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XPM
Reflow Soldering / Curing Systems
Site Preparation
&
Installation
Site Preparation & Installation
1
Revision Date: May 2004
Table of Contents
SITE PREPARATION CHECKLIST
3
ROOM PLANNING
4
Oven Clearances
4
2
XPM 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
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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
2
XPM 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.
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ROOM PLANNING
XPM2
MODEL
520
730 / 820
940 / 1030
1240
LENGTH (in/cm)
139 / 353
175 / 445
211 / 536
247 / 630
WIDTH (in/cm)
52 / 132
52 / 132
52 / 132
52 / 132
HEIGHT (in/cm)
57 / 144
57 / 144
57 / 144
57 / 144
WEIGHT (lb/kg)
2800 / 1275
3950 / 1800
5000 / 2275
6100 / 2770
Oven And Skid
LENGTH (in/cm)
172 / 379
208 / 528
244 / 538
280 / 617
WIDTH (in/cm)
67 / 171
67 / 171
67 / 171
67 / 171
HEIGHT (in/cm)
65 / 165
65 / 165
65 / 165
65 / 165
WEIGHT (lb/kg)
3000 / 1360
4200 / 1905
5225 / 2375
6360 / 2885
Oven And Crate
LENGTH (in/cm)
177 / 450
213 / 541
249 / 633
285 / 724
WIDTH (in/cm)
67 / 171
67 / 171
67 / 171
67 / 171
HEIGHT (in/cm)
76 / 193
76 / 193
76 / 193
76 / 193
WEIGHT (lb/kg)
3425 / 1555
4850 / 2200
5950 / 2700
6885 / 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:
o
o
Temperature: 55 to 90 F (13 to 32 C)
Site Preparation & Installation
Humidity: 20 to 90% Non Condensing
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Site Preparation & Installation
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Revision Date: May 2004
FACILITY SERVICES & CONNECTIONS
Exhaust Specifications
Number of Connections per Oven
2
Oven Exhaust Duct Size
8”
Facility Duct Material
0
High Temperature Flexible Hose – Rated For 125 C Minimum
Onload Stack
( Entrance )
Offload Stack
( Exit )
CFM
IWC
CFM
IWC
Standard Air or N2
250 - 300
- 0.05 to - 0.10
250 - 300
- 0.05 to - 0.10
With Polar Cooling or
Controlled Cooling
250 - 300
- 0.05 to - 0.10
350 - 400
- 0.03 to - 0.05
With Integrated Exhaust
Stack Filter
400 - 450
- 0.19 to – 0.24
250 - 300
- 0.06 to - 0.10
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
Site Preparation & Installation
End View - Service Position Shown
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Revision Date: May 2004
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
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Revision Date: May 2004
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 60204-1. Vitronics Soltec makes no claims or warranties for compliance to
any other standard or any local, state, federal or country codes, expressed or implied.
2
Unless purchased as an option, XPM 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
XPM2
Current Draw at Start-up in Amperes (kVA)
MODEL
520
730 / 820
940 / 1030
1240
200 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.
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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.
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Revision Date: May 2004
Nitrogen Supply (optional)
Oven Model
520
730 / 820
940 / 1030
1240
3
400 (12)
600 (17)
800 (23)
1000 (28)
3
1400 (40)
1600 (45)
1800 (51)
N2 Process volume [low] CFH (M /hr)
N2 Process volume [high] CFH (M /hr)
3
N2 volume [w/quick atmosphere purge]
2500 CFH (71 M /hr)
Pressure
regulated to 50-70 PSI (3.5-4.8 Bar)
Fitting size
1/2" Female National Pipe Thread (FNPT)
Supply pipe size
1/2"
Nitrogen purity [typical] *
99.9995%
Moisture content
< 1 Volume Parts per Million (VPPM) @ 70 C
Oxygen content [typical] *
< 5 Parts per Million (PPM)
*
2000 (57)
o
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 O2 levels greater
than the source N2 purity.
%N2 Purity
N2 PPM
O2 PPM
99.0000%
990000
10000
99.5000%
995000
5000
99.9000%
999000
1000
99.9500%
999500
500
99.9900%
999900
100
99.9950%
999950
50
99.9990%
999990
10
99.9995%
999995
5
99.9999%
999999
1
The oven is equipped with a pressure regulator and gauge for control of the nitrogen supply.
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Compressed Air Supply
Pressure [Basic]
regulated to 10-30 PSI (0.7-2.1 Bar)
Pressure [N2/Air Switching option]
regulated to 50-70 PSI (3.5-4.8 Bar)
Volume
100 - 200 CFH, (2.8-5.6 M /hr )
Fitting size
1/2" National Pipe Thread (NPT)
Supply pipe size
1/2"
3
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
20° C +/- 5° C
Flow rate
1.0 - 2.0 gpm (3.8-7.6 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)
Pressure (minimum)
sensor trips at 50 psig
Fitting size / type
3/8 FPT (Supply must be 3/8 MPT)
Coolant medium
Supercool (Inhibited Propylene Glycol and distilled water mixture)
Alternative Coolant medium
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
PH
Particulate
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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
Site Preparation & Installation
Shock Indicator Example
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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.
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Revision Date: May 2004
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.
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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
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Revision Date: May 2004