Sounds like you are involved in a very neat project.
Suggestions: * Get a copy to Bob Willis� wave solder machine set-up procedure [ http://www.eps.com ]. It�s a little dated, but it�s a good starting point nonetheless. * Search the fine SMTnet Archives. There is tons of good advice there on wave soldering. * Get a copy of your flux supplier recommendations. Ask them for help in understanding in determining the activity of your flux, understanding when to replace your flux, measuring flux density, etc. * Read the operating manual for the machine and follow the manufacturer�s maintenance recommendations. * Buy a piece of fireplace glass at the local glass store. The stuff is tempered to take the heat. Get it cut to fit your typical conveyor width. It'll cost around $30 and worth every nickel. Use the plate to observe even fluxing and check the wave for dwell and uniform contact. * Learn how to do designed experiments [DOE]. => Search the fine SMTnet Archives.
Guidelines * Control: Flux specific gravity, preheater temp, conveyer speed, solder temperature. * Two most important parameters are: solder temperature & dwell time * Contact time. The optimum contact (dwell) time in the wave should be 2 seconds. Contact bandwidth is a function of conveyor speed. For an example, 5cm of contact band width at 150cm/min conveyor speed will give you 2 seconds of contact time and 2cm of contact band width at 60cm/min conveyor speed also delivers 2 seconds dwell (contact) time. [From a Sandia Laboratories chart] * Immersion depth (1/3 to 2/3 of the board) has the least impact of any variable in wave soldering * Pot temperature: 460-480�F [240-260�C]. * Topside temperature entering wave: Aqueous flux - 180-220�F [82-104�C] No-clean flux � 200-230�F [93-110�C] * Conveyor slope: 8�
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