SonoFlux 2000F

Spray Fluxing Systems

Models 2000F-330M & 2000F-610M

Operating Manual

PN 11-01-00140 V1.8

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 1

Thank you for selecting a Sono-Tek product. We are confident that this product will provide many
years of reliable service in your application.

We intend to provide you with the highest level of support and service in order to assure your
continued satisfaction. Our corporate philosophy in this regard is expressed best by our Mission
Statement:

Sono-Tek is committed to being the world’s leading supplier of ultrasonic spray

technology products and related equipment. We expect to achieve sustained
growth and profitability by providing quality and cost effective solutions to the
global markets we serve.

Through the skills and dedication of our team, working in an environment where
we can all grow and prosper, we shall maintain the highest level of product
performance and customer satisfaction.

We encourage you to contact our highly qualified staff if you have questions regarding operation or
service. Call us at 845-795-2020 or e-mail us at info@sono-tek.com. In addition, extensive technical
information about our products is available on our website at www.sono-tek.com.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 2

CONTENTS
1.0 SYSTEM OVERVIEW 5.0 SYSTEM SETUP 23
1.1 THE SPRAY FLUXING PROCESS 4 5.1 SYSTEM SETUP 23

1.2 SPRAY VERSUS FOAM FLUXING 4 5.2 CALIBRATING SPRAY ON/OFF 23

1.2.1 FLUX CONSUMPTION 4 5.3 SONOFLUX SYSTEM VARIABLES & THEIR EFFECTS 23

1.2.2 DEFECT RATES 4 5.3.1 NOZZLE POWER LEVEL 23

1.2.3 ELIMINATION OF THINNER USAGE & 5.3.2 NOZZLE TUNING 24
FLUX DISPOSAL 4 5.3.3 FLOW RATE 25
1.3 ULTRASONIC ATOMIZATION 5 5.3.4 SPRAY ASSEMBLY: SPRAY WIDTH 25
1.3.1 ULTRASONIC SPRAY NOZZLES 5 5.3.4.1 SPRAY WIDTH PARAMETERS 26
1.3.2 THE APPLICATION OF ULTRASONIC NOZZLES 5.3.5 JET CLEANING FEATURE (JET BURST) 26
IN PCB ASSEMBLY 5 5.3.6 CONVEYOR SPEED 26
2.0 SONOFLUX RETROFIT SYSTEM OVERVIEW 7 5.4 ESTABLISHING A PROCESS FOR A PCB 26
2.1 SONOFLUX SYSTEM COMPONENTS 7 5.5 CHANGING SONOFLUX PARAMETERS FOR
2.1.1 ULTRASONIC SPRAY ASSEMBLY 10 DIFFERENT PCBS 26
2.1.2 ELECTRONICS ENCLOSURE 10 6.0 CALIBRATION PROCEDURES 27
2.1.2.1 NOZZLE DRIVER SUBSYSTEM 10 6.1 INTRODUCTION 28
2.1.2.2 LIQUID DELIVERY SUBSYSTEM 10 6.2 DESCRIPTION OF THE KIT 28
2.1.2.3 INTERFACE PCB 10 6.3 OVERVIEW OF CALIBRATION PROCEDURES 29
2.1.2.4 JETS CONTROL AND ROTARY AIR DISPERSION 6.3.1 FLUX PUMP CALIBRATION 29
DRIVER SYSTEMS 11 6.3.2 ULTRASONIC NOZZLE CALIBRATION 29
2.1.2.5 JET CLEANING FEATURE (JET BURST) 11 6.3.3 JET FORCE AIR FLOW CALIBRATION 29
2.1.2.6 POWER SUPPLIES 11 6.3.4 CONVEYOR CALIBRATION 30
2.1.3 CONTROL AND DISPLAY MODULE 11 6.3.5 MEASURING THE EXHAUST VOLUME 30
2.1.3.1 17-KEY KEYPAD 11 6.4 DETAILED PROCEDURES 30
2.1.3.2 WHEEL ENCODER 11 6.4.1 PUMP CALIBRATION PROCEDURE 30
2.1.3.3 LCD DISPLAY 11 6.4.2 ULTRASONIC NOZZLE CALIBRATION PROCEDURE 31
2.1.3.4 PIEZOELECTRIC ALARM 11 6.4.3 SPRAY FORCE AIR FLOW CALIBRATION
2.1.3.5 ELECTRONICS ENCLOSURE INTERFACE PORT PROCEDURE 32
(PORT 1) 11 6.4.4 CONVEYOR SPEED CALIBRATION PROCEDURE
2.1.3.6 CUSTOMER INTERFACE & CONTROL PORT (STAND-ALONE MODELS ONLY) 33
(PORT 2) 11 6.4.5 EXHAUST AIR FLOW MEASUREMENT PROCEDURE 33
2.1.4 FLUX RESERVOIR 12 6.4.6 DEPOSITION FACTOR 34
3.0 INSTALLATION 15 7.0 MAINTENANCE AND SAFETY 34
3.1. REMOVAL OF SHIPPING MATERIALS 7.1 SAFETY PROCEDURES 34
(RETROFIT SYSTEMS) 15
7.2 MAINTENANCE PROCEDURES 34
3.2 INSTALLING THE SONOFLUX RETROFIT SYSTEM 16
7.2.1 WEEKLY MAINTENANCE 34
3.3 INSTALLING THE SONOFLUX STAND-ALONE SYSTEM 18
7.2.2 MONTHLY MAINTENANCE 35
4.0 CONTROL OF THE SONOFLUX SYSTEM 19 7.2.3 ANNUAL MAINTENANCE 35
4.1 SYSTEM CONTROL 19 7.3 SYSTEM FAILURE MAINTENANCE 35
4.1.1 OVERVIEW 19 8.0 TROUBLESHOOTING 36
4.1.2 POWER UP 19
9.0 SOLDER DEFECT GUIDE 38
4.1.3 ENTER PIN NUMBER 20
10.0 SPARES KITS 39
4.1.4 ALARMS 20
4.1.5 ADJUST CURRENT PROCESS 20 SWAGELOK INSTALLATION INSTRUCTIONS 42
4.1.6 RECIPES 21 WARRANTY 43
4.1.7 EDIT FLUX PARAMETERS 21
4.1.8 CHANGE SPRAY MODE 21
4.1.9 UNITS OF MEASURE 21
4.1.10 SYSTEM MENU 21
4.1.10.1 CHANGE PIN NUMBERS 21
4.1.10.2 CALIBRATION MENU 21
4.1.10.3 JET BURST DELAY 22
4.1.10.4 TEMPERATURE 22
4.2 SYSTEM ALARM MONITORING 22

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 3

1.0 SYSTEM OVERVIEW
Although of relatively recent origin, spray fluxing has already
assumed prominence as a technique for applying solder flux to
printed circuit assemblies in the wave soldering process.
Originally intended as a method for applying low-solids content
“no-clean” fluxes only, spray fluxing, because of the significant
benefits it offers, is also being used to apply water-soluble
organic acid, volatile organic compound (VOC)-free, and even
some RA and RMA fluxes.
1.1 THE SPRAY FLUXING PROCESS
The various types of spray fluxers on the market all achieve the
same basic results. The typical spray fluxer consists of a spray
assembly, incorporating an atomizing nozzle, that coats the
bottom of a PCB with a relatively uniform, controlled layer of flux
as the board passes over the spray area. Flux deposition is
controlled, board after board, through the use of dispensing
systems that precisely meter the amount of flux delivered. The
flux is drawn from a closed reservoir so that no evaporation can
occur prior to the flux being deposited on the PCB. The use of
thinner and the need to dispose of old flux periodically,
requirements for foam and wave-type fluxers, are both
eliminated.
Since flux delivery is precisely controlled, the process can be
optimized such that proper amount of flux is always deposited.
This is particularly important for “no-clean” processes. Too
much flux applied leads to excessive post-soldering residue,
whereas too little causes poor solderability.
1.2 SPRAY VERSUS FOAM FLUXING
The growing popularity of spray fluxing is attributable to the
benefits that it offers over foam fluxing. These can be broadly
categorized as follows:
• Significant reduction in flux consumption.
• Lower defect rates as a result of repeatable,
uniform deposition.
• Elimination of thinner addition and titration.
• Elimination of flux disposal.
1.2.1 Flux Consumption
Foam fluxers, by their very nature, deposit copious amounts of
flux. In general, the amount applied to a PCB is well in excess
of that required for solderability. This holds true for all types of
fluxes. Typically, an air knife is used in conjunction with the
foam fluxer to remove the excess and thereby reduce dripping
onto the preheaters and the consequent fire hazard.
The reduction in flux consumption using spray fluxing is usually
dramatic. It is not uncommon for installations that have
converted from foam to spray fluxing to report flux usage
reductions in the 70-80% range. These figures include that
consumption associated with flux disposal.
11-01-00140 V1.8
Reductions in flux consumption not only provide economic
benefits, but in the case of alcohol-based no-clean and VOC-free
water based fluxes, process considerations make reducing the
amount of flux applied mandatory. As mentioned earlier, an
excessive amount of no-clean flux generally results in
unacceptable residue levels. In the case of VOC-free fluxes,
excessive water on the boards makes drying difficult and
increases the possibility for spattering over the solder wave.
A side benefit of reduced flux deposition is that there is less
build up in the solder pot; dross reductions of 20% have been
reported.
1.2.2 Defect Rates
The sources of defects encountered in the wave soldering
process are numerous. Those typically associated with the foam
fluxing process usually relate to inconsistencies in the foam head
and contamination of the flux reservoir.
In the case of “no-clean” fluxes, additional sources of defects
arise from changes in flux activity due to improper
concentrations of solids in the flux arising from evaporation,
water absorption or the addition of thinner. Defects such as
bridging or solder insufficiencies are often directly attributable to
the variable nature of the deposition from the foam head.
The repeatable and uniform deposition achievable with spray
fluxing minimizes these defects. Each board receives the same
amount of flux, distributed uniformly over the entire board; and
since the flux is delivered from a closed container, the activity
remains constant.
1.2.3 Elimination of Thinner Usage and
Flux Disposal
Two other significant benefits of spray fluxing are the
elimination of all expenses associated with the use of thinner
and the disposal of spent flux.
Since spray fluxing systems utilize closed reservoirs, the alcohol
cannot evaporate. This not only eliminates the need for thinner,
but also makes it unnecessary to perform bothersome titrations,
since the specific gravity of the flux remains constant.
The disposal of spent flux from a foam flux bath usually
represents a significant expense. The actual costs depend on
how frequently the bath is changed and on local disposal
requirements.
SonoFlux 2000F Manual of Operations Page 4

1.3 ULTRASONIC ATOMIZATION
The SonoFlux 2000F series spray fluxers are advanced
production tools that rely upon ultrasonic atomization to achieve
uniform coatings of flux on printed circuit assemblies. The
phenomenon referred to as ultrasonic atomization has its roots
in late 19th century acoustical physics, notable in the works of
the ubiquitous Lord Rayleigh.
Simply stated, when a liquid film is placed on a smooth surface
that is set into vibrating motion such that the direction of
vibration is perpendicular to the surface, the liquid absorbs some
of the vibrational energy, which is transformed into standing
waves. These waves, known as capillary waves, form a
rectangular grid pattern in the liquid on the surface with
regularly alternating crests and troughs extending in both
directions as shown in Figure 1.1.
When the amplitude of the underlying vibration is increased, the
amplitude of the waves increases correspondingly; that is, the
crest become taller and troughs deeper. A critical amplitude is
ultimately reached at which the height of the capillary waves
exceeds that required to maintain their stability. The result is
that the waves collapse and tiny drops of liquid are ejected from
the tops of the degenerating waves normal to the atomizing
surface.
A useful analogy that helps visualize this process comes from
our everyday experience. Ocean waves coming into shore go
through a transition from stability on the open water to
instability as they approach shore. The instability is evident as
the waves form foamy breakers.
The reason for instability in this type of wave is that as it
approaches shore, the bottom of the wave contacts the ocean
floor and is slowed down by frictional forces. The wave top, on
the other hand, continues to move ahead unimpeded. The net
result is that the wave topples over. In this process of breaking
up, a spray of tiny drops is ejected from the wave surface.
Although the mechanisms governing the creation of a spray
from capillary and ocean waves differ, the results are similar.
The other major attribute of ultrasonic nozzles, one which
distinguishes these devices from all other atomizing devices, is
the low velocity character of the spray, typically 0.8 to 1.2 feet
per second as compared to 35 to 70 feet per second for
standard pressure atomizing nozzles. This 100-fold reduction in
spray velocity is equivalent to a 10,000 times reduction in kinetic
energy.
Thus, when the spray is directed toward a target surface to be
coated, there is little tendency for the material to bounce off the
surface and into the environment. This so-called overspray or
“bounce back” that is normally associated with pressure nozzles,
virtually disappears as a problem with ultrasonic nozzles.
The liquid is delivered to the atomizing surface through a large
diameter feed tube that runs the length of the nozzle. The large
liquid feed orifice assures freedom from clogging.
1.3.2 The Application of Ultrasonic Nozzles
in PCB Assembly
Ultrasonic nozzles have been used successfully in critical on-line
PCB assembly operations for many years, principally in applying
solder fluxes to through-hole and surface mount assemblies.
In order to cover the entire board surface with flux, the spray
from a nozzle is entrained in an air stream and deposited
uniformly across the board as the board passes over the spray.
The spray shaping system is shown in Figure 2.2. This assembly,
together with Sono-Tek’s proprietary ultrasonic nozzle, form the
“heart” of the SonoFlux 2000F System.

