(Straight format. Up to estimated 300 panels per hour)

The information contained in the following pages describes the Alchemy ‘D’ horizontal hot air leveling system manufactured by Circuit Engineering Marketing Co. Ltd, usually known as Cemco..

Cemco has been designing and manufacturing high quality equipment for the Printed Circuit Board Industry for over 25 years. Products include wet processing and panel handling systems, registration equipment and laboratory test machines.

However, Cemco is best recognised for equipment associated with solder coating. Many roller-tinning systems were supplied to companies in Europe through the 1970's, and then in 1983 the 'Quicksilver' vertical hot air leveler was launched.

This machine, which incorporated many innovative ideas, has become the most successful vertical leveler ever built. More than 650 Quicksilver machines are in operation around the world, and it is widely recognised as being the very best for quality, reliability and durability.

Alchemy horizontal leveling systems continue this tradition. The result of an extended research and development programme, and substantial investment, Alchemy now leads the field in selective solder coating technology.

• SYSTEM DESCRIPTION

• SYSTEM SPECIFICATION (METRIC)

• SYSTEM SPECIFICATION (IMPERIAL)

• INSTALLATION DATA

• LAYOUT DRAWING LA0586

The benefits from operating an 'Alchemy' system can be significant. Yields of up to 99.8% (first pass yield approx. 97%), new levels of quality and consistency, less maintenance time and materials usage, and the cost of consumables (flux, oil and solder) reduced by 50% to 70%.

1. Major cost reductions in chemistry, solder and labour. These reductions are being demonstrated by 'Alchemy' users in production situations.
2. Increased 'up time'. Production availability on all three shifts.
3. Improved quality. Better handling techniques and processing control mean fewer defects.
4. Highest percentage of 1st pass yield. Reduced solder contact time. Convection pre-heat reduces thermal shock and flux absorption.
5. Improved surface planarity. As a result of precision Air Knife adjustment (+/- 0.001"), and an advanced air regulation system that monitors air pressure at the Air Knife tip, customers can expect excellent solder distribution and a clean, bright solder finish.

   Typical XRF measurements:

   20-25 mil SMT lands: mean - 7.5 u, UCL - 12.5 u, LCL - 2.5 u

   20 mil BGA lands: mean - 10 u, UCL - 13.75 u, LCL - 6.25 u,

    

6. Very clean product. A combination of convection pre-heat and less active fluids, help to produce a product that meets Bellcore S.I.R. requirements without the need for solvent cleaning.
7. Computer aided process control for high reliability and consistency of product.

8. Reduced environmental impact. Significantly lower material usage means: Reduced waste treatment, volatile organic compounds (VOC's), Cleaner air solder re-cycling and landfill.

Note: The above references relate to panels processed with SnPb.Experience indicates that lead free processing is capable of producing thicker minimum deposits and a tighter minimum /maximum variance.

The 'D type' has been designed specifically with low to medium capacity facilities in mind. However, it is an ideal option for existing Alchemy or other Leveler users where additional capacity for high quality product is required, and where floor space is limited. While the solder coater is compatible with lead free alloy alternatives to 63Sn 37Pb, Cemco recommend testing your product to determine capability.

The system incorporates a panel align/rotator, allowing the system to be installed in a straight line. Cemco manufactures the ‘Core system’ comprising pre-heating through to cooling, while the pre and post treatment lines are manufactured by FSL (part of the Cemco group of companies).

The attached description contains information on a fully automated horizontal hot air leveling system, incorporating panel load, chemical clean & rinse, dry, pre-heat, hot air level, cool, flux removal, dry, and unload.

The System Description should be read in conjunction with the accompanying Performance Specification, and Drawing No. LA 0586 issue A.

The pre and post treatment sections have a conveyor width of 69 cm (27"), whereas the hot air leveling module has a conveyor width of 84 cm (33") to accommodate panels being processed diagonally.

The system described is capable of processing up to estimated 300* panels per hour.

