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Operation Manual
Thank you for purchasing the TERRA selective solder controller. This unit has the ability to
program up to 300 solder profiles (recipes) to accommodate virtually all selective solder
applications.
Please read these instructions thoroughly for proper use of this machine.
Make sure to read all "Safety Notes" before you use machine. This information protects you
from possible dangers during use.
Page 2 of 25
Rev. 1.01E
Safety Notes
This manual includes important information to use this machine safely. This
also includes useful information to prevent injury or damaging property. Please read
this manual carefully prior to connecting or operating the TERRA.
Keep this manual nearby the machine all the time.
Do not connect to a power supply greater than the specified voltage. If not,
electrical shock and /or damage to the unit may occur.
Make sure that the electrical outlet is properly grounded. If the outlet is not
properly grounded, electrical shock and/or damage to the unit may occur.
This machine is designed to use an automatic solder feeder and heating iron for soldering.
If you touch a heated soldering iron, you will burn yourself. So, make sure the
iron has cooled down before you touch or replace the iron cartridge.
Please handle this machine with care. If the unit is dropped or mis-handled, it can cause
damage beyond repair and will not be considered a warranty item.
Please turn off the power, remove the power cable and keep it in a dry and cool place.
Page 3 of 25
CONTENTS
Page No.
Safety notes .......................................................................................................... 2
Contents ................................................................................................................ 3
1Summary of TERRA Components ..................................................................... 4
2Description of TERRA Components .................................................................. 5
3WK parameter setting (solder profiles) ..........................................................5 - 6
4How to change the TERRA system parameters ........................................... 7 - 9
5Operation
................................................................................................1011
Page 4 of 25
B)
IRS232C connector
Fuse
Power plug inlet
Page 5 of 25
1.
WK Parameter Setting
1-1. Turn ON the robot/TERRA and program the soldering conditions (WK parameter) and the
X, Y positions.
Refer to the Operation Manual of the specific robot and teach the soldering position and
cleaning position.
Soldering condition number for point soldering
101-199
(Third soldering- cannot be set.)
Soldering condition number for line soldering
201-299
Soldering condition number for special point soldering
301-399
1)
2)
Power on
1-2.
Orange
Page 6 of 25
Command
SV2 Time (ramp-up Temp.)
1st Amount / Speed
1st Rev. Amount / Speed
Pre-Heat Time
2nd Amount / Speed
2nd Rev Amount / Speed
Heating Time
Adjustable Range
0-99.9mm
0-99.9mm
0-99.9mm
0-99.9mm
0-99.9sec
SP0.1-99.9
SP0.1-99.9
0-99.9sec
SP0.1-99.9
SP0.1-99.9
0-99.9sec
Command
SV2 Time
1st Amount / Speed
1st Rev. Amount / Speed
Pre-Heat Time
2nd Amount / Speed
2nd Rev Amount / Speed
Heating Time
3rd Amount / Speed
3rd Rev Amount / Speed
Adjustable Range
0-99.9sec
0-99.9mm
SP0.1-99.9
0-99.9mm
SP0.1-99.9
0-99.9sec
0-99.9mm
SP0.1-99.9
0-99.9mm
SP0.1-99.9
0-99.9sec
0-99.9mm
SP0.1-99.9
0-99.9mm
SP0.1-99.9
WK301-399
Point soldering
Line soldering
Point soldering
(No up)
Adjustable Range
Command
SV2 Time
0-99.9sec
st
0-99.9mm
SP0.1-99.9
st
0-99.9mm
SP0.1-99.9
1 Amount / Speed
1 Rev. Amount / Speed
Pre-Heat Time
0-99.9sec
nd
0-99.9mm
SP0.1-99.9
nd
0-99.9mm
SP0.1-99.9
2 Amount / Speed
2 Rev Amount / Speed
Heating Time
0-99.9sec
rd
0-99.9mm
SP0.1-99.9
rd
0-99.9mm
SP0.1-99.9
3 Amount / Speed
3 Rev Amount / Speed
Pool Wait Time
0-99.9sec
Page 7 of 25
1-4
Page 8 of 25
2.
1)
2)
3)
4)
5
6
7)
Note
Once the TYPE has been changed, turn off the TERRA power and turn on again in
order for the change to take effect.
