Miyachi America.  Use the appropriate tools for terminating the connecting cables, being careful not to nick the wire conductors.
  • Page 98 CHAPTER 5: MAINTENANCE Message Description The Control is operating in the Postheat Time period after the Head Up time Postheat – Head Up has passed. The Control is operating in the Postheat Time period but the Head up Delay Postheat – Head Up Delay time has not been reached yet.

  • Page 99: Section Ii. Troubleshooting

    CHAPTER 5: MAINTENANCE Section II. Troubleshooting Alarm Message Description Corrective Action Maintain firing switch closure for required time. Note: You will get this message if you are using a force-fired reflow head and When the FOOTSWITCH FOOTSWITCH RESPONSE MODE RESPONSE MODE is set to ABORT, is set to ABORT.
  • Page 100 CHAPTER 5: MAINTENANCE Alarm Message Description Corrective Action Clean Thermode Counter Clean Thermode Counter has been No action needed. Information Reset to reset by Control message only. COOL1 EXCEEDS New Cool1 temperature value is Re-enter a Cool1 value that is less than POSTHEAT TEMP greater than the Postheat Temperature the Postheat temperature.
  • Page 101 CHAPTER 5: MAINTENANCE Alarm Message Description Corrective Action Maximum Temperature detected by the Auxiliary thermocouple is above the user-set Max Temperature Limit, a) Cycle the Main Power, then or the Main thermocouple is 100 reduce the Heating Rate. degrees C above the Programmed b) Check to see that the Process Set Point.* MAX TEMP ALARM.
  • Page 102 No action needed. Information Reset To reset by Control message only. Check process settings and consult Amada Miyachi America Service. The temperature measured by the thermal switch has exceeded 65C. Once the thermal switch temperature Transformer Over When the thermal switch exceeds 65C,...
  • Page 103 CHAPTER 5: MAINTENANCE Aborting the Process Step of Alarm Resetting Alarm Cooling to Base or Preheat Temperature All Alarms except for Max Once Alarm is reset, Up Arrow key can The first Digital Input Reset (J4A-7) or Temp Alarm and Emergency be used to abort process step of Cooling Up Arrow key press will clear alarm relay Stop (EMO)

  • Page 104: Section Iii. Maintenance

    CHAPTER 5: MAINTENANCE Section III. Maintenance Thermode Maintenance When a heat profile has been suitable for a particular application over many bonds, but poor quality bonds are now resulting, thermode surface deterioration could be the problem. If you need to increase heat period temperature and time to maintain the same bond quality, the thermode surface is probably coated with heavy flux, adhesive or polyimide ribbon flex cable residue.

  • Page 105: Chapter 6. Calibration

     OMEGA Digital Calibrator/Thermometer Model CL26 or equivalent  Calibration Kit with type thermocouple cable (Amada Miyachi America Part Number: 10-359-01) NOTE: The appropriate thermocouple and connector for the selected thermocouple type must be used to get accurate readings. Before You Start Ensure that reflow cable is disconnected from the weld head/thermode.

  • Page 107: Appendix A. Technical Specifications

    APPENDIX A TECHNICAL SPECIFICATIONS Electrical Mains AC Voltage Ranges: Model Part Numbers 1-298-02 ................90 to 132 VAC except All Model Part Numbers 1-298-02 ............180 to 264 VAC Line Frequency .........................50 or 60 Hz Line Phase ..........................Single Input Circuit Breaker Rating ..................... 15 A Power Cord Connection .............European CE Harmonized Wiring Code, or NEMA Wiring Code Dimensions...
  • Page 108 APPENDIX A: TECHNICAL SPECIFICATIONS REMOTE Version (Including all projections from the housing, but excluding cabling. Remote Controller Weight: All models: 19 pounds (8.6 kg) REMOTE 2KV Transformer (Including all projections from the housing, but excluding cabling. Weight: 31 pounds (14.1 kg) ®...
  • Page 109 APPENDIX A: TECHNICAL SPECIFICATIONS REMOTE 4KV Transformer (Including all projections from the housing, but excluding cabling. Weight: 48 pounds (21.8 kg) Environment Location ..........................Indoor Use Ambient Temperature: Maximum ......................... 104F (40C) Minimum ........................59F (15C) Relative Humidity, Maximum ................93% at 104F (40C) Performance User Programmable Heat Profiles ....................63 Flash Memory...