1.3.1 Ultrasonic Spray Nozzles

As their name implies, ultrasonic atomizing nozzles are devices
that vibrate at frequencies beyond those of human hearing; that
is, in excess of 20 kHz. The atomized spray they produce results
from the unstable capillary waves developed in the liquid
introduced onto the atomizing surface of the nozzle. One of the
principal attributes of ultrasonic nozzles results from the
Figure 1.1: Capillary wave pattern on vibrating tip of ultrasonic nozzle
atomization being solely a surface phenomenon. The amount of
liquid atomized depends exclusively on the rate at which liquid is
introduced onto the surface.
Therefore, in principle, ultrasonic nozzles have infinite variability
with respect to flow rate. Although practical considerations
related to nozzle design limit this variability to a fixed amount
(typically the achievable ratio of maximum to minimum flow
rates is at least 5:1), the ability to precisely adjust flow rates by
adjusting the rate at which liquid is delivered to the nozzle is
often useful in practice.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 5

The SonoFlux System has four (4) main components; the ultrasonic spray assembly, electronics module, control and display module
and flux reservoir (Figure 2.1). Stand-alone models additionally incorporate a frame that houses the spray assembly, control and
display module, electronics module, optional conveyor, and exhaust.
The ultrasonic spray assembly consists of a support frame and enclosure, an ultrasonic nozzle mounted in a jet block, and exhaust
hood. In retrofit models, mounting brackets, attached to the wave solder conveyor or other interior structures, support the spray and
exhaust assemblies. The spray and exhaust assemblies lift out for easy cleaning.
Experimentation will be required to determine optimum settings for each type of board and flux. Refer to Section 5.4 for information
on establishing a process for PCB production.
Once the optimal settings have been determined, the SonoFlux System is ready for use in production. As the printed circuit board
passes into the wave solder machine, an infrared sensor activates the timing electronics causing the system to spray when the printed
circuit board is over the spray assembly. After the printed circuit board passes through the spray area, the spray is shut off until the
next printed circuit board is in position for spraying.
The system electronics is housed in an enclosure. In retrofit systems, the enclosure can be mounted vertically or horizontally in any
free area inside or outside the wave solder machine, but not in areas where it may be exposed to excessive heat. The SonoFlux
System electronics are all microcontroller based, with one microcontroller residing in the display and control module, and several more
located on the main interface board and its associated smart peripheral control cards in the enclosure.
The electronics enclosure contains the liquid delivery system, sensor/monitor electronics, power supply assemblies, and jets control
assemblies.

The control and display module is the user interface for controlling system functions. It contains a keypad, a wheel encoder, a 4-line
by 40-character display and an interface port, as well as housing the system's several microcontrollers.
Refer to Figure 2.1 which shows how the major SonoFlux System components are connected to each other.
The flux reservoir consists of a polypropylene (or stainless steel) tank with an input line to the pump inlet, a return line from the 3-way
valve, and a low level sensor cable to alert the operator if the flux level is low in the tank.
The SonoFlux System can be adjusted to apply precise, repeatable amounts of flux with virtually no top-side overspray to circuit boards.
Adjusting the conveyor speed, jet air flow, liquid flow rate and nozzle power level all affect the amount and uniformity of the deposition.
Because these variables interact, a number of different settings will satisfy a given deposition requirement. The SonoFlux 2000F
System greatly simplifies the procedure for obtaining the correct settings by incorporating a spray mode that sets deposition density
(referred to as "Deposition Mode"), which allows the SonoFlux 2000F system to automatically adjust the flow rate to compensate for
changes in conveyor speed, spray width and flux specific parameters. If desired, the user will still have the ability to select "Flow Rate"
spray mode which allows a specific flow rate to be maintained regardless of all other parameter settings.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 6

2.0 SONOFLUX RETROFIT SYSTEM OVERVIEW
2.1 SONOFLUX SYSTEM COMPONENTS
In the following sections each SonoFlux System component or subsystem is described. To use the SonoFlux System effectively, it is
necessary to understand how the system operates and what function each component performs.

Electronics Box Components

1. 06-03-00215-NPS PLL Chassis Generator

3
1 2. 06-02-00100-### Interface Board*
(-001 standard)
3. 08-00-00206 5.1 VDC Power Supply
4
4. 08-00-00134 24 VDC Power Supply
5. 06-03-00577-### Jet Control
2
(-001 Single, -002 Dual)
6. 06-03-00422 Rotary Valve Assembly
7. 06-03-00465 Humphrey Valve

5 *Serial number is require to order part

7
6

6
9

8 5
2

4 6
7
1

1. 06-03-00173 Micropump Assembly

2. 01-00-00686 1/8” Pump Fitting
3. 01-00-00240 1/4” Pump Fitting
4. 05-03-00012 1/8” Liquid Tubing
5. 06-03-00187-001 Pneumatic Valve Assembly (Liquid)
6. 01-00-00274 1/4” Liquid Valve Fitting
7. 01-00-00222 1/8” Liquid Valve Fitting
8. 05-03-00017 1/8” Air Tubing
9. 01-00-00520 5/16” PI Fitting

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 7

Spray Chamber Components

3
2
4
1

6
5 1

1. 06-03-00364 Jet Block Assembly 1. 02-04-00996 M8 Bulkhead Connector

2. 06-04-00313 Ultrasonic Nozzle 2. 01-00-00229 1/4” Bulkhead Fitting (Liquid)
3. 02-04-00945-003 Nozzle Cable M8, 2 ft (New Style) 3. 01-00-00383 5/16” Bulkhead Fitting (Air)
**06-01-00134 Nozzle Cable SMA, 2 ft (Old Style)
4. 05-03-00047 1/4” Blue Stripe Liquid Tubing
5. 05-03-00040 5/16” Blue Air Tubing
6. 05-03-00045 5/16” Blue Stripe Air Tubing

**Refer to page 39 for clarification (Figure 10.0)

1 2
2

1
3

5 6 7 8
3

1. 06-03-00463-### Display (-005 Single head, -004 Dual Head) 1. 05-01-00006 Belt for Rotary Valve
2. 02-04-00942-001 M8 Nozzle Cable, 8 ft (New Style) 2. 01-00-00229 1/4” Bulkhead Fitting
**06-01-0007M SMA Nozzle Cable, 8 ft (Old Style) (Liquid)
3. 02-10-00015/16 PCB Sensor & Cover 3. 10-00-00001 1/4” Nylon Ferrules
4. 06-03-00374 Air Regulator/Filter (Pack of 10)
5. 05-03-00045 5/16” Tubing Blue Stripe (Air) 4. 10-00-00024 Flux Tank Filters
6. 05-03-00041 3/8” Tubing Blue (Air) (Pack of 12)
7. 05-03-00047 1/4” Tubing Blue Stripe (Liquid)
8. 05-03-00040 5/16” Tubing Blue (Air)

**Refer to page 39 for clarification (Figure 10.0)

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 8

Figure 2.1: System Configuration

NOTE: Some components will differ depending on system.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 9


2.1.1 Ultrasonic Spray Assembly
The spray assembly delivers a uniform, controlled width, linear
dispersion of atomized liquid flux to the bottom of the printed
circuit board as it is transported through the system. This linear
dispersion of flux droplets impacts every part of the board.
The ultrasonic nozzle atomizes the liquid flux producing a
cylindrical spray pattern approximately the diameter of the
atomizing surface. The cylindrical spray is then sheared
vertically by two air jets, symmetrically positioned on both sides
of the nozzle, which capture the spray as it leaves the nozzle tip
(See Figure 2.2). Both jets are directed toward the center of
the spray at a point close to the atomizing surface of the nozzle.
Each jet is alternately pulsed on and off, carrying the spray to
both sides of the PCB. A rotary air dispersion valve contained
within the electronics enclosure provides the mechanism for
alternating air pulses.
The spray system consists of:
- Spray frame/enclosure - Air valve system
- Ultrasonic nozzle - Control circuitry for air valve
- Jet block - Rotary air dispersion valve
- Nozzle positioner
The width of the spray can be varied from 2 to 13 inches by
positioning the direction of the air from the jets. Air to the jets
is derived from house compressed air and is controlled by an
electronic air valve system. The air valve system is located in
the electronics enclosure.
The control setting for the air valve, labeled “Jet Force”, is a
parameter found in the “Adjust Current Process” screen on the
control and display module. The nozzle/jet block assembly is
mounted on a slide assembly, such that the assembly can be
easily positioned, both horizontally and vertically (See figure
2.2). The horizontal position can be set using the ruled scale
located at the bottom of the chamber as a guide. Once a
position is selected, a locking collar on the slide fixes the
position so that when removed for servicing, the jet block
assembly can be reinstalled in exactly the same position. The
vertical position of the assembly can be adjusted as well. The
assembly moves up and down on a pair of uprights. Each
upright is notched at ¼” (6.3 mm) intervals so that when
installing the jet block assembly, it is possible to keep track of
the vertical position by listening to or feeling the number of
clicks made by the mechanism as it moves. Once established,
the position can be fixed using the locking collar on one of the
uprights.
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2.1.2 Electronics Enclosure
The electronics enclosure (Figures 2.3a, 2.3b and 2.4a and 2.4b)
contains the following major subsystems:
Nozzle driver subsystem
Liquid delivery system
Sensor electronics and power supply
assemblies (5.1 and 24 VDC)
Jets control assembly(s)
Rotary air dispersion valve(s)
Auxiliary communications ports (2)
All liquid connections are made on the outside front of the
enclosure. The nozzle driver coaxial connector and the power
entry module also are located on the front of the enclosure.
All wiring and sensing cable interconnections are fed through a
hole on the outside front of the enclosure as shown in Figure 2.4.
2.1.2.1 NOZZLE DRIVER SUBSYSTEM
The nozzle driver electronics supplies energy at the proper
frequency and power to excite the ultrasonic nozzle. The nozzle
driver is an oscillator which is frequency and phase-locked to the
ultrasonic nozzle.
When the spray trigger is activated, the nozzle driver delivers
power to the ultrasonic nozzle. The feedback circuitry in the
nozzle driver dynamically adjusts the power level to insure
smooth operation of the nozzle. This feedback loop also
monitors the nozzle’s performance and will signal a nozzle
malfunction error if it does not oscillate properly.
2.1.2.2 LIQUID DELIVERY SUBSYSTEM
This assembly delivers liquid flux, at a precisely controlled rate,
to the ultrasonic nozzle. The liquid delivery assembly consists of
a gear pump, a servo-controlled motor, motor controller, an air
actuated 3-way Teflon® valve, and an air-controlled solenoid
valve.
The gear pump continuously meters liquid from the flux
reservoir through the valve and back to the reservoir. When the
printed circuit board sensor is activated, the sensor subsystem
causes the flow to switch to the nozzle through the 3-way valve.
2.1.2.3 INTERFACE PCB
The Interface PCB functions as a node for all system
interconnections. It houses the electronics hardware for all of
the sensing circuitry, liquid flow rate control, air force/direction
control, nozzle power control, conveyor speed control, nozzle
position control, and auxiliary outputs. The Interface PCB has
two communication ports that can be configured for RS485 or
RS232 communication. Port 1 is always used as the interface
port for the control and display module. Port 2 is used, when
required, for external system control, monitoring, and backup
functions.
SonoFlux 2000F Manual of Operations Page 10
 Up arrow: moves the cursor to the previous
2.1.2.4 JETS CONTROL AND ROTARY AIR line on the display.
DISPERSION DRIVER SYSTEMS Down arrow: moves the cursor to the next line
The rate at which air is delivered to the jets is controlled by a on the display.
valve assembly and associated electronics contained within the Left arrow: moves the cursor to the previous
enclosure. The control electronics converts the input value for character on the display.
spray force into a differential pressure signal that determines the Right arrow: moves the cursor to the next
rate at which air is delivered to the jets. character on the display.
Air is alternately distributed to the two jets by a rotating air System On/Off: activates and deactivates the system. The current
dispersion valve, located within the enclosure. The transition of stored settings are not affected.
air from one jet to the other is accomplished by precise control 0 - 9: allow the user to enter a numeric
of the timing, duration, and rate of change of air flow through value when prompted.
the valve. Esc: Returns the user to the previous screen except
when in SYSTEM/CALIBRATION mode,
2.1.2.5 JET CLEANING FEATURE (JET BURST) where the start-up screen will appear and the unit will
In order to assure that the air jets remain clear of any flux turn off.
residues over long periods of operation, the SonoFlux system is
equipped with an automatic cleaning feature in which the jets 2.1.3.2 WHEEL ENCODER
are periodically purged with a burst of high pressure air over a The wheel encoder is an alternate method of sequentially
10 second period. The frequency of the purge cycle can be incrementing and decrementing selected variables on the display
changed by the user. Typically the cleaning cycle frequency screen. Pushing down on the wheel encoder's knob performs
depends on the type of flux used and the rate at which PCBs are the same function as pressing the ENTER button on the keypad.
passed through the system. In situations where low-solids
content fluxes are used and the PCB throughput is low to 2.1.3.3 LCD DISPLAY
moderate, there may be little or no need for the cleaning
4 line x 40 character liquid crystal display.
function. In more demanding cases, where high rosin content
fluxes are used, and/or the throughput is high, it may be LCD backlit
necessary to employ the cleaning cycle three (3) to four (4) Green/yellow
times per 8-hour shift.
2.1.3.4 PIEZOELECTRIC ALARM
2.1.2.6 POWER SUPPLIES
The alarm is a 100 db board-mounted alarm contained within
There are two system power supplies located in the electronics the unit.
enclosure. The first is a 5.1 VDC power supply that provides
power to the system control circuits and input devices. This 2.1.3.5 ELECTRONICS ENCLOSURE INTERFACE
supply remains on and active as long as the electronics module PORT (PORT 1)
is plugged into an AC source. The second power supply is a 24
The Electronics enclosure interface port provides all
VDC unit that provides power to all of the output devices (e.g.,
communications between the control and display module and
nozzle driver, rotary air dispersion valve, etc.) Although this
the interface board in the electronics module. This port contains
supply is also on when the enclosure is plugged in, the output is
the 24 VDC power used to supply the control and display
connected to all devices through a relay contact that opens in
module, and the full duplex RS485 level transmit and receive
the event of an emergency condition or when the system is shut
signals required for noise-immune communication between the
off.
two devices. The signals are:
2.1.3 CONTROL AND DISPLAY MODULE +Tx Transmit (+) signal
The control and display module contains one of the systems -Tx Transmit (-) signal
microcontrollers and the I/O interfaces (keypad, display and +Rx Receive (+) signal
interface port) which control, monitor, and operate the SonoFlux
-Rx Receive (-) signal
System (See Figure 2.5). It provides for input of the parameters
that control system power, nozzle power level, conveyor speed, +24 VDC Power
liquid flow rate, deposition density, jet force, flux parameters, GND Return
and spray width.
Operator interface is achieved through a menu driven display 2.1.3.6 CUSTOMER INTERFACE AND CONTROL PORT
and functional keypad. The module also contains an RS232 port (PORT 2)
and audible alarm. The control and display module consists of This port can be configured for RS232 or RS485 communications,
the elements detailed in Sections 2.1.3.1 through 2.1.3.6. and is configured by setting the appropriate jumpers located on
the interface PCB. This interface provides the interconnections
2.1.3.1 17-KEY KEYPAD needed for setting, storing, and retrieving control parameters
The function of each of the keys is as follows: remotely. (A Windows-based computer program and the
Enter: allows the user to choose the
necessary interconnections are available as an option for
option currently listed on the SonoFlux systems).
display and store it into memory.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 11

2.1.4 Flux Reservoir The reservoir operates unpressurized. Flux is constantly
The standard flux reservoir provided consists of a 5-gallon recirculated from, and back to the reservoir when the system is
polypropylene tank fitted with inlet and outlet ports, a low-flux not spraying. Filling is accomplished through a wide-mouthed
level sensor, and a replaceable polypropylene inlet filter. opening at the top.