Loading, unloading and panel handling will also be dependent on the user's requirements, available space, etc.

The Alchemy 'D' leveling module incorporates a panel align/rotate module, flux applicator, solder coating and air leveling unit, and an air support exit table.

Pre-cleaned and pre-heated panels enter the unit via the align/rotate module which automatically rotates the panel to 45^o (panels larger than 46cm x 61 cm (18" x 24") are processed at a proportionally reduced angle). Once panels have been solder coated, they enter the cleaning system via a re-alignment-cooling table.

All adjustments are made via Siemens/Allen-Bradley touch screens, connected to Allen-Bradley PLC's. The system is designed to operate asynchronously, allowing each process element to be set to suit the panel design and solder thickness specification. Adjustment for panel size is automatic.

System specification for Drawing No. LA 0586 issue A.

The following describes an example configuration for an Alchemy 'D' system scaled to operate at up to estimated 300 panels per hour, based on 0.062" thick product (dependent on weight and layer count) .

The System comprises 6 interactive sections:-

NOTE: The pre-clean conveyor speed is adjustable via the touch screen (Drawing Ref.17), commensurate with required etch rate. Nominal conveyor speed is 3.50 metres (11.5 ft.) per minute. Nominal pre-clean temperature is 43^o C. (110^o F.). Pre-clean heat up time from ambient - approx. 1-2 hours. Mains water feed to final wash required at approx. 9.11-18.22 litres (2.0-4.0 imperial gallons) of reverse osmosis water per minute.

65 PANEL FLAT BELT FEEDER (OPTIONAL) (Drg Ref. 1)

A 65 panel fan-type feeder, with software controlled indexing providing one or two step index options to facilitate thin or bowed panels. Panel thickness capability - 0.40 mm to 3.18 mm nominal (0.016" to 0.125" nominal) depending on panel size and rigidity (minimum thickness will be greater for larger, less rigid panels). Panels are manually loaded with the narrowest dimension located in the slats. The mechanism indexes forward until a panel is placed onto the conveyor. Subsequent panels are fed onto the conveyor at a rate necessary to maintain a minimum spacing of 51 mm (2"), or at intervals commensurate with selected pre-heat/pre-clean speed or leveling speed.

FULL LENGTH INPUT CONVEYOR (Drg Ref. 2)

A PVC or Polypropylene tray, with drainage point, supporting a bed of driven rollers. A Panel Sensor is linked to solenoid valves on all water wash inlets for water conservation.

Length                  : 915 mm (36")
Width                   : 940 mm (37")
Conveyor Width          : Nominal: 760 mm (30"), Effective: 635 mm (25")
Drainage Connection     : Nominal 40 mm

CHEMICAL CLEANER MODULE Drg Ref. 3)

A general-purpose spray module comprising a holding sump and pump & spray manifolds suitable for use with chemicals compatible with Stainless steel components. The module is equipped with heating/cooling capability as required and is fitted with all the features found on the larger process modules used with the Alchemy C hot air leveling system.

FOUR STAGE CASCADE WASH MODULE (1 X ACID RINSE; 3 X WATER WASH) (Drg Ref. 4)

A multi-stage washing section based on 4 chambers contained within one module. The first chamber is a re-circulating acid spray and the subsequent 3 recirculating water wash sections are fed with fresh water from the final chamber. Squeegee rollers between each chamber and at module entry and exit points ensure minimal solution losses.

DRYER (Drawing Ref. 5)

Shell Construction                  : PVC
Overall Machine Dimensions (mm)     : Length: 485, Width: 1,175, Nominal Height: 1,230
Conveyor Dimensions (mm)            : Nom. width: 760, Effective width: 635, Height: 920 - 980
Air Knives                          : 1 upper, 1 lower Aerotip patented fluid airknives
Air Blower                          : 5.6 kW variable speed
Heater                              : N/A
Drain Connection                    : 25 mm O/D

VERTICAL BUFFER (OPTIONAL) (Drg Ref. 6)

A vertical buffer offering the advantage of allowing incoming panels to be buffered in the event of a temporary shut-down of the Alchemy leveling section. The innovative reverse action conveyor drive will accommodate panels from the Pre-Treatment section before the buffer and the Pre-Heat section after the buffer, and will re-introduce them into the system once the leveling section is back in operation.