  • Page 110 APPENDIX A: TECHNICAL SPECIFICATIONS Temperature Control Accuracy: 600C and below ..........6C or 2% of reading, whichever is greater Above 600C ......................3% of reading Repeatability ........................1% of setting Display Range ........................ 15C to 999C Settings: Base ..........................25 to 300C Preheat ........................
  • Page 111 Thermocouple ....................... E, J, or K type Thermocouple Extension Cables, Omega Standard: Type E, Amada Miyachi America Part Number 10-355-02 ........ 60 in. (152.4 cm) Type J, Amada Miyachi America Part Number 10-355-02-02 ......60 in. (152.4 cm) Type K, Amada Miyachi America Part Number 10-355-02-01 ......60 in. (152.4 cm) Outputs Audible Alarm ....................
  • Page 112 APPENDIX A: TECHNICAL SPECIFICATIONS Solid State Relays: Air Head Valve ................... ON/OFF for head actuation Head Cool Valve ..............ON/OFF for cooling thermode holder Solder Cool Valve ..........ON at COOL period, OFF at PREHEAT period STANDARD Version Power (Uniflow4 control provided) ............24 VAC or +24 VDC Contact Rating ...................
  • Page 113 Control. If you need to change the voltage setting, contact Amada Miyachi America using the phone, e-mail, or mailing information on the CONTACT US page in the front of this manual.
  • Page 114 APPENDIX A: TECHNICAL SPECIFICATIONS STANDARD Version ● 115 VAC Configuration Switch is set with visible on the switch. 115V The factory-supplied jumper with the 115V/230V BROWN wires is installed on connector as shown. STANDARD Version ● 230 VAC Configuration Switch is set with visible on the switch.
  • Page 115 APPENDIX B ELECTRICAL AND DATA CONNECTIONS RS-232 Connections #1 – No Connection #6 – Data Terminal Request #2 – RS-232 Transmit #7 – Clear To Send #3 – RS-232 Receive #8 – Request To Send #4 – Data Set Ready #9 –...
  • Page 116 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Negative/Positive Logic Operation Your Control is factory-configured for negative logic, active low. That is, when an input terminal is unterminated, an internal resistor pulls the input terminal to a positive voltage and the input terminal is considered to be inactive.
  • Page 117 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Control Input Interface NOTE: The may be connected to a PLC or other interface in the configurations Control Input Interface shown on pages B-4  B-9. UNIFLOW ® 4 PULSED HEAT CONTROL 990-908...
  • Page 118 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Switch Contact Input (Internal Power) UNIFLOW ® 4 PULSED HEAT CONTROL 990-908...
  • Page 119 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Switch Contact Input (External Power) UNIFLOW ® 4 PULSED HEAT CONTROL 990-908...
  • Page 120 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Common Negative Input (Internal Power) UNIFLOW ® 4 PULSED HEAT CONTROL 990-908...
  • Page 121 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Common Negative Input (External Power) UNIFLOW ® 4 PULSED HEAT CONTROL 990-908...
  • Page 122 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Common Positive Input (Internal Power) UNIFLOW ® 4 PULSED HEAT CONTROL 990-908...
  • Page 123 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Common Positive Input (External Power) Force Valve Drive Connections Valve Driver Outputs and Relays 6 and 7 Relay 6 and 7 Rating and Configuration Refer to Relay ratings and configuration information on page B13. UNIFLOW ®...
  • Page 124 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Valve Driver Output Rating and Configuration Output Rating: 24 VAC/VDC, 0.3 A max for STANDARD VERSION 24VDC, 0.3 A for REMOTE VERSION UNIFLOW ® 4 PULSED HEAT CONTROL B-10 990-908...
  • Page 125 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Output Voltage Selection: For STANDARD VERSION, AC or DC 24 volt output power is selectable by connecting the proper plug as shown on the next page. REMOTE VERSION units are 24 VDC only. NOTES: ●...
  • Page 126 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS NOTE: The photos below are rotated 90° for clarity. Timing: The force valve actuates when the first level of the foot switch is closed. It automatically de-activates when the temperature is reached if there is not a Postheat process COOL1 cycle, or after the Head Up Delay if there is a Postheat process cycle, or in the event of a reflow alarm.