Figure 2.3a: Electronics Enclosure Layout (2000F-610M)

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 12

Figure 2.3b: Electronics Enclosure Layout (2000F-330M)

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 13

Figure 2.4a: Electronics Enclosure Front Panel Layout Figure 2.4b: Electronics Enclosure Front Panel Layout
(2000F-610M) (2000F-330M)

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 14

Figure 2.5: Control and Display Module

3.0 INSTALLATION
NOTE - Package of parts (air regulator/filter/gauge assembly,
clamps, Teflon PTFE tubing (1/4" OD with blue or
THERE IS CONSIDERABLE VARIATION AMONG red stripe; 5/16" OD blue, red, blue-stripe and red-
WAVE SOLDERING MACHINES WITH RESPECT stripe; 3/8" OD blue. Tubing supplied may vary
TO THE SPACE AND FACILITIES AVAILABLE FOR depending on the type of SonoFlux system),
INSTALLING THE SONOFLUX SYSTEM. THE pressure hose, hardware)
INSTALLATION HARDWARE PROVIDED HAS - Flux reservoir
BEEN FURNISHED BASED ON THE (c) The following additional items are necessary to install
QUESTIONNAIRE YOU SUBMITTED TO the SonoFlux System. These are to be supplied by the
SONO-TEK WITH YOUR ORDER. customer.
- Flexible ducting for the exhaust hood. The most
3.1. REMOVAL OF SHIPPING MATERIALS common hood supplied has a 4" diameter exhaust
(RETROFIT SYSTEMS) port. Ports of 6" and 8" diameter are also available.

(a) Remove the SonoFlux Fluxing System from its packing. - 100/240 VAC single phase, 50/60 Hz, 10 A service,
properly grounded (dedicated 15A service
(b) Verify that the following parts are present: recommended). The service must be from a non-
- Electronics enclosure and enclosure mounting rail switchable source. Switching AC power on/off while
the system is energized can damage the control
- Spray assembly
electronics.
- Ultrasonic nozzle and coaxial cable
- Compressed dry air (90 - 150 psi, 3 cfm), supplied
- Control and display module to the filter assembly (1/4 NPT female thread).
- Exhaust hood, stand, brackets, and hardware - Exhaust air. IMPORTANT: Maintain a minimum of
- Board detection sensor 140 liters/sec ( 300 cfm) of exhaust. Too much or
too little exhaust volume may affect fluxer
performance.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 15

3.2 INSTALLING THE SONOFLUX
RETROFIT SYSTEM
(a) Attach the mounting brackets to the wave solder
conveyor support rails. Depending on the type of wave
solder machine, the details of this step will vary. In
some cases, it may be necessary to construct a support
framework if the conveyor rails are not present or
cannot be utilized.
(b) Mount the enclosure with one end under the fixed rail
in a position such that the nozzle tip would be centered
under a 2 inch board. In some cases, there may be
obstructions in the wave that prevent this optimal
positioning. In this case, mount the enclosure as close
the optimal position as possible. Orient the enclosure
such that the nozzle points to the entrance of the wave
machine. The enclosure must be mounted such that it
is level from side to side and parallel from front to back
with the conveyor system.
(c) Mount the exhaust hood on a frame work above the
conveyor such that it is as low as possible, centered
side to side with the enclosure or over the conveyor
and centered front to back with the enclosure.
(d) Place the ultrasonic nozzle(s) into the sleeve located on
the jet block of the spray assembly. Be sure that the
nozzle is pushed forward in the sleeve to the stop.
Orient the nozzle so that the liquid connection is below
the nozzle power connection. Lock in place with the
thumbscrew.
(e) Adjust the height of the spray assembly in order to
optimize the spray pattern as described in sections
5.3.4 and 5.4.
(f) Attach the flux tubing to the fitting on the nozzle and
attach the coaxial cable to the SMA fitting on the back
of the nozzle. Both connections should be finger-tight.
NOTE
FOLLOW TIGHTENING PROCEDURES AS
RECOMMENDED BY SWAGELOK. REFER TO
THE INSTRUCTIONS LOCATED AT THE
BACK OF THIS MANUAL.
(g) Mount the control and display module in a convenient
place on the front of the wave solder machine. Use the
bracket provided.
(h) Locate the electronics enclosure on or in the rear
portion of the wave machine in an area where it is not
exposed to excessive heat. It should be placed so that
the flux tank can be located in close proximity. The
bottom of the reservoir should be no more than 1 foot
below the pump housing on the electronics box. Secure
the module using the attached brackets. The details of
this will vary depending on the location chosen.
(i) On the front of the electronics enclosure, locate the
5/16" push-in fittings used to connect the jet air lines
(see Figure 2.4).
11-01-00140 V1.8
(j) Cut the 5/16" OD Teflon® tubing provided into two
equal lengths. The length should be no less than 7 ft.
and no more than 10 ft. Insert one end into each of
the fittings. Snugly tighten the fittings by hand making
sure that the tubing is firmly seated. (Note: Referring
to Fig. 2.2, for single nozzle systems, install the blue
tubing into the 1A position, the blue- striped tubing into
1B. For dual nozzle systems, install the red tubing into
2A and the red-striped tubing into 2B.)
(k) Run the other end of the tubing up to the inlet fittings
on the enclosure. Connect the tubing to these two
fittings as before.
(l) Your system has been supplied with an air filter
regulator/oil mist separator assembly which assures
that the quality of compressed air is satisfactory for use
with the SonoFlux system.
It is imperative that this unit be installed in-line with
the source of compressed air for the system. The filter
element has 5 micron openings. The mist separator
removes more than 99.9% of oil. However, the
incoming air to this assembly should be as clean and
dry and oil-free as possible in order to assure optimum
performance.
(m) Connect a ¼ NPTM fitting to the compressed air inlet
located on the filter/regulator that you have already
installed. A 3/8" Teflon® quick disconnect fitting is
preferable. Connect another line from the regulator
assembly to the electronics enclosure with the supplied
hose and fittings. Hook up the compressed air set the
regulator to 80 psi. Do not vary from this setting.
(n) Mount the board detection sensor preferably 12-14
inches ahead of the center of the enclosure, beneath
the wave conveyor. The details of this will vary
depending on the site chosen but in no circumstance
should the distance be greater than 23”. Attach the
sensor cable affixed to the electronics enclosure to the
sensor and dress the cable appropriately.
(o) Connect the 8-pin M12 connector (with green-jacketed
cable) from the electronics enclosure to the base of the
control and display module. The control and display
module is fitted with two (2) interface connectors.
Either one can be used. Select the connection that
allows for the most convenient mounting of the module.
(p) Connect ¼” OD striped tubing from the outlet line of
the flux reservoir (the line that contains the flux filter)
to the inlet line of the flux pump. Connect blue-striped
tubing to pump 1, and where applicable, red-striped
tubing to pump 2. Connect the return line to the flux
reservoir to the NO fitting of the 3-way valve. Finally,
connect the N.C. fitting of the 3-way valve to the flux
bulkhead connector on the spray enclosure. Tighten all
fittings tightly with fingers only (except for push in
fittings) and make sure all the tubing is firmly seated.
(q) Connect the air extraction ducting (8" diameter is
recommended although other sizes are permissible) to
the duct on the exhaust hood. The SonoFlux System
requires 140 l/sec (300 cfm) of exhaust [230 l/sec (500
cfm) is recommended]. The duct should have a
dampener installed to regulate the flow.
SonoFlux 2000F Manual of Operations Page 16
Figure 3.1: Location of the SonoFlux Retrofit System in a Typical Wave-soldering Machine
NOTE: Actual positions of each SonoFlux module may vary depending on type of wave solder machine.
(r) Connect the power cord from the electronic enclosure
to 100 - 240 VAC, 1φ, 50/60/Hz service.
IMPORTANT
BE CERTAIN THAT THE SUPPLY VOLTAGE
CORRESPONDS TO THE VOLTAGE STAMPED ON
THE LABEL LOCATED ADJACENT TO THE
POWER ENTRY MODULE.
NOTE
THE SYSTEM MUST BE FUSED WITH A 6.3 A
SLOW BLOW FUSE. BE CERTAIN THAT THE
CORRECT FUSE IS INSTALLED. THE FUSE IS
LOCATED IN THE POWER ENTRY MODULE JUST
ABOVE THE POWER SWITCH AND LINE CORD
RECEPTACLE. TO ACCESS THE FUSE, SQUEEZE
THE TWO SMALL CLIPS, LOCATED ON EITHER
SIDE OF THE FUSE HOLDER, TOWARD EACH
OTHER TO RELEASE THE HOLDER, AND
PULL IT STRAIGHT OUT.
(s) Fill the flux container. Make sure the foreign particles
do not find their way into the reservoir, as they may
clog the filter and/or damage the pump.
(t) Attach the flux level sensor connection from the cable
on the reservoir to the cable coming from the
electronics enclosure. The connector is polarized.
(u) Power up the system by flipping the main power switch
located on the power entry module, followed by
11-01-00140 V1.8
pressing the ON/OFF button located on the control and
display module.
(v) Observe that the inlet flux line from the reservoir to the
pump begins to fill and that after this line is filled the
flux fills the return line to the reservoir. Bubbles
forming after any fitting indicate that a fitting is not
tight enough.
NOTE
DO NOT OPERATE THE PUMP
FOR LONG PERIODS IN A DRY CONDITION AS
THIS WILL CAUSE DAMAGE TO THE PUMP. IF
YOU EXPERIENCE DIFFICULTY IN PRIMING THE
PUMP WITHIN TWO TO THREE MINUTES, RAISE
THE FLUX RESERVOIR ABOVE THE PUMP TO
FORCE LIQUID INTO THE PUMP.
THEN RETURN THE RESERVOIR
TO ITS NORMAL POSITION.
PRECAUTION
NEVER OPERATE THE SYSTEM WITHOUT THE
FILTER REGULATOR/OIL MIST SEPARATOR.
PRECAUTION
AVOID LOCATING THE ELECTRONICS
ENCLOSURE IN AN ENVIRONMENT THAT IS
WARMER THAN 100°F (38°C).
SonoFlux 2000F Manual of Operations Page 17
3.3 INSTALLING THE SONOFLUX
STAND-ALONE SYSTEM
(a) Open the hinged exhaust hood and the front door.
(b) Place the ultrasonic nozzle(s) into the sleeve located on
the jet block of the spray assembly. Be sure that the
nozzle is pushed forward in the sleeve to the stop.
Orient the nozzle so that the liquid connection is below
the nozzle power connection. Lock in place with the
thumbscrew.
(c) Locate the nozzle power cable, liquid tubing, and the
two (2) jet air lines, all of which have already been
attached to the electronics enclosure located at the
rear of the unit. Screw on the power connection until
finger tight. Attach the the jet air tubing to the fittings
located on either side of the of the jet block, and the
flux line to the rear of the nozzle. Secure all fittings.
NOTE
FOLLOW TIGHTENING PROCEDURES AS
RECOMMENDED BY SWAGELOK. REFER TO THE
INSTRUCTIONS LOCATED AT THE BACK
OF THIS MANUAL.
(d) Mount the control and display module on the bracket
located on the front door. Use the hardware provided
to secure the module.
(e) Connect the 8-pin M12 connector (with green-jacketed
cable) from the electronics enclosure to the base of the
control and display module. The control and display
module is fitted with two (2) interface connectors.
Either one can be used.
(f) Your system has been supplied with an air filter
regulator/oil mist separator assembly which assures
that the quality of compressed air is satisfactory for use
with the SonoFlux system.
It is imperative that this unit be installed in-line with
the source of compressed air for the system. The filter
element has 5 micron openings. The mist separator
removes more than 99.9% of oil. However, the
incoming air to this assembly should be as clean and
dry and oil-free as possible in order to assure optimum
performance.
(g) Connect a 1/4 NPTM fitting to the compressed air inlet
located on the filter/ regulator which you have already
installed. A quick-disconnect fitting is preferable. The
minimum requirement for compressed air is 6 cfm or
higher at 80 psi. The range of input pressures allowed
is 80 - 150 psi. Adjust the regulator such that the
pressure reading appearing on the gauge provided with
the regulator is 80 psi. Do not vary from this setting.
(h) Connect ¼” OD striped tubing from the outlet line of
the flux reservoir (the line that contains the flux filter)
to the inlet line of the flux pump. Connect blue-striped
tubing to pump 1, and where applicable, red-striped
tubing to pump 2. Connect the return line to the flux
reservoir to the NO fitting of the 3-way valve. Finally,
connect the N.C. fitting of the 3-way valve to the flux
bulkhead connector on the enclosure. Tighten all
fittings tightly with fingers only and make sure all the
tubing is firmly seated.
11-01-00140 V1.8
(i) Connect the air extraction ducting to the duct on the
exhaust hood. Remember, the SonoFlux System
requires at least 140 liters/sec (300 cfm) of exhaust
flow to operate properly; 230 liters/sec (500 cfm) is
recommended. The duct should have a dampener
installed to regulate the flow. Turn on the exhaust.
(j) Connect the power cord from the electronic enclosure
to 100 - 240 VAC, single phase, with at least 10 A
capacity. In all cases the system must be properly
grounded.
IMPORTANT
BE CERTAIN THAT THE SUPPLY VOLTAGE
CORRESPONDS TO THE VOLTAGE STAMPED ON
THE LABEL LOCATED ADJACENT TO
THE POWER ENTRY MODULE.
NOTE
THE SYSTEM MUST BE FUSED WITH A 6.3 A
SLOW BLOW FUSE. BE CERTAIN THAT THE
CORRECT FUSE IS INSTALLED IF A VOLTAGE
CHANGE IS REQUIRED. THE FUSE IS LOCATED
IN THE POWER ENTRY MODULE TO THE LEFT OF
THE LINE CORD RECEPTACLE. TO ACCESS THE
FUSE, SQUEEZE THE TWO SMALL CLIPS,
LOCATED ON EITHER SIDE OF THE FUSE
HOLDER, TOWARD EACH OTHER TO RELEASE
THE HOLDER, AND PULL IT STRAIGHT OUT.
(k) Fill the flux container. Make sure that foreign particles
do not find their way into the reservoir, as they may
clog the filter or damage the pump.
(l) If not already factory preset, connect one end of the 10
foot long, 1/4" ID high pressure hose provided to the
outlet barb fitting of the filter regulator/mist separator
assembly, and the other end to the barb fitting located
on the electronics enclosure. The length can be
shortened if necessary. Secure both ends with the
clamps provided.
(m) Power up the system by flipping the main power switch
located on the power entry module, followed by
pressing the ON/OFF button located on the control and
display module.
(n) Observe that the inlet flux line from the reservoir to the
pump begins to fill, and that after this line is filled, the
flux fills the return line to the reservoir.
NOTE
DO NOT OPERATE THE PUMP FOR LONG
PERIODS IN A DRY CONDITION AS THIS WILL
CAUSE DAMAGE TO THE PUMP. IF YOU
EXPERIENCE DIFFICULTY IN PRIMING THE
PUMP WITHIN TWO TO THREE MINUTES, RAISE
THE FLUX RESERVOIR ABOVE THE PUMP TO
FORCE LIQUID INTO THE PUMP. THEN RETURN
THE RESERVOIR TO ITS NORMAL POSITION.
SonoFlux 2000F Manual of Operations Page 18
 PRECAUTION
4.1.2 Power Up
MAKE CERTAIN THAT THE AIR FILTER, LOCATED When the SonoFlux system is powered up, the Welcome screen
ON THE ELECTRONICS ENCLOSURE, IS IN will appear on the display. At this point, the LED above the
PLACE AND UNOBSTRUCTED. POWER ON button will appear red.

