Wave Soldering Machine: Operators Manual

WAVE SOLDERING MACHINE
Operators Manual
FL-MD300/300N
FOLUNGWIN AUTOMATIC EQUIPMENT CO.

Version: FW208
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Folungwin Operations Manual July 2008
WWW.folungwin.com
Folungwin@folungwin.com
-Forward:
 Read this operation manual before normal operation.
 All the operations including safety and lubrication should be done as per “operational steps” to make
sure the operator’s right operation.
 “Electrical circuit” and “part list” are for electrician and other parts are for operator.
 Please note the operational steps described in the manual.
1. Safety warnings:
1. Caution: High Voltage in the control cabinet.
2. Don’t let any body into the protecting bar or cover to avoid problems.
3. Don’t touch any transmission device, chain, belt and conveyor; don’t let clothes roll into it.
4. Don’t let any part of the body under the delivery and feeder table.
5. Prevent the flux from acuminating at the preheating area.
6. Flux and the finger cleaning liquid are flammable. Always make sure that all pipes of flux and finger
cleaning liquid are in good order and conditions and that the finger cleaning liquid container is free
from jam.
Safety attentions:
1. Don’t dismantle any electric appliance without professional training.
2. Cut off power and turn off switch when maintaining machine.
3. Don’t touch heating system.

4. Don’t touch fan and blower when running and let foreign objects into it.
5. Don’t remove protecting cover.
6. Daily check safety device.
7. Pre-alarm before starting machine.
8. Don’t start machine without proper maintaining and adjusting machine.
9. When rolling out or rolling in the solder pot, pay attention to the conveyor height and conveyor
angle and prevent the solder pot from damaging the conveyor system.
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2. Warning label
Warn marks Name and meanings
Electricity hit danger！

This mark means high voltage danger warn mark, used to warn and indicate
1 the possible danger, high voltage hit or burning, hidden dangerous position or
area.
This mark will be stuck on the outer cover of the machine.
Be careful of the hands being curled in！

This mark indicates to be careful of roller running, for warning and indicating
2 that there will be serious injury in the hidden dangerous place or area.
This mark means when machine is running, keep a certain distance from the
rollers.
Don’t touch overheated places！

This mark means overheat and high temperature label, to indicate and warn
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that overheat and high temperature position easily lead to scald
This mark means keeping off the high temperature position.
Be careful of fire disaster!

This mark is used to indicate “Be careful of fire disaster!”, for warn and
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reminder in the area where there are inflammable objects and there exists
danger. Please keep fire far away from this warned area.
3. Temperature for machine running, storage and rejected things disposal:

 When operated indoor, this machinery requires dry environment with CO2 or extinguisher with dry
powder.
 The machine and its attached electrical parts should be used normally from +5℃ to +45℃.
 The machine and its attached electrical equipments can be used normally at max. Temperature+45℃ and
should not be more its 50% humidity.
 The machine and its attached electrical parts can be operated below sea level height 1000m.
 The machine and its attached electrical parts can be transported at -25℃ to +55℃ temperature
environment. It can be transported within short distance less than 70℃.
 Machine pallet package packaged with film to keep away from powder dirt and rain；
 The requirements of the operator’s clothes and safety wear:
1. There is no special requirement of operators’ clothes. The operators should wear factory uniform in
the safety condition, instead of loosening the clothes.
2. For the operators with long hair, when operating the machine, they should do up their hair in a
safety condition for fear that he long hair would be curled into the machine.
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 When the equipment has run out of its lifetime and can not be used any more, unplug the power supply
and dispose properly according to the local regulations.
4. Machine limited condition

4.1 It should not be reversal.
4.2 Pls avoid open pre-heating cover when pre-heating starting
4.3 Only authorise person could change the password on operation computer.
4.4 PLC protect by manufacture with password, no user could change or open it.
4.5 Don’t turn on the “Wave” if the pre-heating temperature is not high enough to prevent the titanium
finger from solder sticking.
5. Soldering deposit
5.1 flux will be dangerous gas, pls deal with it according to location regulator.
5.2 Oxygenation of soldering will be metal oxid, pls recycle and save it at available method.
6. Noise value: less than 75 dB
7 Safety Measures：
1） Close all the doors and windows when operating the machine.；
2） Make sure the protection covers at on load and off load sides are properly installed before
operating the machine；
3） Make sure the insulation pipes for all the outside electric wires are in good order and conditions。
8. Important attentions for electrical device
1) Always unplug equipment from electrical outlet when not in use. Never use the cord to pull
the plug from the outlet. Grasp plug and pull to disconnect.
2) To reduce the risk of electric shock, do not use on wet surfaces or expose to rain.
3) Do not operate with a damaged cord or if the equipment has been dropped or damaged until
it has been examined by a qualified serviceman.
4) Before shut-off of the power, be sure not to touch any electrical part because there is risk of
being shocked by electricity.
5) Before power on, confirm whether power voltage is corresponding to tagged specifications.
6) The earthing end should be correctly connected to the ground.
7) Don’t touch machine heat-off device due to possible overheat.
8) Checking the electrical circuit during machine running to avoid the damage or injury to
human body.
9) The semi-conductor will be easily damaged by high voltage inside the machine.
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10) To avoid wind or rain to the electrical elements because rain or wind will possibly lead to
damage to electrical parts or gets shocked by electricity.
11) Power supply should be protected by electricity leakage safety switch to guard against the
electricity leakage or operator gets shocked by electricity under the not-to-shut-off condition.
12) Only the professionally qualified mechanical and electrician person can maintain and
disassemble the electrical parts to avoid damage to human body and loss of property.
13) Confirm the firm connection of input power and protect the conductor.
14) After power shut-off, operators should be waiting for five minutes because the electricity
discharge hasn’t been finished to avoid electrical shock accident.
15) Be sure not to modify and reassemble the electrical parts inside the machine. When
maintaining the machine, the operators should maintain the electrical elements according to
the wiring way in electrical circuits.
1. Introduction
At the very beginning, all the FOLUNGWIN PEOPLE thank you for your support all the time and your choosing
of our FL-MD300 Lead-free Dual-Wave Soldering System.
The FL-MD300 system developed by FOLUNGWIN mainly deals with the soldering of various precise PCBs,
which is environment-friendly and of the first-class worldwide.
The machine is controlled by computer with Win2000 interface, steady software and powerful functions. It has
the ability to complete the overall process of soldering, such as pre-heating, soldering, cooling etc, assuring of the
best service automatically and sufficiently.
Customer services: in case of any problems during the operation of the equipment, please contact us
as follows:
Tel: +86 769 83228206 Fax: +86 769 83228210
Email: Folungwin@folungwin.com
Main features of the machine:

1) The dual wave solder pot is made up of anti-erosion alloy, the vibrational wave and the horizontal wave adopt
the world's top technology. The wave soldering machine is available with a beautiful appearance of a
clipper-built cover and is easy to clean.
2) Automatic and synchro PCB input system makes PCB input smooth and steady.
3) High quality anti-erosion clasp claw type conveyor chain of high elasticity and low distortion is available with
the electronic frequency conversion speed adjustment and the conveyor speed V=0~1800mm/min.
4) Servo motor driving spraying system makes distribution of flux on PCB very even; unique wind blade can
prevent the flux going into the preheating zone and causing fire and remove the redundant flux.
5) Unique flux discharging system: prevents the exhaust motor from damage due to flux coagulation.
6) Pre-heater: 1.8m (length) fine even hot wind pre-heating system can protect the PCB from sudden heat
concussion and improve the heating efficiency-power saving.
7) New type solder pot structure can promote excellent soldering quality which may be influenced by low wetness
of lead-free solder . The temperature difference between the first wave and the second wave is less than
30℃. The solder point intensity weakening phenomenon that may be caused by soldering coated surface can
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be prevented efficiently. The anti-erosion titanium alloy solder pot makes very little solder be oxidized. It can
lead the solder residues float towards the fixed conglomeration area automatically and is easy to clean.
8) Automatic claw cleaning equipment: imported high quality mini water pump with propyl alcohol detergent can
clean the chain claw automatically and circularly.
9) Fan cooling system: room temperature quick cooling system.
10) Economical operation: the solder wave rises and lowers automatically as the PCB moves; the daily
oxygenation quantity can be reduced by 30% at the utmost.
11) Computer controlling system
A. Chinese-English Windows2000 communication controlling system has many functions with
convenient operation.
B. The system is controlled digitally, production parameter is inputted with numerical values.
C. Computer/PID controls the machine temperature and the chain speed.
D. It has the functions of overtemperature (too high or too low) auto alarm and PCB auto tracing
counting system.
E. It has the function of alarm when solder level is too low, both manual operation and auto operation
are available.
F. PCB rail width can be adjusted automatically or manually.
G. It is equipped with 3 PCB temperature testing points, and 3 temperature profiles can be tested.
H. Automatically switches on/off according to the date and time set by the user.
I. All the temperature, speed data and temperature profiles can be saved, transferred and printed.
12) Options
A. Centering support system: to support the middle parts of the mosaic boards, which can efficiently
prevent the PCB board from distorting.
B. Nitrogen supplied system: excellent system of low consumption of nitrogen: N2 consumption
15-30m3 /h—02 density 200-800ppm.
C. Hot wind blade repairing system: prevents solder bridged linkage phenomenon with a modularized
design and PID independent temperature control.
D. External air conditioner: temperature of cold air at exit is of 3-8℃, components on upper surface of
PCB are about 150℃, cooling of PCB lower surface is very quick and the soldered points is smooth
and shining with little lift-off phenomenon.
E. External cold water machine: water temperature is of -10℃, the nitrogen can be cooled quickly and
recycled, cooling of PCB upper surface and lower surface is very fast and the soldered point is
smooth and shining with little lift-off phenomenon.
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2.2.2 Technical Specifications
Items Specifications
PCB conveyor motor 3 Phases 220V 250W
PCB width adjustment motor 1 Phases 220V 60W
PCB conveyor speed 100-2000mm/min
PCB size Max. 300mm (width)
PCB conveyor directions L→R
Production output 3000pcs/8Hours
PCB conveyor Height 750±20mm
PCB Soldering angle 4-7°
Soldering flux spraying air pressure 5-6kgf/cm2 10-100ml/min
Soldering flux content Approx. 20Liters
Pre-heater 220V 9× 1.8KW=16.2KW
Solder heating pipe 220V 9× 2.2KW=19.8KW
Solder stirring motor 3 Phases 220V 2 × 370W=740W
Solder pot content 450kg
Solder pot in/out motor 1 Phase 220V 90W
Solder temperature Room temperature~350℃
Pre-heating zone Length:1800mm temperature: room temperature~250℃
Finger cleaning motor 1 Phase 220V 10W
Normal / Starting output Approx. 8.5KW/30KW
Power AC 3Phases 380V 50/60HZ
Dimensions L4500 × W1450 × H1720mm
Weight 1560kg
2.3 Technical Specifications