Because panels pass through the solder pot of a horizontal leveler at a continuous, relatively fast speed, there is insufficient time to absorb the required energy; therefore pre-heating is necessary. The pre-heating required to effect wetting is minimal, but in order to clear holes effectively (without the use of excessive air knife pressures which can result in exposed intermetallic coatings on surface features) the core temperature must be at or above 100^o C. (212^o F.).

The time/temperature profile required to achieve this is directly proportional to the thermal characteristics of the panel. A pre-heat system is normally 'sized' to suit the majority of product produced. The conveyer speed can be increased or decreased to suit thinner and thicker product.

Normally, three pre-heat modules is sufficient for up to 300 panels 1.6mm (.062") per hour but we recommend testing with 'typical' product to confirm productivity estimates. Conventionally, I.R. radiation is employed to pre-heat panels, but this produces excessive surface temperatures relative to core temperature. The high surface temperatures increase flux absorption into the epoxy resin of the laminate and the solder mask, requiring the use of solvents to meet SIR requirements.

Thick product may be darkened or damaged before the required core temperature is achieved. For these reasons the 'Alchemy' system employs forced convection pre-heaters which have the advantages of imparting more energy to the core of the panel than I.R., avoid over-heating of the surface, and eliminate the risk of ignition should a panel jam under the emitters.

PRE-HEAT UNIT (Drg Ref. 7, 20 & 24)

A continuous wire belt conveyor module, providing controllable pre-heating of panels prior to leveling. A re-circulated air flow system is employed incorporating partial fresh air input. A hinged top cover allows operator access to the conveyor system. Two 9kw heaters are fitted to each module to elevate the operating temperature to approximately 428 deg F (220 deg C) In the event of a system fault, the conveyor and hot air fan are isolated.

ALIGN/ROTATE INPUT SECTION (Drg Ref. 8)

The unit incorporates a software controlled independent drive PTFE wheel conveyor. Once the trailing edge of the panel is clear of the Pre-heat exit conveyor, the panel spacing is increased to accommodate the rotate cycle. An alignment mechanism positions the panel in the centre of the conveyor. A panel sensor tracks the leading and trailing edges of the panel, and when it’s mid-point is centrally over the rotate mechanism, the panel is elevated above the conveyor, rotated 45 degrees, and lowered onto the conveyor. While panels up to 457mm x 610mm (18" x 24") are rotated to 45 degrees, larger panels are rotated to the maximum permitted angle, restricted by a 788mm (31") working dimension across the conveyor.

As the panel enters the fluxing section a roller is lowered to provide positive drive into the flux application rollers and prevent any deviation in set angle.

FLUX & SOLDER COATING AND AIR LEVELING (Drg Ref. 9)
Comprising:-

1. Flux coating module

The fluxing section incorporates three pairs of rollers. A set of silicone input rollers provide positive drive for panels as they enter a pair of 76 mm (3") neoprene flux application rollers which are fed from an overhead manifold and a trough below.

A pair of silicone exit rollers remove excess flux, thus ensuring only a thin, even coating of flux remains over both surfaces of the panel. Conventional technology demands thick deposits of flux to ensure that some volatiles remain after aggressive I.R. pre-heating.

The presence of volatiles is essential in conventional systems to assist in the dynamics of wetting when the panel enters the leveling zone. Alchemy technology requires only a thin film of flux, thus reducing consumption by up to 75%.

2. Solder coating module

Panels are transported horizontally between two upper and lower solder manifolds. They then pass through oil coating rollers prior to entering the air knife section.