  • Page 127 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Alarm/Status Relays Connections For Relays 1  5 NOTE: See Connector . The following relay rating applies to all Relays 6 Relays 1 through ATTENTION: The previous version Uniflow 4 with part numbers beginning with 1-298-01 had a Chassis Ground connection on Pin J6A-10.
  • Page 128 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Relay State Timing (Without Postheat process cycle) NOTE: If any out of limits conditions occur, the relay state updates at the end of Out of Limits Preheat and the end of Reflow UNIFLOW ® 4 PULSED HEAT CONTROL B-14 990-908...
  • Page 129 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Relay State Timing (With Postheat process cycle) NOTE: If any out of limits conditions occur, the relay state updates at the end of Out of Limits Preheat and the end of Reflow UNIFLOW ® 4 PULSED HEAT CONTROL 990-908 B-15...
  • Page 130 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Remote Selection with Switches or Opto-Couplers Foot Switch Inputs: You may use either a 1-level or 2-level foot switch with the Control. When using a 1-level foot switch, you must jumper the two-level inputs together so that the two levels operate as an OR-function, as shown in the Figure above.
  • Page 131 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Automation Control Inputs Connections Input Signal: 0 or 24 VDC Remote Profile Inputs: All Profiles must be entered and saved in the Control memory locally (from the Front Panel). Once they are saved, they can be recalled prior to initiating the Reflow process by placing a binary value on the four lines.
  • Page 132 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Remote Profile Selection with Remote Profile Selection with PLC Switches or Opto-Couplers UNIFLOW ® 4 PULSED HEAT CONTROL B-18 990-908...
  • Page 133 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Operator Initiation Switch and Firing Switch Inputs Input Signal: 0 or 24 VDC UNIFLOW ® 4 PULSED HEAT CONTROL 990-908 B-19...
  • Page 134 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS EMERGENCY STOP Input Switch Rating: 48 VDC at 2 Amps minimum Type of Switch: Normally closed pushbutton Timing: When the switch is pressed, it removes 24-volt power EMERGENCY STOP from the reflow head, causing it to retract immediately. Manual Alarm Reset Input Signal : 0 to 24 VDC...
  • Page 135 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Main Thermocouple Input Connector (J9) Thermocouple wires are to be connected to pins 4 and 5 on Connector Polarity Type “E” Type “J” Type “K” J9 - Pin 4 Chromel (purple) Iron (white) Chromel (yellow) J9- Pin 5 Constantan (red) Constantan (red)
  • Page 136 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Auxiliary Thermocouple Input Connector (J15) Thermocouple wires are to be connected to pins 4 and 5 on Connector . No connections are to be made to pins 1, 2 and 3 on connector NOTE: Both the thermocouples must be of the same type: E, J, or K.
  • Page 137 APPENDIX C SYSTEM TIMING No Post-Heat Pulse = Cool1 Temperature Setpoint COOL1 ® UNIFLOW 4 PULSED HEAT CONTROL 990-908...
  • Page 138 APPENDIX C: SYSTEM TIMING Process With Post-Heat Pulse = Cool2 Temperature Setpoint COOL2 UNIFLOW ® 4 PULSED HEAT CONTROL 990-908...
  • Page 139 APPENDIX D COMMUNICATION CODES Section I. Command Format COMMAND KEYWORDS: BOLD. VARIABLE: italics. REQUIRED PARAMETERS: {enclosed in braces} (one required and only one parameter allowed). CHOICE OF PARAMETERS: separated by vertical bar " | " indicates one or another of choices presented.
  • Page 140 APPENDIX D: COMMUNICATION CODES Section II. Control Communication Codes RS-232 and RS-485 Communication Protocol Each command will be formatted as follows: <soh> <@> <cmd> <cnt> <data> <cksum> <eot>. Definition of Command Elements <soh> 1 BYTE The data packet will start with a SOH (start of header 0x01) character .
  • Page 141 APPENDIX D: COMMUNICATION CODES When you issue a command to the Control, you need to wait about 250 ms. before you issue the next command. The answer timeout is set to about 250 ms. in case the Control doesn’t respond to a command.
  • Page 142 APPENDIX D: COMMUNICATION CODES Significance of the Control’s RS232/485 SELECT Parameter on the Communications Screen are mutually exclusive. One or the other is selected at the Communications RS-232 RS-485 screen. 2. The serial link to the host computer should be plugged into the proper socket on the back of the Control.