● Solder melting time: 90mins (normal atmospheric temperature-230℃)
● Time under constant temperature
normal atmospheric temperature-265℃: 120mins (for lead-free solder)
normal atmospheric temperature-245℃: 110mins (for normal solder)
2. Machine Installation & Calibration
1) Lifting of the machine：
A、 Use professional lifting equipment to lift the machine and protect the machine surface；
B、 Keep the machine balanced during lifting process and make sure the hook is at machine’s
gravity center position；
C、Angle of Lifting belt to the machine is less than 90 degree；
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2．Machine Installation
1） Open the packing box and put the machine in a flat and dry place with good ventilation. Then move it to the
working place and remove the feet fixers, and make the machine frame horizontal with the ground.
2） Adjust the oven to a suitable height.
3） Pour flux liquid into the flux box. Stop pouring when the liquid level reach a height of approx. 2/3 of the flux box.
Connect the air input throat and adjust the air pressure to 0.5 Mpa. Then pour alcohol up to approx. 4/5 of the
claw cleaning box and adjust the flow to a suitable value.(Attention: Don’t let the alcohol flow get too large in
case that the alcohol splashes out and causes a fire)
4） Connect the power wires（3ф 380V）.
5） Set up the oven temperature, alarm limits and solder melting temperature. When temperature reaches the set
value of solder melting, the solder melting status indicator turns into green（100%）.Now you can turn on the
solder motor.
3. Set Pre-heater I, Ⅱ&Ⅲ: Press the button on the control panel ‘Pre-heater I ON’ and the Pre-heater I is open.
Following the same steps to set pre-heaterⅡ& pre-heaterⅢ. Select the required temperature(80~130℃ as a rule).
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Pre-heat the PCB until no solder liquid drops and no splashing and smoke at the wave exit then set the temperature
alarm limits(20~50℃ as a rule or to be customized accordingly) which will cut down the heating power to make sure
a good heating result and protect the heating parts when the pre-heater’s temperature exceeds the alarm limits.
4. Start the PCB conveyor motor. Select the required speed value (In the set-up window), start the wave motor and
adjust the wave to a suitable height (by manual panel). Then start the claw cleaning motor.
5. Test manually whether other functional buttons work normally.
6. Don’t turn on the “Wave” if the pre-heating temperature is not high enough to prevent the titanium finger from solder
sticking.
4. Process & Operation
4.1 The basic working process of this machine consists of the following 4 continuous steps: PCB Inputting and flux
Coating →PCB Pre-heating→PCB Soldering→PCB outputting and cooling.
4.2 Operation
1) Check the following items:
●Input voltage: 380V-420V, 50Hz
●Non-clean Flux: density is 0.8000-0.810
●Air Pressure: 5-7kgf/cm2
●Solder pot capacity: 400kg
2) For the normal soldering materials, the solder pot’s temperature can be set at 240~260℃; for the lead-free
soldering materials, the solder’s temperature can be set at 250-300 ℃ ; and the internal preparing
temperature (solder melting temperature) is to be set at 230℃. If the temperature is lower than 220℃, other
functional buttons don’t work. When the temperature reaches 230℃ and the solder melting status indicator
turns into green(100%), the oven motor starts to work. This is designed to protect the oven motor from being
damaged effectively.
3) After the solder melting status indicator turns into green (100%), please turn on the Pre-heater, select the
required temperature (80~130℃ as a rule) and set the alarm upper limit.
4) Select the normal operation mode or economical operation mode in the set-up interface. When the
economical operation mode has been selected, the oven’s motor is controlled by photoelectricity switch. The
oven’s motor will stop when no PCB is entering in a range of approx. 250mm and restart automatically when
any PCB is forwarded in by approx. 400mm. The above-mentioned design can reduce the oxygenation of
the solder in the oven. Under normal circumstances, the switch of the oven’s motor is controlled by the
button in the controlling interface.
5) Adjust the conveyor to the required speed, start the conveyor system and adjust the speed to normal
value(1200mm/min).
6) If auto starting of the machine is to be selected, please don’t shut down the power after work and set the
valid time. If this is the case, once the specified time for next auto starting of the machine comes, the oven
will start and pre-heat automatically until the solder melting status indicator turns into green (100%) , waiting
for further operations.
7) Lower the solder pot or higher the conveyor track before pushing in or pushing out the solder pot form the
machine in order to protect the titanium finger from possible damage caused by solder pot.
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5. Systems of the Machine
5.1 Non-clean soldering flux spraying system
5.1.1 Flux spraying Sketch Drawing ( On the right )
Main Parts Description in the Sketch Drawing:

① Formed Air Channel ② Spraying Nozzle Cap
③ Pin Valve ④ Spraying Air
⑤ Pin Valve Cylinder Air ⑥ Piston
⑦ Flow Rate Adjustment ⑧ Spraying Width Adjustment
5.1.2 Function of flux
Flux is very useful in soldering. When flux contacts the metal’s surface, chemical reaction happens and the
oxygenated stuffs on the metal’s surface is removed. As the copper hole and electrical parts of PCB contact with
the air, oxygen stratum is formed on the surface of PCB, and it must be removed before soldering starts. And after
PCB is covered with flux, the copper hole and electrical parts won’t be oxygenated when Pre-heating.
5.1.3 Spraying Control Sketch Drawing (Below)
雾化流量助焊剂流量
GAS FLOW FLUX FLOW
喷雾压力助焊剂压力风刀流量
FLUX PRESSURE SPRAY PRESSURE COLD AIR FLOW
5.1. 4 Spraying Adjustment