3. Air leveling section and exit table

Panels enter between the air knives, guided by the oil coating rollers on the entry side and supported on an air bearing table on the exit side. The air jets are angled to assist forward motion when the panel disengages from the entry rollers, and the fan is adjustable to suit panel size and mass.

a) Solder knife entry (flux displacement manifolds)

In the Alchemy system, flux displacement manifolds are mounted above the solder bath surface, and flux is removed from the solder mask 'wells' by oxide-free, high velocity solder.

This patented mechanism negates the need for volatiles or high acid content within the flux.

In this way all features are wetted immediately on entry and intermetallic growth will be uniform from site to site, unlike conventional technology where wetting may take place anywhere between entry and exit.

Conventional technology employs submerged flood manifolds below the solder level. This technique cannot provide sufficient velocity to displace the flux trapped in small 'wells' created by the solder mask, without the addition of volatiles (normally water).

While the use of volatiles is effective in displacing entrapped flux in 'vertical' leveling systems (when pre-heating is not employed), horizontal leveling demands that the substrate should be pre-heated above the boiling point of all suitable volatiles.

Pre-heating will drive off a sufficient proportion of the volatiles to severely inhibit their capability to displace trapped fluxes. In conventional systems this results in non-wetting of difficult surface features. The Alchemy flux displacement manifolds overcome this problem.

b) Precision roller transport

Panel speed through the solder pot and airknife section can be adjusted from 6 to 30 metres (20 to 100 ft.) per minute.

Panels are conveyed via multiple pairs of adjustable-pitch parallel rollers that provide smooth, positive transportation through the solder pot and air knife section, essential when processing panels at 45^o.

The precise 'gap' adjustment of the parallel rollers negates the need to tape the panel edges to prevent material damage, particularly to fiducials and isolated conductors that tend to plate more thickly. The parallel rollers also ensure solder does not 'flood' against the air stream from the knives when exiting, allowing lower knife pressures to be employed to obtain thicker coatings when required.

c) Expansion chambers

Expansion chambers are provided for each airknife to prevent the expanding hot gas from the knives creating backpressure against the nozzles. This reduces the incidence of solder tails, random blocked holes and other re-deposition defects, and allows lower knife pressures to be used. The upper expansion chamber incorporates an oil/air separation system, which returns airborne oil to the sump.

d) Patented oil flushing system

A re-circulating oil system is employed to deliver heated, oxide-absorbing leveling fluid to manifolds sited above the rollers and solder manifolds. This prevents carbon build-up on the rollers and oxidisation of the solder. During the leveling cycle, oil washes down the solder balls, absorbing their oxide coating and evenly distributing the spent flux residues. Panels leave the solder pot through an oil application zone, which uniformly coats the surface with the essential leveling fluid immediately prior to the airknives.

e) Unique solder re-circulation system

Solder is delivered to the 'flux displacement' manifolds from a remote sump, and returns to the pump zone. In this way all contaminants that might otherwise be embedded into the panel surface are continually flushed away from the coating area.

f) Environmental containment

The primary exhaust duct is mounted above the roller/sump assembly's sliding containment cover. This in turn is enclosed by a secondary exhaust duct, which serves to cool the primary duct (thereby condensing oil from the air stream) and evacuates the area enclosed by the outer covers.

When the containment cover is withdrawn for maintenance access, both exhaust systems are employed to prevent fumes escaping into the surrounding environment. The solder pump and oil re-circulating tanks are accessed via the sliding rear covers.

g) Air knives

The airknives are designed to ensure stable nozzle pressures when operating against a variable resistance, as is the case with 45^o processing. The quickly removable nozzles are available with differing profiles for different product technology and non-leaded alloys. The knives incorporate high efficiency heat exchangers enabling the air temperature to be maintained to within a few degrees, even at the highest operating speeds.