Page 9 of 25
Initial Setting
50
50
300
OFF
250
ON
ON
ON
Iron U/D
U/D Time
Adjustable Range
0 - 200
0 - 200
1- 500
1 - 500
ON/OFF
1 - 300
ON/OFF
ON/OFF
ON
ON/OFF
0 - 99
ON
Heat Auto
ON/OFF
Tem Lim
Ms-Speed
500
250
100 - 500
1 - 250
Feed Cal
100
1 - 200
TIP
1/2
TCL1
-30
100
TCL2
-30
100
70
0
80
20
1
ON
1- 200
0 - 99
1 - 200
0 - 99
1- 60
STA
STA/ROB
T1PG
T1IG
T2PG
T2IG
Wait time*
Type
Stand-Alone
or Robot
Use for
E-Stop
ON/OFF
ON/OFF
Detail
Temp. alarm range High
Temp. alarm range Low
Setting temperature
SV2 temperature setting
Stand by temperature setting
Solder feed :
Enable/Void
Heater :
Enable/Void
Iron
up/down
sensor:
Enable/Void
Iron up/down sensor error limit
Heater auto start when power
on.
Maximum temperature
Manual solder feeding speed
Auto solder feeding quantity
adjust
Tip select 1 or 2 (DCS/DCN=1)
Tip type 1
temperature
calibration
Tip type 2
temperature
calibration
Tip type 1 Proportion Gain
Tip type 2 Proportion Gain
Tip type 1 Integral Gain
Tip type 2 Integral Gain
Wait time min. Enable/Void
Required emergency signal
STA Break contact
ROB Normal contact
If the Wait time is ON, enter adequate Wait Temp to operate according to your
requirements
Page 10 of 25
3.
3-1
Operation
Preparation
Make sure the following items are checked prior to initial operation.
1. Check the power supply, the connections of the power supply, the line voltage
and air pressure (The pressure range is from 4 to 7 kg/cm2).
2. The diameter of the solder wire is correct and the solder wire is sufficient.
3-2 Order of Operation
1. Turn ON the TERRA power supply. (Make sure the lamp for Power ON is on.)
2. Attach the solder wire in the following order.
3-3 Solder Wire Loading
1)
2)
3)
(2)
(3)
(1)
3-4 Turn on the Robot Power (if applicable Janome Robot Instructions)
1. Turn ON the Robot power supply and press the Start button.
2. The screen changes to green color after a while and shows the operation screen.
If not check the air supply and the iron cartridge.
3. Press the start button and one cycle operation will start.
Page 11 of 25
Page 12 of 25
Page 13 of 25
Input
Pin No.
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
Signal
EMERGENCY
Description
Prog SEL 1
Prog SEL 2
Prog SEL 4
Prog SEL 8
Prog SEL 16
Prog SEL 32
Prog SEL 64
START
STOP
Automatic start
Partial stop
RESET
Error reset
S+
S-
Iron U/D
Air blow
OUTPUT
B1
EMERGENCY
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20
READY
Solder Error
Temp Error
Emergency stop if
STA mode :A1B1 opens
Ready for automatic operation
Terra is running
One cycle end
Slider start signal
Solder shortage or clogging error
Iron temperature error
AUX OUT1
Out signal for iron up/down. Use for soldering tip life count
OUT P24V
DC24V(500mA) supply
DC24V(500mA) supply
DC24V(500mA) can be entered
RUNNING
CYCLE END
ACK
OUT P24V
EXT.P24V
0V
0V
Page 14 of 25
5.
5-1
Maintenance
Daily inspection requirement items are as follows:
Note: When inspecting the unit, turn off the power and cool down the iron tip (3~5 minutes).
1)
2)
3)
4)
Air Pressure
Make sure the air pressure is correct. (4-5kg/cm2)
5)
6)
Up/down Movement
Make sure if the up/down movement of iron unit of iron unit is smooth. Also, make
sure there is no flux sticking in moving parts. Use the silicone rings to prevent fumes
from building up on the iron cartridge unit. If the iron up/down speed is too fast,
solder balls can be created from excessive force & splatter.
7)
8)
9)
Monthly
Check the solder feed delivery tube. Make sure that there is no flux build-up on the
tube end (Teflon / Stainless). The Teflon inner tube should protrude through the
stainless end by approx. 0.5 ~ 1.5 mm (0.020 ~ 0.060)
10)
Annually
Calibrate the temperature controller by using an external Thermo-couple. Set the
Terra parameters accordingly per the results. Contact Apollo Seiko for details.
Page 15 of 25
1)
3) Adjusting screw
for alignment
tighten
Page 16 of 25
6.
Page 17 of 25
7.