PRECAUTION
NEVER OPERATE THE SYSTEM WITHOUT
THIS FILTER OR WITHOUT THE FILTER
REGULATOR/OIL MIST SEPARATOR.

4.0 CONTROL OF THE SONOFLUX Pressing the POWER ON button will load the Active Process
screen. The LED will turn green indicating that the system is
SYSTEM functioning properly. The Active Process screen displays the
process that is currently running, followed by the name of the
4.1 SYSTEM CONTROL flux being used. The Spray mode is also shown, which can either
be “Flow Rate” or “Deposition”. These will be explained in more
detail later. To access the MAIN MENU from this screen, simply
4.1.1 Overview
hit the MENU key.
The SonoFlux control and display module permits adjustment
and calibration of system variables such as nozzle power, flux
flow rate/deposition density, air jet force, conveyor speed, spray
on, spray off, spray width and spray offset. Up to 1500 recipes
consisting of various combinations of these parameters can be
created and stored for later use.
On 330M models, one nozzle provides a spray width range of
50mm (2") to 330mm (13"). On 610M models, two nozzles are
employed for a spray width range of 50mm (2") to 610mm (24"). The MAIN MENU consists of 11 functions which can be viewed
by using the UP/DOWN scroll keys. These are shown below and
In addition, various aspects of the system can be password
will now be explained in more detail.
protected. Two levels of password protection are available. The
lower level password permits limited user access. The upper
level password enables access to ALL system functions. The
lower level password might be used by a line operator, and the
upper level password by process or maintenance engineers.
The user can set these passwords or deactivate them as
required.
A sketch of the system controller showing the location of the
functional keypad and backlit liquid crystal display (LCD) is
shown in Figure 2.5. The keypad consists of the POWER
ON/OFF key, 10 number keys (0 through 9) for data entry, 4
cursor keys for UP, DOWN, LEFT and RIGHT, an ENTER key for
initiating commands, a MENU key for bringing up the Main Menu,
and an ESCAPE key to return to the previous screen. An
encoder wheel is used for selecting alphanumeric characters in
the name field.
The following functions can be performed with this system:
(a) Monitor alarms.
(b) Adjust current process.
(c) Select Spray mode (flow rate or deposition).
(d) Set up system calibration.
(e) Edit existing processes.
(f) Create and store new processes.
(g) Set jet burst delay.
(h) Monitor system temperature and alarms.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 19

4.1.3 Enter Pin Number 4.1.5 Adjust Current Process
Selecting ENTER PIN NUMBER brings up the Password screen.
Two (2)levels of passwords are available. The Level 1 password This menu option requires a LEVEL 2 PIN and allows the user to
allows very limited access to the MAIN MENU functions such as change any and all of the parameters for a particular process.
changing the units of measure, flux parameters, viewing a These parameters are shown in the screens below.
process, or viewing alarms. All other functions require a Level 2
password. These passwords are set or changed using the
SYSTEM MENU. Once a valid password is entered, a screen will
appear briefly showing whether the password entered was
either valid or invalid. This screen also appears when pressing
the MENU key from the Welcome screen.

4.1.4 Alarms
When the system is functioning normally, the Alarms screen will
display NO ALARMS. Otherwise, it will indicate which
subsystem(s) of the machine is experiencing a problem.

Editing any parameter within this menu will immediately apply

the new value. To save values permanently, the Save function at
the bottom of the scroll list must be selected and the ENTER key
depressed. To edit a parameter, use the UP/DOWN keys to select
The following system functions are monitored continuously to
the line for the desired parameter. Once selected, push ENTER.
ensure integrity and safety of operation:
A right pointing arrow will appear to the left of the numerical
Nozzle operation
value. Move the cursor to the digit(s) to be changed and use the
Liquid pump operation keypad or the UP/DOWN keys to modify each digit as desired.
Jet forces Hit ENTER when done. This value will be maintained as long as
Rotary valves
you are in this screen. To permanently change it, use the Save
function as described above. To reload the process with the
Width offset original values, select Refresh at the bottom of the scroll list. To
Flux levels save the process as a new process, select Save as New. Before
Conveyor
doing this, the name of the process should be changed to a new
name. Otherwise, a new process with the same name will be
Emergency off input (hardware optional) created and the name of the second process will need to be
Exhaust integrity (sensor optional) edited afterwards.
Flame detector (Optional) Because of the interdependency between Flow Rate and
Auxiliary warnings Deposition, depending on which spray mode has been selected
in the MAIN MENU, you will only be able to edit the parameter
Auxiliary interlocks corresponding to the mode selected. The other parameter will
be changed automatically by the software and displayed for
reference only.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 20

4.1.6 Recipes
The Recipe screen allows the user to select a new process
(recipe). The currently loaded process is displayed at the upper
right of the screen. It cannot be edited from this screen. The
four (4) navigation options at the top left of the screen allows
paging through recipes. The UP/DOWN arrows move the
cursor from line to line. Within each line, the LEFT/RIGHT
arrows are used. Selecting a process and pressing the ENTER
key will present the edit screen for that process. At that point,
the process can be edited or loaded as in the ADJUST CURRENT
PROCESS screen.
4.1.7 Edit Flux Parameters
This screen allows the user to change the flux name and its
associated properties, density and percent solids content. This
screen requires a Level 1 or higher PIN.
4.1.8 Change Spray Mode
This screen allows the user to select either the Flow Rate or
Deposition mode for controlling the amount of flux deposited on
the boards. The Deposition mode allows more flexibility in that it
will allow the system to automatically adjust the flow rate to
compensate for changes in conveyor speed, spray width or flux
parameters. Flow Rate mode will maintain a constant flow rate
regardless of any changes in other parameters. Once a mode is
selected, it will be used in any active process. This screen
requires a Level 2 PIN.
11-01-00140 V1.8
4.1.9 Units of Measure
This screen requires a Level 1 PIN or higher and allows the user
to select either English or metric units, which will be used to
specify parameters within the MENU screens. Once selected, the
ENTER key must be depressed to apply and store the setting.
4.1.10 System Menu
The SYSTEM MENU contains four (4) options as shown in the
following screens which allow the user to change passwords,
perform calibration of the major system components, adjust the
Jet Burst Delay, and read the system temperature.
4.1.10.1 CHANGE PIN NUMBERS
Both levels of password are set to 0000 at the factory to allow
unrestricted access to all functions. Once the passwords are
changed from 0000, they can only be changed by entering the
correct LevelL 2 PIN. Once the PIN is entered using the keypad,
it is stored and saved by pressing the ENTER key.
4.1.10.2 CALIBRATION MENU
The SonoFlux system allows dynamic calibration of all of the
major functions including nozzle power, pump flow rate, air jet
force, conveyor speed, nozzle position, jet block position, spray
width and deposition factor. In each case, this is accomplished
by performing physical measurements of the desired parameter
at preset voltage levels and adjusting values in the associated
calibration tables accordingly. The Calibration Kit (P/N 06-05-
00271) is required to perform these calibrations, which are
described in more detail in Section 6.
The CALIBRATION MENU for the model 610M contains 10
parameters which are shown in the screens19,20,21 below.
Since this model has two (2) nozzles/jet blocks, there are two
(2) calibration menu items for each of the nozzle power, pump
and jet force parameters. In general, each of these parameters
has a calibration table with 11 discrete values in 0.5 increments
from 0V to 5V (or from 0 to 5 in the case of Jet Force). When
the calibration table is displayed for one of these parameters by
placing the cursor on it and hitting ENTER, the calibration table
is displayed.
SonoFlux 2000F Manual of Operations Page 21