The upper airknife assembly hinges to permit rapid access to the upper and lower nozzles for cleaning. Both the upper and lower complete airknife assemblies can be removed from the machine in a short time, aided by quick-release electrical and air connections.

Adjustment of gap and offset between nozzles is motorised and can be set via the touch screen or automatically entered from established data.

Nozzle pressures are monitored and continually adjusted by electronically controlled regulators. Pressure settings are made and displayed at the 'view' screen.

h) Serviceability

All soldering machines need scheduled maintenance to ensure first pass yields and minimal down time. Considerable attention and twenty years of experience has been embodied within this latest 'Alchemy' design.

The following is an example of the serviceability and flexibility built into the 'Alchemy' leveler:-

Covers slide or lift completely clear of the machine, permitting unrestricted access. Provision is made for efficient extraction of fumes while working on the machine with covers removed.

All major electrical and air interconnects are plug and socket or quick-release.

The airknife nozzles can be simply and rapidly cleaned or removed.

The 3 pairs of transport rollers can be removed individually, as can the flux displacement manifolds.

The solder pump is attached to its manifolds by a quick-release mechanism.

The design of the leveler allows easy access to the solder sump for removing and replacing solder.

The oil circulation and flushing system virtually eliminates formation of dross and reduces cleaning within the solder pot area to a minimum.

As solder coated panels leave the airknives they are transported onto an air support table. A guide arm (adjustable via the computer control system) directs the panels towards a stop gate where it is held and re-aligned.. As soon as the panel is below approx. 180 C deg (356 F deg) the stop gate is lowered and the panel is transported onto the following conveyor by means of a lower (driven) support roller and overhead air knife, which applies a downward pressure pushing the panel onto the roller.

CONVEYOR /COOLING MODULE (Drg Ref. 10)

Required when thicker product is being processed, this module reduces the panel temperature to below glass transition temperature to minimise warp and twist. It incorporates upper and lower air manifolds, providing balanced forced air cooling to both faces of the panel. Note: A conveyor section is supplied as standard unless the cooling module option is incorporated.

NOTE: The post-clean conveyor speed is adjustable via the touch screen. Nominal conveyor speed is 3.50 metres (11.5 ft.) per minute. Post-clean heat up time from ambient - approx. 1 hour. Mains water feed to final wash required at approx. 9.11-18.22 litres (2.0-4.0 imperial gallons) of reverse osmosis water per minute.

PRE-WASH NEUTRALISER (Drg Ref. 11)

The process assists the performance of the flux removal system to meet exacting surface insulation resistance (S.I.R) and ionic contamination (I.C) specifications. The unit applies a thin coat of flux neutraliser, negating the need to dose wash tanks with detergent. The application rollers are located within the composite Wash/Brush section Drawing Ref 12.

HOT WASH/BRUSH/WASH MODULE (Drg Ref. 12)

A composite wash and brushing section within one module. The chamber is heated to provide a warm water wash fed with fresh water from the following module. Squeegee rollers at module entry and exit points ensure minimal solution losses.

DRYER (Drawing Ref. 14)

Shell Construction              : PVC
Overall Machine Dimensions (mm) : Length: 485, Width: 1,175, Nominal Height: 1,230
Conveyor Dimensions (mm)        : Nom. width: 760, Effective width: 635, Height: 920 - 980
Air Knives                      : 1 upper, 1 lower Aerotip patented fluid airknives
Air Blower                      : 5.6 kW variable speed
Drain Connection                : 25 mm O/D

FULL LENGTH EXIT CONVEYOR (Drg Ref. 15)

A slip wheel conveyor providing 'pick-up' area for panels.

Length              : 915mm (36")
Width               : 940mm (37")
Conveyor Width      : Nominal: 760mm (30"), Effective: 635mm (25")
Drainage Connection : Nominal: 40mm

65 PANEL FLAT BELT UNLOADER (OPTIONAL) (Drg Ref. 16)

A 65 panel fan-type unloader with software controlled indexing providing one or two step index option. Panel thickness capability - 0.40 mm to 3.18 mm nominal (0.016" to 0.125" nominal) depending on panel size and rigidity (minimum thickness will be greater for larger, less rigid panels).