  • Page 143 APPENDIX D: COMMUNICATION CODES Host Originated Command Set These are commands sent by the host computer, via the RS-485/RS-232 port to the Control. NAME COMMAND DATA SIZE COPY “CP” Set Source schedule # 2 Bytes 1 Byte Destination schedule # 2 Bytes 5 Bytes Total COUNTER...
  • Page 144 APPENDIX D: COMMUNICATION CODES 13 DATASCR, 14 DEFAULTS, 15 FINE_HEATING, 16 FREQ_DETECT, 17 GOOD_REFLOW_CNTR, 18 GRAPHSCR, 19 HARDWARE, 20 UNUSED_SCREENID1, 21 HEATSWTEST, 22 Not Used 23 HW_LIST, 24 KBDTEST, 25 KDSCR, 26 KISCR, 27 KPSCR, 28 UNUSED_SCREENID2, 29 LOWER_TEMP, 30 MANUAL_TUNING, 31 MAX_TEMP, 32 PASSWORD, 33 PIDPARAMS,...
  • Page 145 APPENDIX D: COMMUNICATION CODES 67 PREHEAT_AVG_DELAY_TIME 68 PREHEAT_PEAKHI_TEMP, 69 PREHEAT_PEAKLO_TEMP, 70 PREHEAT_AVGHI_TEMP, 71 PREHEAT_AVGLO_TEMP, 72 REFLOW_PEAKHI_TEMP, 73 REFLOW_PEAKLO_TEMP, 74 REFLOW_AVGHI_TEMP, 75 REFLOW_AVGLO_TEMP, 76 PREHEAT_ENVHI_TEMP, 77 PREHEAT_ENVLO_TEMP, 78 REFLOW_ENVHI_TEMP, 79 REFLOW_ENVLO_TEMP, 80 RISE1_ENV_DELAY_TIME 81 RISE2_ENV_DELAY_TIME 82 GRAPHPERIOD_TIME, 83 Not Used 84 NEW_REF_TEXT, 85 IOSTATUS 86 RELAY5, 87 RELAY6,...
  • Page 146 APPENDIX D: COMMUNICATION CODES 121 AUX_START 122 AUX_PREHEAT 123 AUX_REFLOW 124 SOLDER_COOL_VALVE 3 Bytes Total PROFILE “DR” Read Profile # 2 Bytes “DS” Set ProfileNum (Profile number to be modified: 01 - 63) 2 Bytes 1 Byte PreheatTemp (Preheat temperature: 060 - 300) 3 Bytes 1 Byte ReflowTemp (Reflow temperature: 060 - 600)
  • Page 147 APPENDIX D: COMMUNICATION CODES 1 Byte Reflow Delta Temperature (00 – 99) 2 Bytes 1 Byte PID Control (100 – 269) 3 Byte 1 Byte Solder Cool Valve Delay (00 – 99 2 Bytes 91 Bytes Total PROFILE “PR” Read Profile # 2 Bytes “PS”...
  • Page 148 APPENDIX D: COMMUNICATION CODES Reflow Upper Temperature Limit (000-999) 3 Bytes 1 Byte Reflow Lower Temperature Limit (000-999) 3 Bytes 1 Byte Aux Enable Peak and Average Limits (1 = yes, 0 = no) 1 Byte 1 Byte Aux Preheat Peak Delay (000-999) 3 Bytes 1 Byte Aux Preheat Avg Delay (000-999)
  • Page 149 APPENDIX D: COMMUNICATION CODES ALARM=03 OUTOFLIMIT=04 CLEANTHERM=05 REPLACETHERM=06 IDLEHEAT=07 BASEHEAT=08 RISE1=09 PREHEAT=10 RISE2=11 REFLOW=12 COOL1=13 ENDOFREFLOW=14 CYCLEPWR=15 NOTACTIVE_TRIG = 16 1 Byte Relays2.on_off (As above) 1 Byte 1 Byte Relays2.when (As above) 2 Byte 1 Byte Relays3.on_off (As above) 1 Byte 1 Byte Relays3.when (As above) 2 Byte...