Troubleshooting
This table is designed to help trouble shoot common problems that may occur with the Terra
unit and related components (feeder, iron etc.). If you have tried the recommended solution
and the problem persists, please contact Apollo Seiko directly for technical support.
Problem
Failure Reason
The power cable is disconnected
Fuse is blown
The Control PCB is not working
(incorrect system function)
The internal heating element is
broken
Heater/Iron controller is damaged
The temperature
controller does
not allow for
adjustment or is
not functioning
properly
Recommended Solution
TM 14 A is damaged
An error code is being displayed
on the robot panel or Heater LED is
ON
Page 18 of 25
Problem
Failure Reason
Temperature
abnormality
(unstable) or the
error condition
persists
Recommended Solution
Page 19 of 25
8.
Introduction
Soldering is a technique which connects a metal to another metal by an alloy reaction.
Solder material melts, but the base material (metal pieces on the work-piece) never melt
during soldering.
There are three important factors (Three great factors of soldering) that contribute to the
alloy reaction:
Cleaning the metal surface (normally with flux core solder or additional liquid flux)
Formation of an alloy layer done by melting solder and creating a metallurgical bond
Heat source which should be maintained at a suitable temperature in order to form
An alloy layer by soldering
The solder iron tip design and plating are very important to the formation of the alloy &
metallurgical bonding of the solder to the component & PCB plating. Therefore it is very
important to ensure that the solder tip is kept clean and maintains its shape. Iron tips will
wear during use and need to be replaced on a scheduled basis to ensure optimal quality and
provide the correct thermal transfer.
Care of Iron Unit
The Apollo soldering tip, HI-TIP (AS, HQ, TM and TB & DC models) achieve high
performance and long life by using 99.9% oxygen-free copper as a base material with
special iron plating and a proprietary plating over the iron plating.
Usually, the life of the tip is about 50,000 points. However, if it is used at more than
400 or with a highly aggressive flux or the solder feeding position is incorrect, the life
can be shortened up to 25%. Lead free alloys also are highly abrasive due to the high
Tin content and can cause reduced wear. Apollo Seiko recommends using pre-heated
N2 gas to help lower the overall soldering temperature and provide a local, inert
environment to help reduce oxidation to the tips plated surface.
The correct solder feeding position, minimum allowable temperature and proper
positional programming can help extend tip life by as much as 50% in many cases.
A) Check the iron tip visually first to ensure that the tip is on good condition and clean.
If the tip shows evidence of wear, change the tip immediately for best results
B) Ensure that proper tip cleaning methods are utilized which may include a rotating
sponge cleaner, compressed air and occasionally manual cleaning of the tip with a
brass cleaning pad, wooden or metal scraper or even tip tinning paste.
C) Program the SLEEP MODE (WAIT TEMP) on the Terra parameter list to ensure that
the temperature drops to a moderate temperature (100 Deg. C) during periods of
inactivity.
D) Solder at the lowest possible temperature to help extend tip life
E)
Follow the solder feed set-up instructions in order to help extend tip life as long as
possible. Proper solder feed set-up may be the most important factor to extend
useful tip life.
Page 20 of 25
There are many solder defects not mentioned above which include:
Insufficient Solder
Icicling or Solder Spikes
Excess Solder
Melting of Substrate (Kapton or flex material)
Solder Pad Lifting
Please contact an Apollo Seiko engineer for assistance with eliminating solder defects. It is
always a good idea to insert a new iron tip and test again for quality prior to making any
changes to the program or solder profiles.
Page 21 of 25
9.
1) Make sure to turn the power off and cool down the iron
cartridge to room temperature and pull down on the iron
cartridge to remove and replace with a new one. If it does
not come out, using the silicone tube pull it down strongly.
In case flux is jammed, remove it carefully with an
alcohol. You can also increase the temperature to
approx. 450 Degrees C to break the flux barrier.
Power off & remove with a silicone tube. The tip will be
very hot.