The Alchemy and Pre-heat control cabinet control the pre and post treatment sections of the system. The controls incorporate a touch screen to permit independent operation and adjustment.

The touch screen allows adjustment of all process variables and component settings, with three levels of password protection.

The solder heat-up sequence is software controlled to minimise thermal stresses and peak power demand, commensurate with minimum heat-up time.

Rinse water valves close when not processing panels.

Conveyors and pumps shut down when not processing panels.

Pumps cut in automatically to maintain constant temperature during idle mode.

After a user-specified time interval, the system will automatically switch to standby mode if no panels are processed. In this mode the solder temperature set-point is reduced and all air and pre-heat elements are isolated. The standby to run time interval is approx. 20 minutes.

To ensure jam detection and fail-safe shut down, panels are tracked during processing. Should a panel jam at any position, the preceding processes will shut down until the system is reset.

Solder and fluid levels are monitored, and warning is given of low levels. If any levels reach a dangerous low, the system will shut down, and level correction will be necessary before re-setting is possible. Full over and under set point temperature protection is provided.

1. Facility to allow batch information to be uploaded, permitting process parameters to be controlled by bar code entry (see below), reducing potential operator entry errors.
2. Bar code wand to enable process parameters to be automatically adjusted to match those uploaded in a) above.
3. On line instruction manual, help functions, etc.,
4. Leveling oil re-circulation and recovery system for automatically transferring spent oil to an independent holding tank.
5. Automatic fault detection to component level.
6. Monitoring of chemical and water manifold pressures.
7. Closed loop copper recovery system.
8. Optional Mix Tank for chemical clean

Minimum            : 270 mm diagonal (i.e. 230 x 152 mm) dependent on panel stability
Maximum            : 610 x 762 mm

Will process 458 x 610 mm and smaller at a 45^o angle.
For panels larger than 458 x 610 x less than 0.8mm thick, the degree of angling is subject to panel rigidity. It may be necessary to process at 90 degrees to the air knife.

B. PANEL THICKNESS

Mechanical adjustment from 0.5 mm - 5.00 mm (up to 6.35 is also available)
Loaders, unloaders and buffers/accumulators capable of handling panels with nominal thickness of 0.50 - 4.00 mm.

D. PRE-CLEAN

1. Conveyor speed: 3.5 M/min (nominal) with the ability to adjust from 1.0 -4.0 M/min based on etch rate.
2. Operating temperatures: 32^o to 49^o C., controlled to within 2.8^o C.
3. Pre-clean heat up time from ambient to 43^o C.: approx. 1-2 hours.
4. Minimum fresh water consumption: approx. 4.54-9.1 litres/minute. Fresh water feed is shut off when no panels are in pre-clean line.
5. Panel thickness range from 0.41 - 6.35 mm dependent on panel stability.

E. POST-CLEAN

F. SYSTEM START-UP

System start-up time (from cold start): approx. 2 hours.

1. SURFACE MOUNT PADS:

a. All measurements to be taken at the geometric centre of the pad.

b. All measured product to be run at 45^o angle.

c. 0.5 mm pitch: 2.5 micron minimum, 25 micron maximum, 5 - 10 micron average

d. 0.625 mm pitch: 2.5 micron minimum, 25 micron maximum, 5 - 10 micron average

e. 1.1 mm pitch: 2 micron minimum, 25 micron maximum, 2.5 - 10 micron average

f. Discrete pads (1.78 mm x 3.05 mm and smaller): 1.5 micron minimum, 25 micron maximum, 2 - 7.5 micron average

a. 0.076 mm maximum hole size reduction.

b. Less than 0.051 mm average hole size reduction.

c. * Holes drilled smaller than 0.20 mm may plug with solder (for panels up to 1.6 mm thick).
For panels thicker than 1.6 mm, holes with aspect ratios larger than 8:1 may plug with solder.