The screens below are the screens showing the values for PUMP
1 CALIBRATION. Scrolling up or down within this table using the
UP/DOWN keys will dynamically change the flow rate of the
pump to match what is contained in the table. The Calibration
Kit is used to verify that the pump is producing the flow rate
shown in the table for the selected voltage. If the measurement
is different from the value in the table, the value in the table is
corrected to match the measurement taken.
Calibration screens for Jet Force, Conveyor Speed, and Nozzle
Power (not shown) are similar to the above and the calibrations
are performed similarly.
NOTE
THE NOZZLE POWER TABLES ARE PROVIDED
FOR REFERENCE ONLY AND SHOULD NEVER
NEED TO BE ADJUSTED.
11-01-00140 V1.8
Once the values in a table have been calibrated, they are saved
by scrolling down to the Save function, selecting it and pressing
ENTER. This will turn the machine off and display the Welcome
screen. Turning power back on will load the new parameters into
the system and display the MAIN MENU screen. The Deposition
Factor is set at the factory to 75 and normally will not need to
be re-calibrated.
4.1.10.3 JET BURST DELAY
This screen allows the user to adjust the time interval between
jet bursts, which keep the air jets clear of any flux residues that
might build up during long periods of operation. This value is set
by first entering the number of seconds (between 2 and 3600)
and then positioning the cursor in front of the SET command
and pressing ENTER.
4.1.10.4 TEMPERATURE
This screen allows the user to view the internal operating
temperature of the system as measured inside of the electronics
module.
4.2 SYSTEM ALARM MONITORING
In the event that a problem is detected in any subsystem, an
audible alarm mounted inside the Control and Display module
sounds and the LED on the display glows amber. The alarm will
sound every 50 seconds for 10 seconds until the unit receives
operator attention. The source of the alarm can be isolated by
going to the ALARMS function under MAIN MENU. Safety related
faults (such as interlock failure) will totally inhibit machine
operation. The display will sequence to the Welcome screen,
and the unit will not restart until the fault is cleared.
Non-safety related faults will not shut down the SonoFlux
system. The audible alarm will sound every 50 seconds until
the unit receives operator attention. An alarm will clear when
the condition causing it has been corrected.
SonoFlux 2000F Manual of Operations Page 22
5.0 SYSTEM SETUP
5.1 SYSTEM SETUP
The SonoFlux System should be exercised prior to process
calibration in order to stabilize all system functions.
(a) Place an opaque object four (4) inches above the
infrared PCB sensor located on input side of the
SonoFlux System. The sensor diode will change state.
(b) After several seconds the nozzle will begin to spray flux.
The delay is keyed to the conveyor speed setting. If
this is the first time the unit has been run, there may
be some initial sputtering as air is cleared from the
liquid delivery tubing. Increasing the flow rate will
speed the process of clearing the air.
Remove the opaque object from above the sensor
when the atomized stream is stable and free of
interruptions.
Occasionally, black-colored board carriers (palettes) will
not reflect light to the sensor. In that case a through-
beam sensor is required. Consult Sono-Tek.
5.2 CALIBRATING SPRAY ON/OFF
(a) The conveyor speed must be set on the control and
display module in order to set the timing delay for the
spray sequence. This is true for both retrofit and
stand-alone installations. For the optional conveyors
provided by Sono-Tek for stand-alone models , this
setting is also used to control conveyor speed. Any
conveyor speed change must be reflected in the
SonoFlux conveyor speed setting.
Check the sensitivity of the infrared sensor located on
the input side of the system. This is done by placing an
opaque object at circuit board height over the sensor.
If the diode on the sensor does not change state,
increase the sensitivity of the sensor by turning the
potentiometer, located next to diode, clockwise.
(b) The spray trigger timing can be set on the second frame
of the System Setup menu. Set the Spray Off to a
value x equal to the horizontal distance (in inches) from
the infrared sensor to the plane formed by the vertical
air sheet plus 1 inch, and Spray On to the value x
minus 1 inch. Use the center of the enclosure as the
reference point.
(c) Using the wave solder machine calibration glass, (or a
blank circuit board, or a piece of plexiglass cut to the
pallet or circuit board dimensions) make a test run
through the SonoFlux System.
Place the calibration glass on the conveyor and let it
travel through the machine. Check the leading and
trailing edge of the pallet or circuit board for flux
coverage.
Width coverage will be addressed in Section 5.3.4.
Adjust the spray on/off values up or down to ensure
adequate edge coverage and minimal overspray. If
there is a problem with leading edge or trailing edge
coverage, verify that the conveyor speed is correct.
11-01-00140 V1.8
5.3 SONOFLUX SYSTEM VARIABLES
AND THEIR EFFECTS
Having completed the initial setup and calibration steps detailed
in Sections 5.1 and 5.2, the SonoFlux system is now operational
and ready for establishing parameters to flux circuit boards.
The SonoFlux allows the user to select 2 different spray modes,
Flow Rate and Deposition. The deposition mode requires the
user to specify the flux density and percent solids in the EDIT
FLUX menu. Once this is done, the system will automatically
calculate the flow rate based on conveyor speed and spray width.
The flow rate is displayed when in ADJUST CURRENT PROCESS,
but cannot be modified in this mode of operation.
The Flow Rate mode allows the user to manually adjust the flow
rate for different applications, and basically override the settings
that Deposition mode would provide.
In this mode, the Deposition value is calculated for reference
when on the ADJUST CURRENT PROCESS screen but cannot be
edited. When using this mode, the flow rate calculated in
Deposition mode could be used as a starting point (assuming
the flux parameters have been entered). Then the rate could
then be adjusted up or down from there based on the results
the user is trying to achieve.
The Nozzle Power Width and Jet Force are the only parameters
that need to be set up for either of these modes. In general,
5W is the recommended initial power setting for low solids flux
and VOC-free flux. For high-solids content fluxes, the initial
recommended power level should be 12W. The power level can
be adjusted for optimum performance as will be discussed in
section 5.3.1. The Jet Force is a less critical parameter and can
be set initially to 65 l/min for most applications. Problems
generally occur with too little Jet Force rather than too much.
Greater force enhances top-side fill. Higher settings may be
necessary to achieve optimal results.
5.3.1 Nozzle Power Level
For ultrasonic atomization to occur, the power supplied to the
nozzle must be above a certain critical threshold level. The
critical power level may be different for different fluids, and can
vary based upon the solids content, composition of the flux
being used, and flow rate.
(a) For all low-solids, no-clean fluxes or VOC-free fluxes set
the initial nozzle power level to 5 watts. For all other
fluxes set the power level to 12 watts.
(b) Set the Flow Rate or Deposition Density to a value you
expect will be in the range that will ultimately be
required.
(c) Place an opaque object over the PCB sensor.
(d) Stand in a position where it is possible to both observe
the spray and adjust the nozzle power on the control
and display module.
(e) Gradually decrease power level until the atomization
stops and the nozzle tip becomes flooded with flux.
This is the critical power level for the flux being tested
at this flow rate. Increase the power level by one (1)
watt. This will be the operating power level.
SonoFlux 2000F Manual of Operations Page 23
 The procedure for changing dip-switch settings is very simple.
However, it requires access to the electronic circuitry contained
NOTE within the electronics enclosure. Please follow all safety
RECOMMENDED POWER LEVEL FOR procedures carefully, and read the following instructions.
NORMAL OPERATION = CRITICAL POWER (a) Turn off the power to the SonoFlux System. Remove
LEVEL + 1.0 WATT the cover from the electronics enclosure.
(b) Locate the nozzle driver subsystem. (See Fig. 2.3 for its
location.)
NOTE
(c) On the printed circuit assembly for the nozzle driver
TOO LOW A POWER LEVEL MAY subsystem, locate the 7-position dip-switch assembly
CAUSE INTERMITTENT ATOMIZATION AND on the printed circuit card, as shown below.
FLOODING OF THE NOZZLE TIP (d) Note the position of switches 1 through 7 and the
location of the word OPEN on the assembly.
NOTE (e) Your nozzle was shipped with a laminated tag affixed to
the rear fitting. The tag describes the procedure for
TOO HIGH A POWER LEVEL WILL CAUSE setting the dip-switches.
“CAVITATION” AT THE NOZZLE TIP - THIS (f) Follow the instructions contained on the tag, a sample
PHENOMENON RESULTS IN THE FORMATION OF of which is reproduced below. Using a pen, or any
VERY LARGE DROPLETS OF FLUX AND WILL other type of pointed object, depress the individual
RESULT IN NONUNIFORM DEPOSITION AND switches to conform with the punched hole pattern
POOR TRANSFER EFFICIENCY contained on the tag.

5.3.2 Nozzle Tuning

An ultrasonic nozzle is a tuned device; that is, it operates
properly only if the frequency of the electrical signal delivered to
it is the same as what the nozzle expects. (Refer to Section 1.4
for further details on the operating principles of ultrasonic
nozzles.)
The nozzle driver electronics, described in Section 2.1.2.1, is
designed to provide the proper drive frequency to the nozzle. It
will track and “lock on” to the correct frequency during normal
operation. A dip-switch contained on the nozzle driver board is
used to set the proper frequency.
All Sono-Tek ultrasonic nozzles are shipped with a tag attached
that specifies the proper internal dip-switch settings that the
nozzle driver uses to lock onto a nozzle’s resonant frequency.
If your SonoFlux System has been shipped to you from the
factory, the proper dip-switch settings have already been pre-set
at the factory and will never require adjustment for that nozzle
or for any other nozzle of exactly the same type.
For other circumstances, the dip-switch settings may require
changing. These include the case where the nozzle to be (g) Turn on the SonoFlux system and trigger the spray. If
installed is of a different type than previously installed. the nozzle is not operating properly, the Control and
Display module will sound an alarm and the LED will
glow amber. Checking the ALARMS in the MAIN MENU
will indicate the source of the alarm. For further
information, consult Section 7.4, “System
Troubleshooting”.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 24

 the jet block assembly, it is possible to keep track of the vertical
5.3.3 Flow Rate position by listening to or feeling the number of clicks made by
NOTE the mechanism in the jet block as it moves. Once established,
the position can be fixed by tightening the locking collar located
THIS SECTION IS ONLY RELEVANT IF FLOW on one of the uprights.
RATE MODE IS CHOSEN IF DEPOSITION MODE Jet Position Distance to Suggested Jet Spray Width
IS SELECTED, THE FLOW RATE IS CALCULATED (Detent #) PCB (in.) Force (lpm) (in.)
AUTOMATICALLY BASED ON FLUX PARAMETERS,
SPRAY WIDTH AND CONVEYOR SPEED. 5 60 5.5

1 6 65 6.5
Flow rate will vary based on the types and sizes of PCBs to be
processed, solids content of the flux, conveyor speed and 7 70 7.0
variables associated with the wave solder machine, such as 8 75 7.8
preheat temperatures.
5 60 6.5
For conveyor speeds in the range of 5-6 ft/min (1.5-1.8 m/min),
the following flow rates may be used as guidelines for most low 2 6 65 7.5
solids fluxes. 7 70 8.0
PCB WIDTH* TYPICAL FLOW 8 75 8.3
(inches) RATE (ML/MIN)** 5 60 7.8
2-6 10 - 25 6 65 8.8
3
7 - 10 20 - 40 7 70 9.5
11 - 13 30 - 50 8 75 10.3
* Excluding pallet 5 60 9.0
** These recommended flows will vary significantly for different 6 65 10.0
4
fluxes. For example, highly active water soluble fluxes may
7 70 10.5
require only 60% of the recommended flow rate. For best
performance, economy, and minimum residues, the flow rate 8 75 11.0
should be set at the lowest possible value that will still result in 5 60 10.0
acceptable solderability.
5 6 65 11.0

5.3.4 Spray Assembly: Spray Width 7 70 11.8

The following procedures describe functionality and procedure 8 75 12.8

for setting spray width parameters. 5 60 11.5

6 6 65 12.5
5.3.4.1 SPRAY WIDTH PARAMETERS
7 70 13.0
Achieving the optimal spray width is a function of three parts of
the system. Once a good pattern is established, nothing needs 8 75 13.5
to be set again for a given board size. 5 60 12.5
The three variables are: jet force, jet position, and jet block 6 65 14.0
7
height all contribute to the width of a pattern.
7 70 15.5
Jet Force: This is a setting on the display and control module
8 75 17.0
that controls how much air passes through the jets. The air is
responsible for entraining the spray and transferring it to the
PCB. Increasing the jet force generally enhances top-side solder
fill. Adjust the jet force for best top-side fill using the table
below as a guide for initial settings.
Jet Position: This is the angular position of the jets on the jet
block. Six (6) positions are available. The position, coupled with
the correct jet block height relative to the PCB, will achieve the
desired result. It is always preferable to have the jet angle as
narrow as possible. (Use the table below as a guide.)
Jet Block Height: This is the distance from the nozzle tip to
the bottom of the PCB. The greater this distance, the wider the
pattern will be. Smaller distances are generally more desirable,
but the jet position (described above) is more critical in reducing
defects on the outer edges of a PCB. (Use the table below as a
guide.) In order to adjust the height of the jet block assembly,
it is mounted on a pair of uprights that move up and down.
Each upright is notched at 1/4" intervals so that when installing

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 25

5.3.5 Jet cleaning Feature (Jet Burst)
In order to assure that the air jets remain clear of any flux
residues over long periods of operation, the SonoFlux system is
periodically purged with a burst of high pressure air. The
frequency of the purge cycle can be changed by the user.
Choosing the delay time is accomplished using the Control and
Display module using the JET BURST DELAY option under
SYSTEM MENU. Enter a value between 2 and 3600 seconds,
and then position the cursor in front of the _SET command and
press ENTER.
The cleaning burst of air only occurs during periods of "idle"
time, that is intervals when boards are not being processed. For
example, if work flow is such that typically there is a 2 second
interval between boards and the process is continuous, setting
the delay between when the last board was processed and the
cleaning feature turns on at 30 seconds is appropriate. This
occur during break periods and assures that the cleaning feature
turns on at least 3 - 4 times per shift.
On the other hand, if the work cycle is such that the system is
idle for long periods during a shift, a delay setting of 10 minutes
may be more appropriate. If a buildup of flux is noticed that
starts to affect performance, you may want to shorten the delay
time setting.
5.3.6 Conveyor Speed
The speed at which a printed circuit board passes through the
spray chamber is directly related to the quantity of flux
deposited on it when each of the other variables is fixed. When
in Flow Rate mode, if the conveyor speed is doubled, then the
flux deposition density will be cut in half. In Deposition mode,
the flow rate will be adjusted automatically as a function of
conveyor speed.
5.4 ESTABLISHING A PROCESS
If you are upgrading your wave machine from a previous drum,
foam, or spray fluxer, certain variables of your wave process
may change dramatically, such as topside temperature. The
SonoFlux system can be set up to cut flux usage considerably.
However, this will necessitate tighter control of the wave
machine process. Remember to monitor all variables of the
wave process when upgrading your system.
The following is a guideline for establishing a new recipe for a
PCB and should allow for quick optimization.
a) Select Deposition mode for the spray mode.
b) Edit the flux parameters for the type of flux used.
c) Set the deposition density.
d) Set the nozzle power to 5W for low solids flux, 12W for all
others.
e) Set the Jet Force initially to 65 l/min.
f) Set the Spray On and Spray Off values. (Experimentation with
these values may be required to achieve adequate coating on
the front and rear edges of the boards respectively).
g) Set the jet position to position 2.
h) Set the block height to the top.
i) Set the flow rate to 20 ml/min.
j) Set the jet force to 45 l/min.
11-01-00140 V1.8
k) Run a blank, unpopulated PCB and remove the board after the
fluxer, but before it reaches the pre-heaters.
l) Examine the pattern:
1) You should have a narrow strip centered on the board.
2) If the strip is not centered, position the horizontal position
of the nozzle to center the pattern.
m) Correct the width:
1) Lower the jet block an inch, clean the board and run it
again as above.
n) Repeat the above steps until the pattern coats the board from
side to side. If you reach the bottom of the jet block
adjustment and the pattern is still not wide enough, change
the jet positions to the next wider setting, increase the jet
force by 5 l/min, raise the jet block back to the top, and
repeat until you have a uniform coating of flux from side to
side.
o) It may be helpful to increase the flux flowrate as necessary
such that the pattern is more visible.
p) Set the Spray Width to the width of the board being sprayed
and verify the jet block height and jet position.
q) Run populated boards through the wave soldering machine
and check for defects.
r) If consistent defects are found on the leading or trailing edges
of the boards, adjust the Spray On and/or Spray Off settings.
s) If consistent failures occur on the two sides of the boards, try
increasing the jet force and/or raising the Deposition Density
value in the CALIBRATION menu. This will have the effect of
increasing the flow rate. Alternatively, if there are no defects,
the Deposition Density value can be lowered by small
increments until defects occur, and then raised slightly.
Lowering the value has the effect of decreasing the flow rate,
so this procedure will result in the optimal flow rate for
achieving satisfactory results with the least amount of flux and
waste.
5.5 CHANGING SONOFLUX
PARAMETERS FOR DIFFERENT PCBS
Every type of PCB potentially requires a unique set of fluxing
parameters including flow rate, nozzle power, conveyor speed,
spray force, spray width, spray offset, etc. The SonoFlux system
allows for the storage of up to 1500 unique processes (recipes).
When a board is run, a new process should be created and
stored in the system under a unique, easily identified name to
facilitate future recall. When running a particular board again,
the following steps should be performed:
a) Find the associated process for the PCB and load it. If there is
no existing process, find a similar one, edit it, and save it
under a new name. Then load the new process.
b) If a new type of flux is required, enter the new flux properties.
Also, change the flux reservoir and purge the liquid lines of
the old flux using alcohol or water. Let the system pump
purge liquid for two minutes with the spray off to clear the
return lines of flux. Then force the system to spray for one
minute by activating the spray trigger to clear the line
between the solenoid valve and nozzle.
c) Now connect the new flux reservoir to the SonoFlux system
and wave solder machine to check operation.
d) Select the spray mode (Deposition or Flow Rate).
e) Run one PCB through the SonoFlux system and wave solder
machine to check operation. The SonoFlux system is now
ready to be used in production.
SonoFlux 2000F Manual of Operations Page 26
6.0 CALIBRATION