1. There are 2 flow rate adjusting valves in one control box.
2. Cylinder pressure refers to the general gas pressure in the cylinder.
3. Gas Flow: to be used to adjust the air flow during spraying process.
4. Flux Pressure: to be used together with Spray Pressure.
5. Cylinder Control: to adjust the air inlet rate during cylinder moving forth or back and control the moving speed of
the cylinder.
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5.1.5 Maintenance of the Flux Spraying System
1) The flow control valve should not be adjusted by unauthorized parties in order to keep a good spraying.
2) The water content in the air filter should always be cleaned.
3) Disassemble the leaves on the wind-displacing motor and clean the solidified flux on it once a week.
5.2 Pre-heater
5.2.1 Structure figure of the pre-heater.
Back Cover
Front Cover
Pre-heating Box
Frame Fan
The machine is available with a circling heating mode. The pre-heater made up of high temperature-resistant
materials is a heating box with internal heating pipe. The drawer at the bottom can be disassembled, which makes
it easy to remove the covered solder flux; the thermocouple inside the pre-heater can control the temperature
precisely
5.2.2 Maintenance
1) Power voltage for the heating pipe should be steady. A too high voltage may damage the heating pipe.
2) Flux covered on the heating shelf drawer may cause a fire so it must be removed every day to get the best
pre-heating.
3) When the pre-heating temperature is too high, the power of pre-heater will be shut down by the return circuit
automatically with an alarm. If the temperature fluctuates greatly, please check the set value of PID
adjustment to see if it is too low. If this is the case, enlarge the set value. If the temperature is too high,
please make sure if the SSR has been punctured and replace it.
4) Temperature at the bottom of PCB should be kept at 130-150℃ to ensure a best soldering.
5.3 Solder Pot

5.3.1 Working Principle
When the solder in the oven has been welted, under a spiral power of the moving solder stirring motor,
the solder liquid flows toward the solder spraying seat. After passing the squared net and the steel board net,
the solder liquid formed a mirror wave. The spraying solder wave has no oxygenated solder contacting with
PCB, which ensures a high quality soldering.
5.3.2 Maintenance
1) Always make sure there is no leaks in the solder spraying mouth at the bottom of the oven. Tighten the
solder-releasing bar in case of leaks. When solder is to be released, loosen the solder-releasing bar and put
the solder into specified container (Be careful! The solder is hot!).
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2) Always check the solder level and add the solder when the solder level is lower than the over box level by
10mm.
3) Check the solder melting temperature by means of mercury thermometer. Compare the temperature with the
set temperature value to ensure the solder melting temperature is not too high or two low.
4) As the solder’s internal temperature is as a rule approx. 250-300℃. It is very necessary to protect the solder
from being oxygenated by means of oxygen-resistant wax.
5) Always clean the oxygenated items in the solder.
6) Always check the cables connected to the solder.
7) Record the relevant flux proportion, pre-heating temperature and the solder’s temperature when soldering
different PCBs. The above-said is to be recorded once an hour as a rule to ensure a best soldering.
8) Always smooth the relatively moving parts(e.g. shaft, chain etc) by means of lubricating oil or butter.
9) Always clean the water content of the filter.
10) Always check the pre-heating cycling wind machine. If there is any abnormal noise or burning, repair or
replace the fan.
5.4 PCB Conveyor System
5.41. PCB Conveyor Rail

PCB conveyor rail is the transporting system of PCB soldering. The users can adjust the width of the rail
according to the size of PCB through the width adjustment panel at the outer side of the machine which
have 3 adjustment buttons. Make sure to shut down the conveyor rail when makeing width adjustment.
5.4.2 Conveyor Motor ( 3 phases 220V 180W)

Bad connection of the conveyor motor or the conveyor chain finger’s being blocked during conveyor
process will cause the stoppage of the conveyor chain fingers, seriously influence the machine running or
even cause the conveyor motor to be spoiled. If the above mentioned situation lasts more than 5 seconds,
the computer control program will cut off the preheaters and wave motors and generate an alarm ( The
computer monitor displays: “ Conveyor Error”; if the above mentioned situation lasts another 10 seconds
without change, the conveyor motor will be shut down. Only after the troubleshooting is finished, can the
machine be restarted and operated again.
5.4.3 Fingers Cleaner (1 phase 220V, 10W)

When the machine is turned on and in working status, the finger cleaning pump takes the finger cleaning
detergent into the finger cleaner which can clear the covered flux and other stuffs on the chain fingers.
5.4.3 Fingers Protection

When the machine is for the first time, the titanium fingers are under low temperature. So turn on the
preheaters for about 10 minutes then turn on the solder waves or the solder will easily stick on the titanium
fingers.
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Folungwin International User Interface Operations Manual
6. Software Manual
6.1 How to: Enter Program
- Double click “Wave Solder” icon on desktop
- Select language (Chinese or English)
- Select “Imperial” or “Metric” measurement reporting
- Click “Enter” (system will begin 20 second self diagnostics)
6.2 How to: Login

- Click “Login” menu
- Enter “Password” 222 (this is System default password for initial entry)
- Enter “Valid Time” (default is 5 minutes of system software use, but it is recommended to increase to
minimum of 555 minutes)
- Click “Login” and you are finished
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6.3 How to: Establish “User Settings”
- Click “System” menu
- Enter “User Setting”
- Create “New User Name” “00” is “System Administrator”. You can only add or modify user
settings when in “00” System. (Select or modify “New User Set-up number; ex: 01, 02, 03…)
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- Enter “New User Name” example: Joe
- Enter “Password” (new user password; ex: 1234)
- Enter “Confirm Password” (confirm new password ex: 1234)
- Enter “Re-Confirm Password” (use same password 1234)
- View “Current User” (this will show who the current user is ex: Joe)
- View “Valid Time Remaining” (this shows “Valid Time” remaining from initial “Login” step; ex: 554
min)
- Select “User Privileges” for new user. When enabling the privileges, the new user will now have full
access to all privileges enabled. Click “Save”
6.4 How to: Establish “Machine Parameters”