* Holes can be cleared accepting lower minimum thickness’. Holes must be free of any contamination.

1. Only unscheduled downtime due to equipment malfunctions is to be included for determining total up time.
2. Scheduled weekly maintenance should not exceed an average of 25 hours per week based on operating 24 hours per day, 5 days per week.
3. Scheduled daily maintenance should not exceed an average of 0.5 hour between shifts (oil changes not to be included in this calculation).
4. Mean time between equipment failure should be a minimum of 100 hours measured on a monthly basis.
5. Mean time to repair should not exceed 2 hours measured on a monthly basis.

1. Process meets Bellcore specification for SIR.*
2. Standard Bellcore comb pattern (0.625 mm line, 1.1 mm space) to be used for test.
3. Test to run for 24 hours at 38^o C./85% RH.
4. Minimum log-average 3.0 E9 ohms (3,000 Megohms).
5. No single reading to be less than 3.0 E8 ohms (300 Megohms).
6. Reduction in SIR due to solder leveling should not exceed two orders of magnitude from bare copper.

Up to estimated 300 panels per hour, of standard 458mm x 610 mm x 1.6 mm thick (weight and layer count dependent).

Data assumes the required setting parameters have been established.

Solder: Typically 20% less than SnPb.

Flux: 11-25 M²/Litre. (Weight testing indicates 11, field experience with a wide range of product type has peaked at 20-25).

Oil: For guidance purposes the oil requires changing after three-six shifts or 24-48 hours whichever is the sooner. 30-40 Litres per change excluding periodic top-ups during normal production caused by extraction and drag-out.

Copper: Dependent on alloy used.
Tin: Dependent on alloy used.

Estimated at £15,000 Per Annum.

Please note:
All performance data relates to a complete system, cleaned, maintained, serviced and operated to Cemco's recommendations, using approved chemicals and materials. No data is available on "hybrid" systems at this time, but providing the 'hybrid' system integration functions correctly and the processes are compatible we believe the data is still valid.

The specifications described are subject to ongoing development and are subject to change without notice.

Minimum        : 10.5" diagonal (i.e. 9" x 6") dependant on panel stability.
Maximum        : 24" x 30"

Will process 18" x 24" and less at a 45 degree angle.
For panels larger than 18" x 24" x less than 0.030" thick, the degree of angling is subject to panel rigidity. It may be necessary to process at 90 degrees to the air knife.

Mechanical adjustment from .020" - .200" (up to 250" is available).
Loaders, unloaders and buffers/accumulators capable of handling panels with nominal thickness of 0.020" to 0.157".

1. Conveyor speed: 11.5 ft/min (nominal) with the ability to adjust from 3 to 13 ft/min based on etch rate.
2. Operating temperatures: approx. 90 to 120 degrees F, controlled to within 5 degrees F.
3. Pre-clean heat up time from ambient to 110 degrees F.: approx. 1-2 hours.
4. Maximum fresh water consumption: approx. 1-2 imperial g.p.m. Fresh water feed shut off when no panels are in pre-clean line.
5. Panel thickness range from 0.016" up to 0.250" dependent on panel stability.

System start-up time (from cold start): Approx. 2 hours.

1. SURFACE MOUNT PADS:

a. All measurements to be taken at the geometric centre of the pad.
b. All measured product to be run at 45o angle.
c. 20 mil pitch: 100 microinch minimum, 1000 microinch maximum, 200 to 400 microinch average
d. 25 mil pitch: 100 microinch minimum, 1000 microinch maximum, 200 to 400 microinch average
e. 50 mil pitch: 80 microinch minimum, 1000 microinch maximum, 100 to 400 microinch average
f. Discrete pads (0.070" x 0.120" and smaller): 60 microinch minimum, 1000 microinch maximum, 80 to 300 microinch average

a. 0.003" maximum hole size reduction.
b. Less than 0.002" average hole size reduction.
c. * Holes drilled smaller than 0.008" may plug with solder (for panels up to 0.062" thick). For panels thicker than .062" thick, holes with aspect ratios larger than 8:1 may plug with solder.
* Holes can be cleared accepting lower minimum thickness’. Holes must be free of any contamination.