Figure 6.1: Calibration Kit

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 27

 3. Variable-Area Flowmeter (AIR) (P/N 06-05-00270)
6.1 INTRODUCTION Use
Most of the system calibration is accomplished by using the
To measure air flow (lpm) in the spray force air system.
Calibration Kit (P/N 06-05-00271). It is intended for use on a
routine basis to calibrate most of the operational parameters of Description: The flowmeter consists of a tapered-bore acrylic
the SonoFlux spray fluxing system to assure that the system is flowtube with a 316 stainless steel float. Scale divisions marked
operating within specifications. in liters per minute (lpm). Positioned vertically, air enters
through an opening at the bottom of the flowtube. Upward
The kit contains all the instrumentation required to measure the
pressure causes the float to rise.
various parameters associated with its operation. Traceability
documentation to NIST standards for the instrumentation is Air flow occurs in the annular area between the float and the
provided where appropriate. inside wall of the tube. As the float rises, the flow area
increases due to the tapered bore of the tube. An equilibrium
height is reached when the combined upward buoyant force of
the air displaced by the float and the force generated by the
pressure of the flow itself equals the weight of the float.
6.2 DESCRIPTION OF THE KIT
Specifications
The components of the calibration kit are identified in Fig. 6.1.
There are six (6) instruments plus cables and tubing. Range: 14 - 140 lpm
1. Anemometer (P/N 07-00-00015) Accuracy: ± 3% full scale
Use Wetted Parts: Acrylic body, 316 stainless steel
float
To measure exhaust air flow. Although not a part of the
calibration procedure, maintaing the proper amount of exhaust
is essential for proper system operation. 4. Graduated Cylinder and Stopwatch
Description Use
A hand-held probe placed in an airstream senses air flow. The
To measure isopropyl alcohol flow rates (ml/min) through the
probe assembly consists of two (2) thermistor sensors, one to
liquid delivery system.
sense air flow by the cooling effect that occurs as air passes
over it and the second for temperature compensation. The air Specifications
flow reading is displayed on an analog meter located in the Graduated Cylinder:
anemometer control module.
Range: 0-100 mL
Specifications
Accuracy: ± 2% full scale
Ranges: 0-600 fpm; 500-6000 fpm
Wetted Parts: Polypropylene
Accuracy: ± 5% of full scale
Stopwatch:
Response Time: 1 sec
Resolution: 1/100th second
Power: 2 9V alkaline batteries
Accuracy: ± 0.4 sec/hour
Battery Life: 8 hours operating time, average

5. Continuous Power Monitor (P/N 06-05-00336-002)

2. Pressure Gauge (P/N 06-03-00354)
Use
Use
To display ultrasonic power (watts) delivered to the ultrasonic
To measure pressure in the spray width air supply system. spray nozzle.
Description: Bourdon type pressure gauge. Description: The power delivered to the ultrasonic nozzle is
Specifications detected by this tool.

Range: 0-30 psi Specifications

Accuracy: ± 3% Range: 1-20 watts

Face: 2 in. diameter Accuracy: ± 5%
Power: 24 VDC, 18W Power Adapter

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 28

6. Multimeter (P/N 07-00-00016)
Use
For measuring voltages.
Description: A hand-held, 4-digit, digital multimeter.
Specifications
DC Voltage Ranges: 800 V
DC Voltage Accuracy: ± 0.03% of reading
Power: (1) 9V alkaline battery
Accessories
A compartment on the right side of the case contains the cables
for the multimeter and watt translator, and a screwdriver for
making electrical adjustments. Tubing for the gas and liquid
lines are housed in the top of the case, behind the layers of
foam.
7. Variable-Area Flowmeter (Liquid) (P/N 06-05-00045)
(NOTE: OPTIONAL EQUIPMENT NOT INCLUDED IN KIT)
Use
To measure isopropyl alcohol flow rates (ml/min) through the
liquid delivery system.
Description: The flowmeter consists of a tapered-bore glass flow
tube with a spherical sapphire float (red-colored) within the bore.
Positioned vertically, liquid enters through an opening at the
bottom of the flowtube. Upward pressure causes the float to
rise.
Liquid flow occurs in the annular area between the float and the
inside wall of the tube. As the float rises, the flow area
increases due to the tapered bore of the tube. An equilibrium
height is reached when the combined upward buoyant force of
the liquid displaced by the float and the force generated by the
pressure of the flow itself equals the weight of the float. The
scale divisions are millimeters of height from the bottom of the
flow tube. Actual flow rates (ml/min) are obtained using a
correlation chart provided with the kit.
Specifications
Range: 0-150 mm (approx. 0-80 ml/min)
Accuracy: ± 2% full scale
Wetted Parts: Teflon, borosilicate glass, sapphire
float
11-01-00140 V1.8
6.3 Overview of Calibration Procedures
This section gives a brief description of each calibration
procedure.
6.3.1 Flux Pump Calibration
Purpose
To confirm that the actual rate of flux delivery from the pump to
the ultrasonic spray nozzle corresponds to the value displayed in
the Calibration Menu.
Procedure
The liquid lines are purged of flux and replaced by 99%
isopropyl alcohol. The flux return line is removed from the
reservoir connection and a sample of flux is collected into the
graduated cylinder over a 1 min interval to determine flow rate
in milliliters pre minute. This is repeated for each step increment
in the valibration menu.
For use of optional variable-area flowmeter:
A precision Teflon variable-area flowmeter is inserted in the
liquid line that connects the output from the pneumatic valve
and the return to the flux reservoir. Flowmeter measurements
are recorded for different flow rate settings on the control and
display panel. A fine resolution correlation chart is provided with
the kit to translate flowmeter readings into flow rate in ml/min.
Flow rate adjustments are made in the Calibration Menu if the
indicated flow rates do not agree with the measured values.
6.3.2 Ultrasonic Nozzle Calibration
Purpose
To confirm that the actual power level of ultrasonic energy
delivered to the spray nozzle corresponds to the value displayed
in the Calibration Menu.
Procedure
The power monitor instrument is inserted in-line between
the signal output from the nozzle electronics module and
the ultrasonic nozzle input. Each voltage level in the
calibration menu is triggered and the power level in the
calibration menu is compared to the power level read on
the device. Adjustments are made if the indicated power
values do not agree with the measured values.
6.3.3 Jet Force Air flow Calibration
Purpose
To confirm that the flow rate of air through the jets conforms to
the jet force setting in the Calibration Menu.
Procedure
The technique consists of making measurements of various air
pressures, using a Bourdon type pressure gauge, and air flow
rates, using a variable-area type flowmeter.
The pressure gauge supplied with the kit is attached one of the
jet ports located on the the electronics enclosure. The outlet
pressure is adjusted in the Calibration Menu to agree with the
measured values.
Since pressure measurements are only indirectly related to
airflow through the jets, and since other factors may influence
air flow (such as obstructions in the air lines or leaks), a direct
SonoFlux 2000F Manual of Operations Page 29
measurement of air flow, using the flowmeter, is required. The IMPORTANT
result of this measurement indicates the functionality of the
opposed jet air system with respect to the delivery of the proper RUN THE PUMP JUST LONG ENOUGH TO
amount of air. EMPTY THE LINES. TURN OFF THE MACHINE
IMMEDIATELY AFTER THIS PROCEDURE.
6.3.4 Conveyor Calibration RUNNING THE PUMP DRY FOR MORE THAN
Purpose A FEW MINUTES MAY CAUSE DAMAGE
TO THE PUMP.
To confirm that the actual conveyor speed corresponds to the
value displayed in the Calibration Menu. c. Disconnect the return line from the flux reservoir
return inlet.
Procedure
d. Locate the graduated cylinder and stopwatch supplied
This technique can be used for conveyors supplied with a with the kit.
SonoFlux stand-alone system. It consists of making a
measurement of the time it takes for a board of known length to e. Place the liquid line end just removed in step c into the
pass over the optical sensor supplied with SonoFlux system and mouth of the graduated cylinder.
correlating that observation with the conveyor speed value IMPORTANT
displayed in the Calibration Menu.
If the displayed and measured values do not agree, an THE TOP OF THE GRADUATED CYLINDER
adjustment in the Calibration Menu is made to calibrate the SHOULD BE POSITIONED AT APPROXIMATELY
display with the actual speed. THE SAME HEIGHT AS THE RETURN LINE
OUTLET ON THE PNEUMATIC VALVE.
6.3.5 Measuring the Exhaust Volume h. Place approximately one (1) liter of pure isopropyl
Maintaining an adequate and stable exhaust is essential for alcohol in a container. Be careful to use a sturdy
proper continued system performance. The anemometer probe container which will not tip over when the liquid lines
is inserted into the exhaust duct (through a small hole drilled are immersed in it. Place the container on the floor.
into the ductwork, as close as possible to the fluxer exhaust i. Place both the pump inlet line and the return line into
plenum) and a reading of the air velocity is made. The volume the alcohol.
of air being exhausted (cfm) is obtained by multiplying the air
velocity (ft/min) by the cross-sectional area of the duct (ft2). j. Turn ON the SonoFlux system. Go to the Calibration
Menu and select PUMP from the menu. Refer to Section
4.1.10.2, System Calibration Functions, for information
on the procedures associated with accessing and using
6.4 DETAILED PROCEDURES the Calibration Menu.
k. Set the voltage to 5 volts by using the UP or DOWN
6.4.1 Pump Calibration Procedure keys, in order to prime the pump. This should take no
longer than one minute. If the pump does not prime,
IMPORTANT check that the Swagelok connectors are air-tight.
THE ALCOHOL THAT WILL BE USED IN THE Observe that alcohol is flowing back to the container
PUMP CALIBRATION PROCEDURE MUST BE through the return line before proceeding.
MAINTAINED IN THE RANGE 70 TO 76ºF IMPORTANT
IN ORDER TO ASSURE ACCURATE
FLOWMETER READINGS. DO NOT OPERATE THE PUMP FOR LONG
PERIODS IN A DRY CONDITION AS THIS WILL
CAUSE DAMAGE TO THE PUMP. IF YOU
Set Up
EXPERIENCE DIFFICULTY IN PRIMING THE
a. With the power ON, empty the flux lines by removing PUMP WITHIN TWO TO THREE MINUTES, RAISE
the inlet line to the pump from the flux source. First THE FLUX RESERVOIR ABOVE THE PUMP TO
empty the return line and then trigger the spray ON to FORCE LIQUID INTO THE PUMP. THEN RETURN
empty the line to the nozzle.
THE CONTAINER TO THE FLOOR.
b. Turn the SonoFlux System OFF.