- Click “System”
- Enter “Machine Parameters”
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SEE INSTRUCTIONS FOR “MACHINE PARAMETERS” ON NEXT PAGE
6.5 SECTION “1” SETTINGS ARE ALL ADJUSTABLE TO YOUR MANUFACTURING REQUIREMENTS
(Note: Click “Save” icon after making any changes to “Machine Parameters” settings)
- “Audible Alarm” Enable will activate the “audible” alarm. Disable and the system “tower” light will
respond to an alarm condition. (it is recommended to disable during system set-up)
- “Pot Up/Down” This must be enabled to activate the motor to move the solder pot up and down with
the switches near the solder pot front window (time out is 15 minutes and then must be re-set)
- “Auto Start-Up” Must be enabled for automatic solder pot start up. (see below for instructions)
- “PCB Drop Detect” This is an option that senses if a PCB is jammed in the conveyor. This feature is
inactive if not included with your machine.
- “PCB Drop Detect” This is an option that senses if a PCB is dropped from the conveyor. This
feature is inactive if not included with your machine.
“Operation Mode” has 2 selections:
- “Economy” mode will automatically turn on/off wave 1 and wave 2 motors. The waves will be turned
on before your PCB enters the wave area and then turned off when exiting the wave area. You would
typically use the “Economy” mode when running low or medium volume projects as you may not want
the waves to be running constantly. The “Economy” mode will reduce dross generation. Note: The
wave 1 and wave 2 on/off entry and exit points are pre-set at the factory for optimum machine
operation based on the PCB length and conveyor speed. No adjustment is necessary.
- “Normal” mode will set the solder wave motors to run constantly when activated on the “Main Control
Interface”.
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Section 1
Machine Parameters GUI (Section 1)
6.6 SECTION “2” SETTINGS HAVE BEEN PRE-SET TO YOUR MACHINE CONFIGURATION (THESE WILL NOT
BE ADJUSTED OR CHANGED)
Section 2
- “Pre-heaters” The number of pre-heat modules in your system configuration and cannot be adjusted.
Folungwin has many different system designs.
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- “Conveyor Direction” This is set to the typical running direction of the conveyor. The can be
operated in reverse for jammed PCB conditions.
- “Fluxer Type” This is set to the fluxer type in your system configuration and cannot be adjusted.
Folungwin also offers a foam fluxer.
- “PCB Load” This is set to your system configuration and cannot be adjusted.
- “Wave Type” This is set to your system configuration and cannot be adjusted. Folungwin has many
different system designs
- “Wave Type” This is set to your system configuration and cannot be adjusted. Folungwin has many
different system designs
6.7 SECTION “3” SETTINGS ARE ALL ADJUSTABLE BY THE SYSTEM OPERATOR WITH THE EXCEPTION
OF “STARTUP POWER RATE” (NOTE: “STARTUP POWER RATE” IS RESERVED FOR SOFTWARE
DOWNLOADING TO THE MAIN CONTROL BOARD E-PROM AND REQUIRES SUPPORT FROM A QUALIFIED
SERVICE TECHNICIAN)
- “Auto Start-Up Time Settings” is used to set automatic turn on and turn off of your solder pot.
- Enable “Auto Start-Up” in “Section 1” and then click the “Save” icon
- “Auto” and “Machine On” buttons will automatically be activated on “Main Control Interface”
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Section “3”

- Click “Work Timer Set” button in “Section 3” and the “Work Time Set” page will appear.
Work Timer Set Table
Select existing
“Class” or create
new name here
- Select the “Class” you want to create in “Modify Set” window or select an existing “Class” to modify
- In the “Modify Set” window select an existing “Class” or enter new name (ex: Shift 1 or Class 5;
you can also modify the existing class name here too)
- Click “Add Class” button and the new file name will be added to the “Please select the work class”
section in the window to the left
- In the “Modify Set” window click the “Time” button (“Auto Start up Time Settings” window will
open)
Auto Start up Time Settings GUI
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Enter “√” in time
on/off box to activate
- Select the day/days that you want to enter on/off time in

(NOTE: You can enter up to (5) On/Off times per day)
- Enter On and Off time in each day from Sunday to Saturday (Enter “√” in time on/off box 1,2,3,4,5
to activate)
- Click “Save” button
- In the “Please select the work class” window select the file that you want to activate for auto start up
- Click “Ok” button and your work class will appear in “Section 3” of the “Machine Parameters”
interface
CRITICAL NOTES
1. Wave solder machine must be left in “Power On” condition for “Auto Start” to work
2. PC must be left on for “Auto Start” to work (power off monitor if desired)
Power left “On”

Light On or Off
6.7 Section 3: How to Establish “Machine Parameters” (continued)

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Section “3”
Machine Parameters GUI (Section 3 continued)
6.8 How to calibrate conveyor width in “Section 3”

Note: If the PC control of the conveyor width and the actual PCB width are not the same, please calibrate the
conveyor width as follows:
- Click “Modify”
- Enter password “222”
- Measure real conveyor width (measure rail to rail from inside edge of conveyor fingers)
- Enter real value in “Conveyor Width Calibration” window
- “Actual Output” is the total number of PCBs that have been run for the current process file.
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- The quantity of PCB’s to be soldered for each project is entered into the “Process File” (this will be
covered later in the operators manual)
- The PCB count will be done automatically by the input sensor at the entry end of the conveyor and the
number of PCB’s that have been soldered will be seen on the “Main Control Interface”
- This total is listed in the “PV” (present value) “Output” box of the “Main Control Interface”
- If the “Output” box total on the “Main Control Interface” does not match the actual PCB output, click
“Modify” and enter the correct number. The correct number will now be reflected in the “PV”
“Output” box on the “Main Control Interface”.
Reserved for
technician use
only!
Actual Output GUI
6.9 How to: View “Alarm Settings”