  • Page 150 APPENDIX D: COMMUNICATION CODES 13 Bytes Total SYSTEM “YR” Read Read system values 0 Bytes “YS” Set HeadCoolValveStatus (0 = OFF, 1 = ON) 1 Byte 1 Byte SolderCoolValveStatus (0 = OFF, 1 = ON) 1 Byte 1 Byte FootSwResponseMode (0 = ABORT, 1 = LATCH) 1 Byte 1 Byte BuzzerLoudness (00 –...
  • Page 151 APPENDIX D: COMMUNICATION CODES Control Originated Response Command Set These are commands returned by the Control, via the RS-485/RS-232 port. NAME COMMAND DATA SIZE COUNTER “CR” Read ReflowCntrs.dwTotalUsageCnt (Total Usage Cntr: 0000000 – 9999999) 7 Bytes 1 Byte ReflowCntrs.dwGoodReflowCnt (Good Rflo Cntr: 0000000 – 9999999) 7 Bytes 1 Byte Sign (Clean Counter plus or minus sign: + or -) 1 Byte...
  • Page 152 APPENDIX D: COMMUNICATION CODES 22 Not Used 23 HW_LIST, 24 KBDTEST, 25 KDSCR, 26 KISCR, 27 KPSCR, 28 UNUSED_SCREENID2, 29 LOWER_TEMP, 30 MANUAL_TUNING, 31 MAX_TEMP, 32 PASSWORD, 33 PIDPARAMS, 34 PIXELONTEST, 35 PIXELOFFTEST, 36 REFLOW, 37 UNUSED_SCREENID3, 38 REFLOW_COUNTERS, 39 RELAY, 40 RELAY1, 41 RELAY2, 42 RELAY3,...
  • Page 153 APPENDIX D: COMMUNICATION CODES 76 PREHEAT_ENVHI_TEMP, 77 PREHEAT_ENVLO_TEMP, 78 REFLOW_ENVHI_TEMP, 79 REFLOW_ENVLO_TEMP, 80 RISE1_ENV_DELAY_TIME 81 RISE2_ENV_DELAY_TIME 82 GRAPHPERIOD_TIME, 83 Not Used 84 NEW_REF_TEXT, 85 IOSTATUS 86 RELAY5, 87 RELAY6, 88 RELAY7, 89 RELAY5WHENSCR 90 RELAY6WHENSCR 91 RELAY7WHENSCR 92 RELAY1WHEN2SCR 93 RELAY2WHEN2SCR 94 RELAY3WHEN2SCR 95 RELAY4WHEN2SCR 96 RELAY5WHEN2SCR...
  • Page 154 APPENDIX D: COMMUNICATION CODES SYSTEMREADY = 0, EMERJMPR, BASEHEAT_HIGHERPREHEAT, SYSTEMREADY_IDLEON, PREHEAT_HIGHERREFLOW, COOL_HIGHERREFLOW, 6 COOL_HIGHERPOSTHEAT REFLOW_HIGHLIMIT, RISE1TIME, IDLE_HIGHER_COOL1TEMP, 10 IDLE_HIGHER_COOL2_TEMP, 11 ACCESSDENIED, 12 SETDEFAULTS, 13 FIRINGSWOPEN, 14 SAFETYTIMER, 15 FIRINGSWNOTACTIVATED, 16 DECREASEHEATINGRATE, 17 INCREASEHEATINGRATE, 18 REPLACE, 19 CLEAN, 20 REPLACERESET, 21 CLEANRESET, 22 POWERMODE, 23 NOHEATSWITCH, 24 BASEHEATTIME,...
  • Page 155 APPENDIX D: COMMUNICATION CODES 54 IDLEOFF3, 55 IDLEWARM3 56 POSTHEAT_HIGHLIMIT 57 PREHEATDELTA_TOOHIGH 58 REFLOWDELTA_TOOHIGH 59 HEATINGTOOSLOW 60 THERMOSTATTOOHOT 6 Bytes Total PROFILE “DR” Read ProfileNum (Profile number read: 01 - 63) 2 Bytes 1 Byte PreheatTemp (Preheat temperature: 060 - 300) 3 Bytes 1 Byte ReflowTemp (Reflow temperature: 060 - 600)
  • Page 156 APPENDIX D: COMMUNICATION CODES Solder Cool Valve Delay (00 – 99) 2 Bytes 91 Bytes Total PROFILE “PR” Read ProfileNum (Profile number read: 01 - 63) 2 Bytes Enable Peak and Average Limits (1 = yes, 0 = no) 1 Byte 1 Byte Preheat Peak Upper Temperature Limit (000-999) 3 Bytes...