Calibration Procedure using graduated cylinder

a. Set the voltage in the pump calibration menu to 1 volt,
using the UP or DOWN keys to reach the desired
setting.
b. Collect flux from the return line with the graduated
cylinder for 60 seconds. The volume collected (in ml)
divided by the time (60 s) is the flow rate in ml/min.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 30


d. Compare the flow rate measured with the flowmeter
to the flow rate shown in the Pump Calibration Menu at
1 volt.
e. If required, change the flow rate shown on the screen
such that it equals the measured value.
f. Press the DOWN key to move the voltage to 2 volts.
Collect flux for 1 minute and calculate the flow rate as
in step b. Compare the measured value to the rate
shown on the Pump Calibration menu. If required,
change the flow rate value shown on the screen such
that it equals the measured value.
g. Repeat for all values up to and including 5 volts. Scroll
down to the SAVE line and pres ENTER to save the new
values.
Calibration procedure using optional variable-area
flowmeter:
IMPORTANT
THE ALCOHOL THAT WILL BE USED IN THE
PUMP CALIBRATION PROCEDURE MUST BE
MAINTAINED IN THE RANGE 70 TO 76ºF IN
ORDER TO ASSURE ACCURATE FLOWMETER
READINGS.
Set Up
a. With the power ON, empty the flux lines by
removing the inlet line to the pump from the flux
source. First empty the return line and then trigger
the spray ON to empty the line to the nozzle.
b. Turn the SonoFlux System OFF.
IMPORTANT
RUN THE PUMP JUST LONG ENOUGH
TO EMPTY THE LINES. TURN OFF THE MACHINE
IMMEDIATELY AFTER THIS PROCEDURE.
RUNNING THE PUMP DRY FOR MORE THAN A
FEW MINUTES MAY CAUSE DAMAGE TO THE
PUMP.
c. Disconnect the return line from the flux reservoir
return inlet.
d. Locate the Teflon, variable-area type flowmeter
supplied with the kit. It is recognizable by the small
red sapphire float in the flowtube.
e. Attach the liquid line end just removed in step c to
the inlet port of the flowmeter (the bottom port).
f. Take the length of Teflon tubing supplied with the
kit and attach one end to the outlet port fitting on
the flowmeter (the top port). Finger tighten the
fitting. Place the other end in the alcohol container.
11-01-00140 V1.8
IMPORTANT
MAKE CERTAIN THAT THE TUBING SEATS
FIRMLY INTO EACH OF THE FITTINGS.
g. Place the flowmeter on a convenient surface such
that the flowmeter is perfectly vertical. Secure
with a tie-wrap if necessary.
IMPORTANT
THE TOP PORT OF THE FLOWMETER
SHOULD BE POSITIONED AT APPROXIMATELY
THE SAME HEIGHT AS THE RETURN LINE
OUTLET ON THE PNEUMATIC VALVE.
h. Place approximately one (1) liter of pure isopropyl
alcohol in a container. Be careful to use a sturdy
container which will not tip over when the liquid
lines are immersed in it. Place the container on
the floor.
i. Place both the pump inlet line and the return line
into the alcohol.
j. Turn ON the SonoFlux system. Go to the
Calibration Menu and select PUMP from the menu.
Refer to Section 4.1.10.2, System Calibration
Functions, for information on the procedures
associated with accessing and using the
Calibration Menu.
k. Set the voltage to 5 volts by using the UP or
DOWN keys, in order to prime the pump. This
should take no longer than one minute. If the
pump does not prime, check that the Swagelok
connectors are air-tight. Observe that alcohol is
flowing back to the container through the return
line before proceeding.
This completes the calibration of the liquid delivery pump.
Return the system to its original configuration.
6.4.2 Ultrasonic Nozzle Calibration Procedure
Set Up
a. Turn OFF the power to the system.
b. Unscrew the nozzle cable from the output jack located
on the electronics enclosure.
c. Attach one end of the nozzle cable supplied with
the kit to the output jack on the electronics enclosure.
d. Locate the continuous power monitor measurement
tool supplied with the kit.
e. Attach the free end of the cable from the electronics
enclosure to the jack labelled FROM NOZZLE DRIVER
on the power monitor.
f. Attach the free end of the cable removed in step b to
the jack labelled to nozzle.
SonoFlux 2000F Manual of Operations Page 31
 g. Turn ON the SonoFlux system. Go to the Calibration i. Place the flowmeter on a convenient surface such that
Menu and select nozzle power from the menu. Refer to the flowmeter is vertical. Secure with a tie-wrap if
Section 4.1.10.2, System Calibration Functions, for necessary.
information on the procedures associated with j. Set the pressure on the house source line of
accessing and using the Calibration Menu. compressed air to 80 psi.
h. As each power level is triggered, the power will k. In this mode, when the system is turned on, the rotary
be displayed on the Power Monitor display dispersion valve will move into a position such that the
air will flow only out of one of the two outlet ports. If
you have attached the test tubing to the port which
Calibration does not have the air flowing out of it, press the menu
a. In the Calibration Menu, set the reference voltage to 1 button while in the JET FORCE calibration screen to
volt. Use the UP and DOWN keys to reach this setting. toggle the porrts. This will advance the air flow to the
other port, to which you have made the connection.
b. Ensure that the settings on the dip-switch located in
the nozzle driver subassembly conform to the In calibration mode, the jet control system will not
prescribed settings. Refer to Section 5.3.2 for respond to the spray on signal.
information on the nozzle tuning procedure.
d. A power monitor reading in Watts will be observed. Calibration
e. If required, change the watt value shown on the a. Turn ON the SonoFlux system. Go to the Calibration
screen such that it is the same as the measured value. Menu and select spray FORCE from the menu. Refer to
f. Press the DOWN key to move to the 1 volt calibration Section 4.1.10.2, System Calibration Functions, for
point (4.0 watts setting). The power monitor should information on the procedures associated with
read 4.0 W. accessing and using the Calibration Menu.
g. If required, change the watt value shown on the screen b. Use the UP and DOWN keys to switch between
such that it is the same as the measured value. Repeat the various voltage/lpm points at which calibration
c-f for 1.5 through 5 volts. readings are to be made.
This completes the calibration of the ultrasonic nozzle driver c. Using the table below, take readings at each voltage
module. Return the system to its original configuration. Do not setting shown on the chart.
leave the power monitor installed. d. The calibration procedure is only valid when the scale
readings observed on the variable-area flowmeter and
6.4.3 Spray Force Air Flow Calibration Procedure pressure gauge are within the "acceptable" range
The following instructions, (a through j), relate to the setup for shown on the chart for each voltage setting.
this procedure. Refer to the illustration below to assure the
Voltage Acceptable Flow Corresponding
configuration is proper.
Setting (V) Tube Scale Gauge Pressure
a. Turn OFF the system. Reading (lpm)
b. Disconnect the jet air tubing from one of the outlets on 0 16 - 21 0.0 - 0.6
the electronics enclosure by loosening (not removing)
the fitting located on the front panel. This tubing will .5 25 - 33 1.9 - 2.1
be referred to as the original tubing. 1 33 - 45 3.1 - 3.5
c. Measure its length. The original tubing length is 1.5 42 - 54 4.5 - 5.0
referred to as x in the illustration below.
2 46 - 60 5.7 - 6.3
d. Locate the variable-area type air flowmeter provided
with the kit. It is recognizable by its scale divisions, 2.5 52 - 66 7.1 - 7.9
14 - 140 lpm. 3 58 - 74 8.5 - 9.5
e. Attach the air line end just removed in step b to the 3.5 61 - 80 9.8 - 10.8
outlet port of the flowmeter (the top port).
4 67 - 85 11.4 - 12.6
f. Cut the tubing supplied with the kit (cut tubing) to a
length equal to 10 ft - x. The total length of both the 4.5 71 - 91 12.8 - 14.2
cut and original tubing should be 10 ft.
5 75 - 96 14.2 - 15.8
g. Attach one end of the cut tubing to one of the gauge
assembly fittings and the other end to the inlet port
fitting on the flowmeter (the bottom port).
h. Attach one end of the 6" length of tubing provided to
the outlet fitting on the front panel of the electronics
enclosure, and the other end to the other fitting on the
gauge assembly.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 32

 e. If the readings are not within the specified ranges, look 6.4.5 Exhaust Air Flow Measurement Procedure
for blockages or leaks in the air jet lines. Causes of lower Set up
than specified readings could be the result of a faulty jet
control assembly, leaking rotary dispersion valve, or leaks a. Locate the anemometer tool provided with the kit. Check
in the tubing/fittings before the inlet to the flow meter. that the instrument is properly zeroed using the
anemometer instructions provided. Remove the plastic
Causes of higher than specified flow readings and lower
protective cap from the end of the probe.
than specifed pressure readings can be the result of a
faulty jet control assembly. Always contact Sono-Tek if b. Set the correct range.
the readings obtained are outside the acceptable range. c. Insert the anemometer probe into a small holed drilled in
f. As required, change the flow value shown on each screen the exhaust ductwork as close as possible to the fluxer
such that it matches the value measured on the flow exhaust plemum.
meter.
g. Remove the tubing from the jet block port just tested and Measurement
install it on the other port. Repeat the measurements
above for the second port. They should be within a few a. With the probe inserted in the duct, make certain that
percent of the results for the first port. If not, look for it is perpendicular to the air flow and that the probe
possible problems (step e.). If the problem can not be sensor is close to the center of the duct.
resolved, contact Sono-Tek. b. Take an air velocity reading. Rotate the probe until a
maximum reading is obtained. Record the maximum
IMPORTANT
reading.
THE SCALE READING IS TO BE MADE AT THE c. Use the chart below to determine the volume of exhaust
CENTER OF THE FLOAT. IF THE CENTER OF THE flow (cfm). For a given velocity, this value will differ,
FLOAT IS BETWEEN ADJACENT SCRIBE LINES, depending on the diameter of the duct.
RECORD THE MEASUREMENT TO THE d. The minimum volume allowed is 300 cfm. The preferred
NEAREST SCRIBE LINE. volume is 500 cfm. If possible, adjust the exhaust
This completes the calibration of the spray width air system. system to achieve the recommended 500 cfm value.
Return the system to its original configuration. Do not leave the
Exhaust Conversion Table
flowmeter installed in the air line.
Duct Diameter (inches)
ft/min 4 6 8
6.4.4 Conveyor Speed Calibration Procedure
800 70 157 279
(Stand-alone models only)
Calibration 1000 87 196 349

a. Turn ON the SonoFlux system. Go to the Calibration 1200 105 236 419
Menu and select conveyor from the menu. Refer to 1400 122 275 489
Section 4.1.10.2, System Calibration Functions, for
information on the procedures associated with accessing 1600 140 314 559
and using the Calibration Menu. 1800 157 353 628
b. Set the voltage to 5 volts using the UP or DOWN keys. 2000 175 393 698
c. Measure the actual conveyor speed by passing a board of
2200 192 432 768
measured length on the conveyor over the SonoFlux
System infrared board sensor and precisely measuring the 2500 218 491 873
length of time the sensor detects the board (visually
3000 262 589 1047
observable by the status of the sensing LED located on
the sensor housing). 3500 306 687 1222
d. Compute the conveyor speed by dividing the time (in 4000 349 785 1396
minutes) into the board length (in feet or centimeters
4500 393 883 1571
depending on the units shown on the control and display
module panel). 5000 437 982 1746
e. If required, change the conveyor speed value shown on 5500 480 1080 1920
the screen such that it is the same as the measured value.
6000 524 1178 2095
f. Next, set the voltage to 1 volt. Repeat steps c,d, and e
for 1.5 - 5 volt calibration points. Suggested Inadequate

This completes the calibration of conveyor speed. Return the

system to its original configuration.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 33

6.4.6 DEPOSITION FACTOR
The Deposition Adjust is a parameter that reflects the amount of
flux deposited on a PCB compared to the total amount of flux
sprayed. This parameter can be adjusted up or down in small
increments, based on actual deposition measurements, by using
the UP and DOWN Arrow keys.
7.0 MAINTENANCE & SAFETY
7.1 SAFETY PROCEDURES
Because of the volatile, corrosive nature of many fluxes, the
SonoFlux System must never be operated in an unsafe condition.
The following constitute unsafe conditions:
a. Operating the SonoFlux System with the exhaust off
or inadequate exhaust.
b. Operating the SonoFlux System with leaking liquid
delivery lines.
The liquid delivery lines should be checked on a daily basis. Any
line which is found to be leaking should be replaced. Only use
the tubing supplied originally or an exact replacement. Any
fitting which is found to be leaking should be tightened, or if
that fails to eliminate the leak, replaced.
NOTE
FOLLOW TIGHTENING PROCEDURES AS
RECOMMENDED BY SWAGELOK. REFER TO THE
INSTRUCTIONS LOCATED AT THE BACK OF
THIS MANUAL.
7.2 MAINTENANCE PROCEDURES
The Fluxer is designed to require a minimum amount of
maintenance and requires no tools for the normal cycles.
Frequencies for the following maintenance may vary due to
exhaust conditions and other variables such as PCB design,
operating parameters, flux type and fluxer duty.
Sono-Tek Corporation recommends the following schedule be
adhered to keep the fluxer operating at peak conditions.
However, if you abuse the nozzle or attempt to
disassemble it, you will void the warranty with Sono-
Tek Corporation.
2. Remove the nozzle from the jet-block assembly
inside the enclosure and wipe it with a cloth wetted
with an appropriate solvent.
3. Take care to prevent damage to the nozzle coaxial
cable, the tip and the fitting.
NOTE
DO NOT IMMERSE THE NOZZLE
IN A LIQUID BATH.
d. Clean the jet block:
1. With the nozzle still removed, mark or note the
position of the jet block assembly inside the
enclosure. The placement of this block is critical to
spray patterns!
2. Loosen and remove the screws holding the jet-block
in place.
3. Wipe the jet block clean and inspect inside the jets
for residues.
4. It may be preferable to remove the tubing from the
jet block and soak the jet-block inside an appropriate
solvent.
5. Never use a file, brush, or any tool that may damage
the finish of the air jets to clear the insides of the
jets. Changing the geometry of these jets in any way
will degrade the fluxer performance.
e. Put the jet block assembly back into place.
f. Slide the positioning assembly back into the enclosure.
g. Replace the nozzle into the jet-block assembly and
ensure the nozzle is settled all the way into the block.
Tighten the nozzle-retaining thumbscrew.
h. Replace the side panel.
i. Wipe down the area around the fluxer.