Note: this file is for viewing purpose only. All settings for your machine have been pre-set at the factory
- Enter “Alarm Settings” (“Oxygen Level” is inactive feature at this time)
6.10 How to: View “Factory Settings” (changes will be made by authorized representative only!)
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Note: All settings for your machine have been pre-set at the factory.
Please do not change. (If editing is necessary please see “Appendix 1” for details)
- Enter “Factory Settings”
6.11 How to: Adjust width of conveyor (new feature)

- Enter “Adjust Conveyor Width”
Enter PCB width
- Enter PCB width in the ”PCB Width Set” then click “Start” button to adjust conveyor
- Click “Close” when conveyor has finished adjusting
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6.12 How to set “Wave Control Mode” (new feature)
- Enter “ Wave Control Mode”
- Select “PC Set” or “ Manual Set” Enter password

- Click “Save” icon
Note: * “PC Set” will allow the operator to control the wave height adjustments directly from the PC
* “Manual Set” requires the operator to make manual adjustments at the wave height inverters
* Any changes made in the "PC Set" wave height settings will be reflected on the wave height
inverter digital displays.
* Any manual changes made to the wave height inverters will also be seen in the
"Main Control Interface" in the “Wave 1” and “Wave 2” boxes.
* No manual inverter settings will be automatically saved in the “Process File”. These settings
must be entered manually into the “Process File”. (this is defined later in the operators manual)
6.13 How to adjust wave heights using the PC (new feature)

- Select “PC Set”
- Click “Wave Frequency Setting”
Enter wave height frequency

for “Wave 1” and “Wave 2”
- Enter wave height frequency settings for “Wave 1” and “Wave 2”

- Click “OK” button
Note: “Wave 1” and “Wave 2” settings will be saved in “Process File” (this is defined later in the
operator’s manual)
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6.14 How to: Establish “New Process File”
- Click “Process File”
Enter file name
- Enter “New Process File”

- Enter “File Name” (new name for new process file ex: Joe)
- Click “Save” (will default to “New Process File Set-up Guide”)
- Click “Next” (will default to “New Process File Set-up Guide Page 1)
NOTE: All Page 2 settings are “customer adjustable” based on the type of PCB being processed.
Default settings are “Recommended Process Parameters” for lead-free PCB processing.
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New Process File Set-up Guide Page 1
NOTE 1: All Page 1 settings are “customer adjustable” based on the type of PCB being processed.
Default settings are “Recommended Process Parameters” for lead-free PCB processing.
NOTE 2: At any time click “Defect Set Value” button to return to recommended process parameters for
lead-free PCB processing
- Set “PreH1 Operating Temp”: (adjust as necessary to PCB requirements)
- Set “Solder Operating Temp”: (set to “Lead-Free” or “Standard” solder operating temperature
specifications)
6.14.1 How to set wave height using the “PC Set” mode
Enter wave height

Frequency settings
frequency here
from “Process File”
- Enter wave height frequency for “Wave 1”

- Enter wave height frequency for “Wave 2”
- These settings will automatically transfer to the inverter displays
- All settings will be saved when you complete the “Process File” (see next page)
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6.14.1 How to set wave height using the “Manual Set” mode
Inverter Mode set to “F”
Push up/down arrows Manual inverter settings will be

to change frequency seen on Main Control Interface
Note: Inverters are set to “F” (frequency) mode. (See appendix 1 for other inverter mode settings)
- Operator must manually adjust inverters for “Wave 1” and “Wave 2” (at exit end of system)
- Adjust wave height frequency for “Wave 1” (push up/down arrows)
- Adjust wave height frequency for “Wave 2” (push up/down arrows)
- These settings will automatically transfer to the “Main Control Interface”
- These settings will not be saved in the “Process File” (please record these in data log book)
- Set “Conveyor Speed”: (adjust as necessary to PCB requirements)