  • Page 157 APPENDIX D: COMMUNICATION CODES 1 Byte Aux Reflow Peak Upper Temperature Limit (000-999) 3 Bytes 1 Byte Aux Reflow Peak Lower Temperature Limit (000-999) 3 Bytes 1 Byte Aux Preheat Average Upper Temperature Limit (0-999) 3 Bytes 1 Byte Aux Preheat Average Lower Temperature Limit (0-999) 3 Bytes 1 Byte Aux Reflow Average Upper Temperature Limit (0-999)
  • Page 158 APPENDIX D: COMMUNICATION CODES Relays2.on_off (As above) 1 Byte Relays2.when (As above) 2 Byte 1 Byte Relays3.on_off (As above) 1 Byte 1 Byte Relays3.when (As above) 2 Byte 1 Byte Relays4.on_off (As above) 1 Byte 1 Byte Relays4.when (As above) 2 Byte 1 Byte Relays5.on_off (As above)
  • Page 159 APPENDIX D: COMMUNICATION CODES StatusMsg (Resulting Status Msg: 00 – 61) 2 Bytes SYSTEMREADY = 0, EMERJMPR, BASEHEAT_HIGHERPREHEAT, SYSTEMREADY_IDLEON, PREHEAT_HIGHERREFLOW, COOL_HIGHERREFLOW, 6 COOL_HIGHERPOSTHEAT REFLOW_HIGHLIMIT, RISE1TIME, IDLE_HIGHER_COOL1TEMP, 10 IDLE_HIGHER_COOL2_TEMP, 11 ACCESSDENIED, 12 SETDEFAULTS, 13 FIRINGSWOPEN, 14 SAFETYTIMER, 15 FIRINGSWNOTACTIVATED, 16 DECREASEHEATINGRATE, 17 INCREASEHEATINGRATE, 18 REPLACE, 19 CLEAN,...
  • Page 160 APPENDIX D: COMMUNICATION CODES 51 POSTHEATTIME_HDDLY, 52 POSTHEATTIME_HDUP, 53 IDLEON3, 54 IDLEOFF3, 55 IDLEWARM3 56 POSTHEAT_HIGHLIMIT 57 PREHEATDELTA_TOOHIGH 58 REFLOWDELTA_TOOHIGH 59 HEATINGTOOSLOW 60 THERMOSTATTOOHOT 53 Bytes Total SECURITY “SR” Read ProfileLock (Profile Lock: 0 = OFF, 1 = ON) 1 Byte 1 Byte SystemLock (System Lock: 0 = OFF, 1 = ON) 1 Byte...
  • Page 161 APPENDIX D: COMMUNICATION CODES 7 Bytes Total TYPE “TY” Read “Control ”, Release #, Revision # 17 Bytes Example: “Control 1.00 AxP” GRAPH “GR” Read Graph data points Variable number of Bytes This command returns all of the temperature data points from the start of firing to the end of reflow for the current actual temperature graph.
  • Page 162 APPENDIX D: COMMUNICATION CODES EXAMPLES: An example of sending a TYPE command to the : <soh>”01TY0009E”<eot> Control The Unit’s address is “01” The command: “TY” The Count is: “000” The check sum is “9E”. Which is calculated from the ASCII (American Standard code for information interchange) and is a two charter ASCII HEX string calculated from the sum of all bytes except <soh>, <cksum>, and <eot>.
  • Page 163 APPENDIX E GUIDELINES FOR REFLOW SOLDERING Overview This Appendix covers the process definition and components used in the pulse heated reflow soldering of flexible circuits to printed circuit boards. We will look in depth at the component part design criteria necessary to achieve the optimum quality and consistency of a flex to PCB assembly, concentrating on the most popular joint designs and component parts used in the process today.
  • Page 164 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING There are three common types of termination designs used on flex circuits for the pulse heated reflow process: The “exposed lead” design has both sides of the polyimide material removed, leaving the traces free of insulation. This allows the thermode to contact the traces directly, and conduct heat to the parts.