1. Only unscheduled downtime due to equipment malfunctions is to be included for determining total up time.
2. Scheduled weekly maintenance should not exceed an average of 25 hours per week based on operating 24 hours per day, 5 days per week.
3. Scheduled daily maintenance should not exceed an average of 0.5 hour between shifts (oil changes not to be included in this calculation).
4. Mean time between equipment failure should be a minimum of 100 hours measured on a monthly basis.
5. Mean time to repair should not exceed 2 hours measured on a monthly basis.

1. Process meets Bellcore specification for SIR.*
2. Standard Bellcore comb pattern (0.625 mm line, 1.1 mm space) to be used for test.
3. Test to run for 24 hours at 38^o C./85% RH.
4. Minimum log-average 3.0 E9 ohms (3,000 Megohms).
5. No single reading to be less than 3.0 E8 ohms (300 Megohms).
6. Reduction in SIR due to solder leveling should not exceed two orders of magnitude from bare copper.

Up to estimated 300 panels per hour, of standard 18" x 24" x 0.062" thick, (weight and layer count dependent).

Data assumes the required setting parameters have been established.

Solder: Typically 20% less than SnPb.

Flux: 545 – 1,227 Ft²/Imperial gallon (Weight testing indicates 545, field experience with a wide range of product type has peaked at 1,000 – 1,227).

Oil: For guidance purposes the oil requires changing after three-six shifts or 24-48 hours whichever is the sooner. 6.6 –8.8 imp gallons Litres per change excluding periodic top-ups during normal production caused by extraction and drag-out.

Copper: Dependent on alloy used.

Tin: Dependent on alloy used.

Estimated at £15,000 Per Annum.

All performance data relates to a complete system, cleaned, maintained, serviced and operated to Cemco's recommendations using approved chemicals and materials. No data is available on hybrid systems at this time, but providing the 'hybrid' system integration functions correctly and the processes are compatible we believe the data is still valid.

The specifications described are subject to ongoing development and are subject to change without notice.

Leveler:

Max height (top of hood extraction duct) 2420 mm (95.3")
Max width 2250 mm (88.6")
Depth (front door to rear door) 2020 mm (79.5")
Gross weight (including solder) 2,200 kg (4,840 lbs)
Solder fill 350 Kg approx. (770 lbs approx.)

Infeed (pre-heat) height 1000mm (39.5")
Outfeed (air table) height 965mm (38")

Cabinet height 1448mm (57")
Cabinet length 1702mm (67")
Cabinet depth 660mm (26")

Cabinet height 1524mm (60")
Cabinet length 1257mm (49.5")
Cabinet depth 660mm (26")

Pre-Treatment 63 amp supply, Peak 35A per phase. Nominal 30A per phase 25 kva

1 x Additional Pre-heat 63 amp supply. Peak 40A per phase. Nominal 35A per phase. 28 kva

Post-Treatment 120 amp supply, Peak 105A per phase 87 kva. Nominal 70A per Phase 58kva

Heat Load around preheats and Alchemy 5-10 deg C (41-50 deg F) to be confirmed

Compressed air 3,920 Ltrs (140 cu/ft) per minute) @ 7.0 Bar (100 psi).
Minimum air receiver requirement 1,350 ltrs (48 cu/ft) @ 7.1 Bar (100psi)
Air quality required ISO/DIS 8573.1 class 4.6.4.
Air connection 2" BSP.
Air input location On main rear frame of Align/rotate module.
Air input height from floor 650mm approx. (27" approx.)

            Mascon Polaris 0-300 EL oil, and F-200 EL flux.