- Set “PH Fan Speed”: This is pre-set to a “typical” pre-heater fan blower speed setting for most PCB
assemblies. However, you may want to reduce the speed for PCBs with smaller components.
- Set “Pot Exhaust Start Temp”: (This is a system option) Note: It is recommended to keep this
temperature setting “higher” than the solder operating temperature.
- Set “PCB SV Length”: (This is a system option) This feature will be active if your system includes
PCB Jam and PCB Drop options. Enter actual PCB length. (please subtract .50” or 10mm from
the total length to eliminate overspray)
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- “OutPut SV” this is the actual number of PCBs that will be processed at one time. (Example:
Project “A” has a lot size of 100. Enter 100 as the PCB Output parameter. This must be changed
for each new project) this setting will be reflected on the “Main Control Interface” “SV Output”
- Click “Set Temp Alarm Limits” (Note: these settings are for the safety of the machine and your
factory. If an alarm condition occurs it will be reported in the “Alarm Status Report” which will
be described later)
- Set “PreH1, PreH2 and PreH3”, upper and lower alarm limits. Enter “√” in enable box and click
“OK” to save.
Note: These are pre-set to typical “Lead-Free” requirements for your machine. If you
change the limits simply click “OK” to save settings.
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- Set “Solder Melting Temp”: (Note: This is not the solder operating temperature! Do not enter
solder operating temperature in this file!) This parameter is based on the melting temperature
specification from your solder supplier.
- To change this parameter click the “Solder” tab and enter new temperature setting.
- Enter “√” in enable box and click “OK” to save.
- Click “Next” will default to “New Process File Set-up Guide Page 2”
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- Set “Spray Speed”: This is pre-set at the factory for typical PCB processing. The “Spray Speed”
will automatically adjust based on the speed of the conveyor. To manually adjust the spray speed
simply increase or decrease the speed setting.
- Spray X1, Spray X2, Spray Y1, and Spray Y2, are controls to change position of where the spray
fluxer starts and stops spraying your PCB.
- Your spray fluxer has been pre-set to spray the exact dimensions of your PCB. (Example: L:
300mm x W: 200mm). You may have PCBs that require different spray coverage, possibly more or
less coverage. If you want to increase or decrease the spray area, simply make adjustments to these
settings as follows:
- Set “Spray X1”: Default setting is “0”. Adjust this setting +/- to change the starting location of the
spray fluxer as it begins to spray your PCB.
- Set “Spray X2”: Default setting is “0”. Adjust this setting +/- to change the length coverage or
stopping location of the spray fluxer.
- Set “Spray Y1”: Default setting is “0”. Adjust this setting +/- to extend or reduce the width
coverage of the spray fluxer. (See diagram for details)
- Set “Spray Y2” Default setting is “0”. Adjust this setting +/- to extend or reduce the width coverage
of the spray fluxer. (See diagram for details)
- “N2 Volume” (Inactive button, for future use)
- “Flux Volume” (Inactive button, for future use)
- Set “Wave Entry” Default setting is “0”. (“Economy Mode” only) System is pre-set to optimum entry
into the wave during “Economy Mode” based on 3-4 feet/min conveyor speed. If the conveyor speed
increases, you may need to make an adjustment to this setting.
- Set “Wave Exit” Default setting is “0”. (“Economy Mode” only) System is pre-set to optimum exit
from the wave during “Economy Mode” based on 3-4 feet/min conveyor speed. If the conveyor
speed increases, you may need to make an adjustment to this setting.
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6.15 How to: Monitor “COM Port Status”
(Note: This is for trouble shooting purpose only. You may be required to enter this file to assist in trouble
shooting) to enter, follow instructions below.
- Click “Reports” menu
- Enter “COM Port Status” (this is trouble shooting data needed)
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6.16 How to: Monitor “ADAM COM Status”
(Note: This is for trouble shooting purpose only. You may be required to enter this file to assist in
trouble shooting) To enter please follow instructions below.
- Enter “ADAM COM Status” to access the window
ADAM 4018 Status are communications from the control board and thermocouples and are
standard communication terms and abbreviations
- TXD: Signal from the “Low Software IC”
- RXD: Received signal from the ADAM thermocouple
- CRC: Error report signal (Check Sum)
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6.17 How to: Monitor “Trouble Shooting”
(Note: This is for trouble shooting purpose only. You may be required to enter this file to assist in
trouble shooting) To enter please follow instructions below.
- Enter “Trouble Shooting” to access the window

Note: All “Trouble Shooting” categories will be highlighted in “green” if operating correctly. If there
is a problem, the category will be highlighted in “red”.
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6.18 How to: Monitor “Machine Status”
- Enter “Machine Status” to access the window

Note: The “Machine Status” window will provide you with daily machine updates including; user
login/log off, machine on/off, and daily running times of the machine.
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6.19 How to: Monitor “Alarm Status”
Note: When an alarm condition occurs it will be reflected on the Main Control GUI in the “System
Status” section with a red indicator. In addition, the description of the alarm condition will be
presented in the “Alarm Code” column of the Main Control GUI.
To enter the “Alarm Status” report, please follow the instructions below.
Alarm condition displayed

on Main Control Interface
- Enter “Alarm Status” to access the window

Note: The “Alarm Status” window will provide you with daily history of “Alarm Status” conditions.
When an alarm condition occurs, it will be stored in the “Alarm Status” report.
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6.20 How to: Use the “Help” Menu
- Click “Help”
- Enter “System Info”
- “System Info” will display the software version, mother board program version and PLC program
version
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6.21 How to “Exit” the program
- Click icon in the tool bar to quit the program
- Close window using red “x”

Note 1: You must click “Machine Off” button on “Main Control Interface” before exiting a program
Note 2: If “Valid Time” has expired, you will need to “Login” again to exit the program
Congratulations! You are now an expert at operating the FL-MD450 software!
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7. Profile analysis
7.1 How to: Establish “Profile Test” (PT)
- Select “Manual” operation mode button on Main Control GUI
- Select “Machine On” operation mode button on Main Control GUI
- Turn on Pre-Heater 1, 2, 3 on Main Control GUI
Turn “On”
- Remove (3) thermocouple (TC) plugs from TC outlets near conveyor entrance.
- Insert (3) TC cables to TC plugs
- Attach (3) TC cables to PCB to be profiled
- Place PCB in conveyor and adjust conveyor to PCB width
- Turn on Conveyor on Main Control GUI (do not process PCB yet!)
- Click “Process File” menu
- Enter “Profile Test” (PT)
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- Place PCB in conveyor
- Run the “Profile Test” (PT) of the PCB now
- Click “Start” icon to begin PT (test will take 2-3 minutes typical)
- When PT is completed, the “peak temperature” on the Profile Test Graph GUI will begin to drop
(Need pic of profile test!!)
- Click “Stop” icon
- Click “Save As” icon and enter PT file name and “Save”
- Click “Open File” icon to retrieve PT file at any time
- Click “Cancel” icon to clear Profile Test Graph GUI at any time
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7.2 How to: Use “Profile Analyzer”
- Click “Process File”
- Enter “Profile Analysis”
- Click “Open” icon and select Temperature Profile Test to be analyzed, then click “Open”
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- Click “Set” file
- Enter “Temp Type”
- Select “Curve Range” and “Save” (NOTE: this will be the highest temperature range to be
displayed on the on the SMT-Curve Analyzer GUI)
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- Enter “SecType”
- Select “Curve Range” and “Save” (NOTE: this will be the longest amount of time to be displayed
on the on the SMT-Curve Analyzer GUI)
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- Enter “SelCurve”
- Select “Curve 1, 2, 3…..” and “Save” (NOTE: this will display the profile curves for each pre-heater
on the SMT-Curve Analyzer GUI)
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- Enter “Remark”
- Enter comments in “Dialogue” box and “Save”
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- Enter “Unit”
- Select “Metric or Imperial” and “OK”
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- Click “Level Line” icon to highlight temperature peaks on the SMT-Curve Analyzer GUI
(NOTE: a maximum of (2) Level Lines can be presented at same time)
- Click “Vertical Line” icon to highlight temperature time line on the SMT-Curve Analyzer GUI
(NOTE: a maximum of (2) Vertical Lines can be presented at same time)
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NOTE: When Level Line and Vertical Line have both been selected, they will intersect at the point of interest on
the SMT-Curve Analyzer GUI
Intersection
- Select “Clear the Line” icon to erase Level and Vertical Lines
- Click “File”
- Enter “Print Preview” to see result page
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- “Print Preview” result page
- Printer must be connected for this feature to work
- Click “Colors Set” to adjust screen color, text and grids.
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Appendix 1
Factory setting:
The following parameters we need to check and adjust during installation sometimes.
6.9 How to select consumption mode

