When utilizing Wave Height Control, ensuring the machine is properly configured and the recipes are accurate is crucial for improved Wave Control. This document offers guidance to assist with this process.
Main Wave Location from Input PCB Detect Sensor:
To establish this location,
• Confirm the location when the typical pallet is initially detected by the Input sensor while moving through the fingers of the conveyor. Place a mark on the conveyor rail.
• Adjust the Main Wave Pump Speed to achieve the appropriate Wave Height and place a mark on the same conveyor rail where the pallet first makes contact with the Main Wave.
• Measure the distance between the two marks and enter this information on the Conveyor Configuration Page for the Main Wave Distance from the Input PCB Detect Sensor, as shown in green below.
Board Exit Sensor Location from Input PCB Detect Sensor:
• Place a mark on the same rail as mentioned above where the typical pallet initially activates the Exit Sensor while traveling in the fingers on the conveyor.
• Measure the distance from this mark to the first mark for the Input PCB Detect Sensor. Enter this distance for the Board Exit Sensor, as highlighted in red above.
Setting the Wave Height Sample Restriction Window:
This establishes the range in which Wave Height Readings are disregarded when a PCB is within it.
If the nozzle is wider, it may be necessary to increase the End Window. The default values, illustrated below and highlighted in green, determine the distance before and after the previously set Main Wave Location. The Start should be no closer than 1” prior to the Initial contact. The position of the pallet of the Main Wave and the end should be far enough from the Main Wave mark to ensure that the pallet is no longer creating turbulence in the wave. This can be tested by shifting the pallet across the typical Wave Height and identifying where the main wave returns to its normal condition.
The Main Wave Maximum RPM Deviation allows the Pump Speed control to be limited to deviation of the Main Wave Recipe Setpoint. 300 is default.
Wave Height Control:
To successfully achieve Wave Height Control, it is crucial to configure the recipe with the appropriate solder level and ensure the machine is stabilized at processing temperatures for 30 minutes. Below is a checklist of settings and conditions to implement wave height control.
• Set up the Main Wave Location and Wave Height Restriction Windows as specified above.
• Set the Standby Windows like below for all recipes using to Wave Height Control.
o Main Wave “Start of Window” should be large enough for the pumps to stabilize to last controlled setpoint, 8 seconds, and have time to adjust during Process Time.
o Main Wave “End of Window” should be set to Trailing Edge of pallet leaving the Wave.
Setting the Initial Main Wave Setpoint:
• Verify that the machine has maintained the Process Temperature for a minimum of 30 minutes, and ensure the Solder Level in the pot is adequate.
• Temporarily deselect the Standby checkbox on the Solder Pot Standby page, if it is checked.
• Set the machine to Manual mode.
• Press the Start button for Wave Height and modify the height to achieve the correct wave level.
• Adjust the Main Wave Setpoint to match the Actual.
Wave Height Control Limitations:
• Do not switch to Wave Height Control while processing boards. When Wave Height Control is activated, the first board to enter after the recipe has started will trigger the main Wave to begin control as soon as the board enters the machine. This allows the control to stabilize before the board reaches the Wave. If control is initiated after the boards are already in the machine, it will only have the Process Window to stabilize, which is insufficient time.
• Avoid making significant adjustments to Wave Height while the boards are in the machine. The outcome will be similar to what was described above, and the recovery of control will be sluggish.
• Ensure there is spacing between boards, at least from time to time, to enable some degree of Wave Height control. If the boards are positioned too closely together, remaining consistently within the Sample Restriction Window, control will not take place.