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Beginners' steps to run wave soldering process

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#39756

Beginners' steps to run wave soldering process | 16 February, 2006

Hello,

We�ve ordered the line machinery for our TV factory. It should be ready after two to three months. We will start producing Analog CRT TVs using single sided FR2 or CEM1, thru-hole components and tin-lead wave soldering process.

Knowing that we have no prior experience in wave soldering processes; my questions are: 1- Will we be able to select the materials (flux and alloy) and run the process depending only on ourselves, distributors� help, machinery documentation, web data and �trial and error?� 2- Should we demand experts to calibrate the process and to educate our staff? When and where do we need them? What is the required staff size and level prior to the visit of the experts? 3- Are there any tutorials or technical data sources that can help us running the process without out-team expertise?

Any one has had a similar experience? Any one knows the correct steps in order to get the process working? I would appreciate your time and effort in answering some of my BIG questions.

Thanks in advance and best regards...

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RDR

#39758

Beginners' steps to run wave soldering process | 16 February, 2006

You are pretty much on your own when selecting fluxes. search archives in forums and see what everyone else is using and doing.

Whoever you purchased the wave from should be installing this machine, certifying it, and providing training for your company, If not, get them to do it. If they won't, you bought from the wrong company.

You should have at a minimum an operator and one of your engineers present during the installation, certification, and training. this is when you ask questions!! and you will not ask too many.

Tutorials and tech data are usually provided by manufacturer. there are some troubleshooting charts available from companies like Alpha Metals.

Solder is pretty much solder - use 63/27 or one of the leadfree solders out there? Is your wave leadfree compatible?

Fluxes - contact your largest most well known manufacturers in your area. the flux data will tell you pretty much how to set wave parameters.

the wave process is quite simple in practice. basic soldering principals apply:

Proper flux coverage. Adequate preheat per flux type and recommendations. adequate dwell time and depth of wave.

With more experience you can then start playing with things like conveyor angle.

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Samir

#39759

Beginners' steps to run wave soldering process | 16 February, 2006

Read Ralph Woodgates', "The Handbook of Machine Soldering."

Ralph is a true lead-head from way back, and his expertise is Wave Soldering. I know later editions have sections on that new fangled technique, "Reflow Soldering", but Ralph does a very concise job of explaining the Wave process. It was my personal bible during my 1st year as an Engineer. they didn't teach that stuff at Riyadh University. Now, this was the mid-'90's when the internet was just starting.

As Russ says, you can get tons of free info. online nowadays..

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Gilligan

#39760

Beginners' steps to run wave soldering process | 16 February, 2006

#39798

Beginners' steps to run wave soldering process | 18 February, 2006

Thank you all. You gave us the strength to go ahead!

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#39819

Beginners' steps to run wave soldering process | 20 February, 2006

Q1- Will we be able to select the materials (flux and alloy) and run the process depending only on ourselves, distributors� help, machinery documentation, web data and �trial and error?� A1- Your materials suppliers [eg Kester, Alpha Metals, etc] will assist you in selecting materials. You should be able to figure out how to run the machine with the help of the people you mentioned. If you can�t, you�re in the wrong business. It�s not rocket science.

Q2- Should we demand experts to calibrate the process and to educate our staff? When and where do we need them? What is the required staff size and level prior to the visit of the experts? A2- We�d expect that your machine supplier would describe the facility requirements, require you to hook-up the machine, and provide a technician for installation and training. You need an operator and someone that can act like an engineer that will understand how the machine operates.

Q3- Are there any tutorials or technical data sources that can help us running the process without out-team expertise? A3- Sources of information about running a wave solder machine are: * Manufacturer provided tutorials and tech data. * Books by Ralph Woodgate "Guide Control Solderability�, "Guide Defect Free Soldering", and "Handbook Machine Soldering� * Machine setup procedure by Bob Willis [bobwillis.co.uk ] * Links at Daan Terstegge�s excellent jump site [ smtinfo.net/Db/_Wave%20Soldering.html ]

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