- Click “Default Set Value”
- Select “Economy Type” or “ Universal Type”
- Click “Ok” icon
Note: 1. All parameters will be set default.

2. Economy is option for low consumption, solder pot heater elements are 1.8KW
3. More details please see appendix 1
1. If the temperature is not stable. (normally it is very stable)

We need to decrease “KI”, “KP” and “KD”. For example:
Temperature of PH is not stable; we can decrease “KI” from 120 to 100, reduce “KP” from 0.2 to 0.1 and
decrease “KD” from 600 to 400.
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2. If real temperature of pot is higher than display temperature.
Please decrease “samslope”. But do not change too much. Check temperature again when temperature gets
stable after adjusting. Usually we can adjust from 0.9-1.2, base on difference.
3. If real temperature of pot is lower than display temperature.

Please increase “samslope”. But do not change too much. Check temperature again when temperature gets
stable after adjusting. Usually we can adjust from 0.9-1.2, base on difference.
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4. If display temperature (PV) gets very higher than setting temperature (SV).
First, please check “Solder Melting Temp”. For example,
If real solder melting temperature is 230 degree, “Solder Melting Temp” can not exceed 235 degree.
4.1 Click “Modify process file” to enter “Modify process file guide” window
4.2 Click “Set Temp Alarm Limits”
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4.4 Modify solder melting temperature.
Second, please increase “adjstart”. Usually we can set from 20 degree too 40 degree. If you set too high,
heating speed will get slow.
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Wave Soldering Machine: Operators Manual

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Wave Soldering Machine: Operators Manual

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WAVE SOLDERING MACHINE

FOLUNGWIN AUTOMATIC EQUIPMENT CO.

 Read this operation manual before normal operation.

sure the operator’s right operation.

 Please note the operational steps described in the manual.

1. Caution: High Voltage in the control cabinet.

3. Don’t touch heating system.

Warn marks Name and meanings

Electricity hit danger！

Be careful of the hands being curled in！

Don’t touch overheated places！

Be careful of fire disaster!

3. Temperature for machine running, storage and rejected things disposal:

4. Machine limited condition

Tel: +86 769 83228206 Fax: +86 769 83228210

Main features of the machine:

2.3 Technical Specifications

4. Process & Operation

5.1 Non-clean soldering flux spraying system

5.1.1 Flux spraying Sketch Drawing ( On the right )

Main Parts Description in the Sketch Drawing:

5.1.2 Function of flux

5.1.3 Spraying Control Sketch Drawing (Below)

喷雾压力 助焊剂压力 风刀流量

FLUX PRESSURE SPRAY PRESSURE COLD AIR FLOW

5.1. 4 Spraying Adjustment

5.2.1 Structure figure of the pre-heater.

5.3 Solder Pot

5.4 PCB Conveyor System

5.41. PCB Conveyor Rail

5.4.2 Conveyor Motor ( 3 phases 220V 180W)

5.4.3 Fingers Cleaner (1 phase 220V, 10W)

5.4.3 Fingers Protection

6.2 How to: Login

6.4 How to: Establish “Machine Parameters”

- Enter “Machine Parameters”

Machine Parameters GUI (Section 1)

Machine Parameters GUI (Section 2)

Machine Parameters GUI (Section 3)

- Select the day/days that you want to enter on/off time in

Power left “On”

6.7 Section 3: How to Establish “Machine Parameters” (continued)

Machine Parameters GUI (Section 3 continued)

6.8 How to calibrate conveyor width in “Section 3”

Actual Output GUI

6.9 How to: View “Alarm Settings”

6.11 How to: Adjust width of conveyor (new feature)

Enter PCB width

- Select “PC Set” or “ Manual Set” Enter password

6.13 How to adjust wave heights using the PC (new feature)

Enter wave height frequency

- Enter wave height frequency settings for “Wave 1” and “Wave 2”

Enter file name

- Enter “New Process File”

Enter wave height

- Enter wave height frequency for “Wave 1”

Inverter Mode set to “F”

Push up/down arrows Manual inverter settings will be

- Set “Conveyor Speed”: (adjust as necessary to PCB requirements)

New Process File Set-up Guide Page 2

- Enter “COM Port Status” (this is trouble shooting data needed)

- Enter “ADAM COM Status” to access the window

- Enter “Trouble Shooting” to access the window

喷雾压力助焊剂压力风刀流量