  • Page 165 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING Flex and PCB Trace Sizes Ideally, the flexible circuit pads should be narrower in width than that of the pads on the printed circuit board. As the solder melts and the parts compress, solder is forced to the side. This design will allow space for the solder to flow on either side of the flex pad and will be more tolerant of solder quantity on the PCB, avoiding solder bridging problems.
  • Page 166 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING A. Heat is easily transferred away from the joint area to the large landmass, which is positioned too near to the joint area. B. Increased trace width and plated through-hole draw heat from the joint area. C.
  • Page 167 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING A. A smaller screen aperture can provide 40% solder coverage of pad. B. Shows an alternate screen design. C. Resulting solder deposit prior to the reflow (IR) process. D. Solder is spread evenly across pad after the reflow (IR) process. Note smaller height profile. TARGET SOLDER SCREEN THICKNESS OPENING CHEM.NI/AU...
  • Page 168 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING TARGET SOLDER SCREEN THICKNESS OPENING CHEM.NI/AU Cu PASSIVE / PALLADIUM PAD SIZE AND VOLUME HOT AIR LEVEL PITCH mm³ / inches Microns / inches mm / inches mm / inches Mm/ inches 200 micron / 0.008” 0.4 x 1.4 / 0.016 x 0.055 0.4 x 2.0 / 0.016 x 0.055 100 micron / 0.004”...
  • Page 169 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING Flex Pad Width Note that the flex pad finishes short of the PCB pad. This is to allow easy inspection of the joint. PCB Pad Width Extra width allows for excess solder and ease of inspection. PCB pad is approximately three times the width of thermode.
  • Page 170 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING Thermode Manufacturing And Temperature Characteristics Modern wire erosion techniques such as EDM and advanced materials have allowed the manufacture of precisely designed thermodes to suit most applications. Three-dimensional thermodes pass the current around the face and thus have zero voltage potential across the traces. These technological advances in machining processes produce designs with constant temperature across the length, and special alloys achieve flatness and co-planarity under heating.
  • Page 171 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING Flux Flux has two important features. It conducts the heat to the solder and it promotes the wetting of the surfaces by cleaning and removal of surface oxides. For easy to solder parts, the pulse heated soldering process requires only a minimum of non-activated flux.
  • Page 172 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING Preheat It takes approximately two seconds to heat a modern designed thermode of up to 2” in length to soldering temperature. During this time, the flux activates and starts to promote wetting by removal of the oxide layer.
  • Page 173 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING Force Control And Simple System Examples Most reflow joints of this nature require fewer than 20lbs. (9 Kg.) pressure. A range of force control modules is available to suit all applications up to 150lbs. (68Kg.). Force must be precisely controlled. Force can be calibrated and set to the correct level to achieve the right thermal transfer of heat to the solder joint.
  • Page 174 APPENDIX E: GUIDELINES FOR REFLOW SOLDERING Conclusion Pulse heated thermode reflow soldering of flex to PCB is a stable and well controlled process if certain basic design guide rules are followed. These rules differ from the rules that apply to conventional soldering processes.
  • Page 175     http://www.amy.amada.co.jp/e/    AMADA MIYACHI AMERICA, INC. 1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A.  TEL. +1‐626‐303‐5676  FAX. +1‐626‐358‐8048               http://amadamiyachi.com  AMADA MIYACHI CO., LTD. 200, Ishida, Isehara‐shi, Kanagawa 259‐1196, Japan    AMADA MIYACHI KOREA CO., LTD. 28, Dongtanhana 1‐gil, Hwaseong‐si, Gyeonggi‐do, 445320, Korea  TEL. +82‐31‐8015‐6810  FAX. +82‐31‐8003‐5995  AMADA MIYACHI SHANGHAI CO., LTD. Room01,15th Floor, SML Center, No.610 Xujiahui Road, Huangpu District, Shanghai 200025, China  TEL. +86‐21‐6448‐6000  FAX. +86‐21‐6448‐6550    AMADA MIYACHI EUROPE GmbH Lindberghstrasse 1, DE‐82178 Puchheim, Germany  TEL. +49‐89‐839403‐0  FAX. +49‐89‐839403‐10    AMADA MIYACHI TAIWAN CO., LTD.
  • Page 176                                                                   AMADA MIYACHI AMERICA, INC.     1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A.     TEL. +1‐626‐303‐5676  FAX. +1‐626‐358‐8048  ...

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