Note:
Page 22 of 25
Iron Tip List (Model DCM and DCS for point soldering)
DCM iron cartridge
DCM-**D-2, DCS-**D-2
DCM-**D, DCS-**D
Type
DCM DCS-08D
DCM DCS-10D
DCM DCS-13D
DCM DCS-16D
DCM DCS-20D
DCM DCS-24D
DCM DCS-30D
DCM DCS-40D
DCM DCS-50D
DCM DCS-60D
DCM DCS-80D
a
(mm)
3
4
4
4
4
4
5
5
5
6
8
0.8
1.0
1.3
1.6
2.0
2.4
3.0
4.0
5.0
6.0
8.0
0.3
0.4
0.5
0.6
0.6
0.8
1.0
1.0
1.3
1.3
1.6
d
3s
1.0
1.0
2.0
2.0
2.0
2.0
3.0
3.0
4.0
4.0
3.0
Type
a
(mm)
d
2s
DCM/DCS-16D-2
DCM/DCS-20D-2
DCM/DCS-24D-2
DCM/DCS-30D-2
DCM/DCS-40D-2
4
4
4
5
5
1.6
2.0
2.4
3.0
4.0
0.6
0.6
0.8
1.0
1.0
2.0
2.0
2.0
3.0
2.5
Page 23 of 25
Iron Tip List (Model DCM and DCS for point soldering)
DCM-** DV1, DCS-** DV1
Type
a
(mm)
DCM/DCS-08DV1
DCM/DCS-10DV1
DCM/DCS-13DV1
DCM/DCS-16DV1
DCM/DCS-20DV1
DCM/DCS-24DV1
DCM/DCS-30DV1
DCM/DCS-40DV1
DCM/DCS-50DV1
3
4
4
4
4
4
5
5
5
DCM-** PC, DCS-** PC
d
3s
0.8
1.0
1.3
1.6
2.0
2.4
3.0
4.0
5.0
0.3
0.4
0.5
0.6
0.6
0.8
1.0
1.0
1.3
1.0
1.5
2.0
2.0
2.0
2.0
3.0
3.0
4.0
d
2s
Type
a
(mm)
DCM/DCS-10PC
DCM/DCS-13PC
DCM/DCS-16PC
DCM/DCS-20PC
DCM/DCS-24PC
DCM/DCS-30PC
DCM/DCS-40PC
DCM/DCS-50PC
3
4
4
4
4
5
5
5
1.0
1.3
1.6
2.0
2.4
3.0
4.0
5.0
Type
a
(mm)
DCM/DCS-10DV1-2
DCM/DCS-13DV1-2
DCM/DCS-16DV1-2
DCM/DCS-20DV1-2
DCM/DCS-24DV1-2
DCM/DCS-30DV1-2
DCM/DCS-40DV1-2
DCM/DCS-50DV1-2
4
4
4
4
4
5
5
5
DCM-** DV2, DCS-** DV2
d
2s
1.0
1.3
1.6
2.0
2.4
3.0
4.0
5.0
0.4
0.5
0.6
0.6
0.8
1.0
1.0
1.3
1.5
2.0
2.0
2.0
2.0
3.0
3.0
4.0
Type
a
(mm)
d
3s
DCM/DCS-13DV2
DCM/DCS-16DV2
DCM/DCS-20DV2
DCM/DCS-24DV2
DCM/DCS-30DV2
DCM/DCS-40DV2
DCM/DCS-50DV2
4
4
4
4
5
5
5
1.3
1.6
2.0
2.4
3.0
4.0
5.0
0.5
0.6
0.6
0.8
1.0
1.0
1.3
2.0
2.0
2.0
2.0
3.0
3.0
4.0
Page 24 of 25
Iron Tip List (Model DCM and DCS for slide soldering)
DCM-** R, DCS-** R
Type
a
(mm)
DCM/DCS-20R
2.0
0.6
DCM/DCS-30R
DCM/DCS-40R
DCM/DCS-50R
3
4
5
3.0
4.0
5.0
0.6
0.9
1.3
Type
DCM/DCS-16FPR
6.0 DCM/DCS-20FPR
DCM/DCS-24FPR
6.4 DCM/DCS-30FPR
7.0
8.0
a
(mm)
6.0
6.0
6.0
6.0
3.4
3.4
4.0
4.5
1.6
2.0
2.4
3.0
Page 25 of 25
Example :
TAL-0.8-650S60
TAL is the tube model
(0.8 is solder diameter in mm)
(650 is total length in mm)
(S60 is stainless steel end length in mm)
Model Number
Point*
Slide*
TAL0.3-450S60
TAL0.4-450S60
TAL0.5-650S60
TAL0.65-1000S60
TAL0.8-1500S60
TAL 1.0-450S60
TAL0.3-450S90
TAL0.4-450S90
TAL0.5-650S90
TAL 0.65-1000S90
TAL0.8-1500S90
TAL 1.0650S90
* The length of feed tube listed above is for example only. Any of the specified lengths can be ordered with
any wire diameter. It is recommended to use shorter tube lengths with smaller wire diameters
RS-P
S60 (60 mm)
RS-L
S90 (90 mm)