7.2.1 Weekly Maintenance

a. Clean the PCB sensor cover: Use a soft cloth wetted
with an appropriate solvent to clean the sensor. The
selection of your solvent will depend on the type of flux
that you are using. Contact Sono-Tek if you would like
some help in making a choice. This may need to be
done daily depending on the characteristics of the wave.
b. Slide out the exhaust plenum and clean with a cloth
wetted with an appropriate solvent. You may prefer to
do this daily to ease the cleaning and keep the plenum
cleaner.
c. Clean the nozzle(s):
1. An ultrasonic nozzle is by definition self-cleaning on
the inside and needs only to be wiped clean. This
nozzle will give you years of trouble-free fluxing.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 34

7.2.2 Monthly maintenance
a. Replace the filter inside the flux tank with the approved
part found in this manual.
b. Inspect the inside of the flux tank for a build up of
debris. An accumulation of debris can plug the filter or
if debris gets beyond the filter, it can cause pump
failure.
1. If debris is found, pour out the flux through a filter
or China Cap and wipe out the tank and replace the
flux.
2. Large amounts of debris may require that you
inspect your flux delivery or storage method or that
you inspect the flux upon receipt.
c. Clear the accumulated oil and water from the demister
filters on the Compressed Air Regulator Assembly.
d. Inspect the flux lines for leakage: Leaks may be
evident by bubbles in the flux lines after a certain
fitting or an accumulation of residues around a fitting.
e. Inspect the air lines for leakage: Joints may be
inspected by feel and by listening for air.
f. Inspect the cables:
1. Inspect the coaxial cable near the nozzle. If there is
discoloration replace the cable as soon as possible.
2. Inspect the remaining cables for kinks and damaged
insulation.

7.2.3 Annual Maintenance

The Fluxer must be calibrated once a year in accordance with
procedures in this manual.

7.3 System Failure Maintenance

The following maintenance procedure relates to the replacement
of any electronic module. This procedure should be performed
only in the event of a system failure.
a. Disconnect the SonoFlux System from the AC power
line.
b. Remove the cover from the electronics module.
c. Write down the type and placement of the connections
before disconnecting.
d. Unplug the assembly or subsystem to be replaced.
e. Replace assembly or subsystem.
f. Reconnect the plugs.
g. Close the cover and reconnect any connectors or
fittings that have been removed.
h. Go through the Setup and Calibration procedures listed
in Section 6.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 35

8.0 TROUBLESHOOTING
SYSTEM TROUBLESHOOTING
Problem Possible Cause Recommended Actions
Liquid flows back in Air pressure to pneumatic valve is too low Confirm that air pressure is at least 80 psi.
nozzle feed line when
nozzle is idle Fittings or ferrules Check fittings for tightness and ferrules to establish that they are installed and properly
oriented.
Pneumatic valve (see Figures 2.3.a, 2.3.b and With no spray signal present at the board detector, remove the 1/16" OD soft, clear
2.4a,2.4b) tubing from the valve. If no air is observed flowing through the tubing, the pneumatic
valve could be at fault.
Solenoid control valve If air is flowing through the clear tube, the solenoid control valve could be at fault.
Also check for 24 VDC to the valve. If there is no voltage, the valve is at fault. If there is
24 VDC present, the problem is probably at board level. Consult Sono-Tek in that case.
No flux flow through Flux filter, pump Check to see that flux returns to the flux reservoir when no spray signal is present. If not
ultrasonic nozzle pump or filter could be faulty.
Air pressure to pneumatic valve is too low Confirm that air pressure is at least 80 psi.
PCB sensor or sensor sensitivity Place a PCB over the sensor and observe whether Sensor changes state. If not, the sensor
could be faulty or its sensitivity may need adjustment.
Pneumatic valve (see Figures 2.3.a, 2.3.b and With a spray signal present at the board detector, remove the 1/16" OD soft, clear tubing
2.4a,2.4b) from the valve. If air is observed flowing through the tubing, the pneumatic valve could
be at fault.
Solenoid control valve If no air is flowing through the clear tube, the solenoid control valve could be at fault.
Also check for 24 VDC to the valve. If there is a voltage, the valve is at fault. If there is no
24 VDC present, the problem is probably at board level. Consult Sono-Tek.
Flux flows through Nozzle power level is too low (See Section 5.3.1) Power requirements may change if flux type has been changed.
nozzle, but liquid is not
atomized Flow rate is too high for nozzle power setting Verify that the flow rate has inadvertently been changed.
Coaxial cable to nozzle Check the cable. Disconnect at both ends. Make Certain that the center conductor pin is
not missing or bent. Check for continuity.
Observe whether there is any green corrosion on the connectors.
Loose flux fitting at rear of nozzle, or missing or Check the integrity of the fitting.
improperly installed ferrules
Spray does not turn off PCB sensor Check the sensor to see if it has either a dirty lens or its sensitivity is set too high.
Disconnect the sensor and observe that the spray ceases. If it does, the sensor could be
faulty.
No power Incoming AC power disconnected Reconnect.
Main power switch on power entry module is OFF Turn switch on.
Blown fuse Disconnect system from AC power and check fuses in power entry module and in DC
supplies and interface board.
No flux on leading or Fluxer conveyor speed setting does not match Adjust as required. Conveyor speed control may be out of
trailing edge of PCB actual conveyor speed calibration. Measure actual speed.
Boards are being placed on conveyor over the Better operator training or adjusting the feed conveyor speed is suggested.
sensor, or being pushed forward while over the Relocate the sensor.
sensor (manually or by a transport conveyor whose
speed exceeds that of the wave-soldering machine
conveyor)
Incorrect "spray on" or "spray off" settings Refer to Section 5.1 for details on setting these parameters.

Missing or light flux Dirty spray assembly components Check for excessive residue on the jet block assembly. Verify that the jets are not
deposition one side of a plugged.
PCB
Flux filter Replace filter.
Improper reassembly after cleaning Make sure that the jet block assembly and all tubing are properly installed.
Nozzle not positioned properly in jet block The nozzle must be positioned such that the front of the nozzle housing is in contact with
the front wall of the jet block's nozzle well.
External air currents Make certain that there are no external air currents in the vicinity of the spray fluxer, such
as produced by fans, openings in the wave-soldering machine, etc.
Missing or light flux Jet force setting See Section 5.3.4.
deposition both sides of a
Flux filter Replace.
PCB
Flux obstructing jet block Clean.
Input air pressure Set to 80 psi.
Nozzle power setting See Section 5.3.1.
Jet block assembly position Lower jet assembly; reposition jets.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 36

ALARMS TROUBLESHOOTING
Problem Possible Cause Recommended Actions
Nozzle (NOZ ALARM_1 or Poor electrical connection to the nozzle Check the integrity of the coaxial cable to the nozzle. Replace if required.
NOZ ALARM_2)
Incorrect power level setting See Section 5.3.1.
Incorrect dip switch settings See Section 5.3.2.
Blown fuse on the nozzle driver PCB Check coaxial cable to nozzle and replace fuse.
Component failure on the nozzle driver PCB Replace board.
Nozzle Replace.
Jet Force (JET FORCE_1 Pressure of air supplied to the jets is Set incoming air pressure to 80 psi.
and JET FORCEe_2) inadequate Check air tubing connections. Examine input regulator filter for blockage.
Failure of the PCB that controls the jets. Replace.
Rotary Valve (ROT Rotary air dispersion valve belt off its track Reinstall belt.
VALVE_1 and ROT
VALVE_2) Rotary air dispersion valve optical switches misaligned Realign switches.
Rotary air dispersion valve cable unplugged or broken Reattach cable.
Rotary air dispersion valve not spinning Look for obstructions in belt path; all elements should move freely.
Rotary air dispersion valve not spinning at proper rate Look for obstructions in belt path; all elements should move freely.
Liquid level low Low flux level in reservoir Fill reservoir.
(LL_LOW)
Level sensor obstructed Free up sensor.
Cable unplugged Reconnect.
Liquid Level Empty Board jumper unplugged Place a jumper across the LL_EMPTY pins on TB200 of interface board.
(LL_EMPTY)
Low flux level in reservoir Fill reservoir.
Level sensor obstructed Free up sensor.
Cable unplugged Reconnect.
Pump (PUMP ALARM_1 No pumping action Check all connections. Replace if fault cannot be found.
and PUMP ALARM_2)
No control voltage to pump Replace digital-to-analog (DAC) IC. Consult Son-Tek Corp.

Fire (used on INTLK_1 or Fire has been detected Turn off system.
INTLK_2, depends on
which used) (option) Flame detector disconnected Reconnect.
Flame detector aimed at high intensity light Redirect detector.

Flame detector inoperative Replace.

Emergency stop (ESTOP) E-stop function is active Clear error.

(option)
Failure of 24 VDC power supply Check for 24 VDC on P17 of interface board. (See Figures 2.3.a or 2.3.b for location.)
Replace fuse in 24 VDC power supply.
E-stop circuit fuse F300 on interface board has opened Check and replace fuse with the same type.
Exhaust failure Exhaust sensor Remove flux buildup on tubing to sensor.
(EXHAUST) (option) Adjust sensor.
Make sure exhaust is present.
Door panel (PANEL) Jumper removed from panel pins on TB200 header on Replace jumper.
the interface board
Panel interface device has been interrupted Verify that panels are back in position.
Auxiliary(AUXWARN_1 Jumper removed from AUXWARN_1 or AUXWARN_2 Replace jumper.
and (AUXWARN_2) pins at TB200 header
Device connected to AUXWARN inputs has activated Check device for proper operation.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 37

9.0 SOLDER DEFECT GUIDE

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 38

10.0 SPARES KITS
SMALL 4 PIN CONNECTOR FOR NOZZLE END, LARGE
SMA-SMA 5 PIN CONNECTOR FOR ELECTRONICS BOX END
06-01-00134 (2 FT), 06-01-00007M (8 FT) 02-04-00945-003 (2 FT), 02-04-00942-001 (8 FT)

FIGURE 10.0 NOZZLE CABLE

SPARES KIT, 2000F-330M LEVEL 1

P/N DESCRIPTION QUANTITY
01-00-00229 BULKHEAD FITTING, 1/4" ............................................................................................................6
02-10-00015/16* PCB SENSOR AND LENS COVER ..................................................................................................1
05-01-00006 BELT FOR ROTARY VALVE ............................................................................................................2
05-03-00017 TYGON TUBING 1/16" .................................................................................................................2 FT
05-03-00040 TUBING, PTFE BLUE 5/16" OD .....................................................................................................10 FT
05-03-00041 TUBING, PTFE BLUE 3/8" OD .......................................................................................................10 FT
05-03-00045 TUBING, PTFE BLUE STRIPE 5/16" OD .........................................................................................10 FT
05-03-00047 TUBING, PTFE BLUE STRIPE 1/4" OD ...........................................................................................20 FT
SEE FIG 10.0 ABOVE NOZZLE CABLE (2 FT) .................................................................................................................2
SEE FIG 10.0 ABOVE NOZZLE CABLE (8 FT) .................................................................................................................2
06-03-00364 JET BLOCK ASSEMBLY 2000F .......................................................................................................1
06-03-00465 SOLENOID CONTROL VALVE ASSEMBLY........................................................................................1
06-03-00577-001 330M JET CONTROL CARD...........................................................................................................1
10-00-00001 NYLON FERRULES FOR 1/4" SWAGELOCK FITTINGS (SET OF 10) ..................................................2
10-00-00024 FLUX TANK FILTERS (SET OF 12) .................................................................................................1 BAG

SPARES KIT, 2000F-330M LEVEL 2

P/N DESCRIPTION QUANTITY
01-00-00229 BULKHEAD FITTING, 1/4" ............................................................................................................6
02-10-00015/16* PCB SENSOR AND LENS COVER ..................................................................................................1
05-01-00006 BELT FOR ROTARY VALVE ............................................................................................................2
05-03-00017 TYGON TUBING 1/16" .................................................................................................................2 FT
05-03-00040 TUBING, PTFE BLUE 5/16" OD .....................................................................................................10 FT
05-03-00041 TUBING, PTFE BLUE 3/8" OD .......................................................................................................10 FT
05-03-00045 TUBING, PTFE BLUE STRIPE 5/16" OD .........................................................................................10 FT
05-03-00047 TUBING, PTFE BLUE STRIPE 1/4" OD ...........................................................................................20 FT
SEE FIG 10.0 ABOVE NOZZLE CABLE (2 FT) .................................................................................................................2
SEE FIG 10.0 ABOVE NOZZLE CABLE (8 FT) .................................................................................................................2
06-03-00173 STANDARD PUMP ASSEMBLY .......................................................................................................1
06-03-00187 PNEUMATIC VALVE ASSEMBLY - POSITION 1 ................................................................................1
06-03-00215-NP5 ULTRASONIC GENERATOR ...........................................................................................................1
06-03-00364 JET BLOCK ASSEMBLY 2000F .......................................................................................................1
06-03-00465 SOLENOID CONTROL VALVE ASSEMBLY........................................................................................1
06-03-00577-001 330M JET CONTROL CARD...........................................................................................................1
06-04-00313 ULTRASONIC NOZZLE ..................................................................................................................1
10-00-00001 NYLON FERRULES FOR 1/4" SWAGELOCK FITTINGS (SET OF 10) ..................................................2
10-00-00024 FLUX TANK FILTERS (SET OF 12) .................................................................................................1 BAG

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 39

SPARES KIT,2000F-330M LEVEL 3
P/N DESCRIPTION QUANTITY
01-00-00229 BULKHEAD FITTING, 1/4" ..................................................................................................... 6
02-10-00015/16* PCB SENSOR AND LENS COVER ........................................................................................... 1
05-01-00006 BELT FOR ROTARY VALVE ..................................................................................................... 2
05-03-00017 TYGON TUBING 1/16" .......................................................................................................... 2 FT
05-03-00040 TUBING, PTFE BLUE 5/16" OD .............................................................................................. 10 FT
05-03-00041 TUBING, PTFE BLUE 3/8" OD ................................................................................................ 10 FT
05-03-00045 TUBING, PTFE BLUE STRIPE 5/16" OD .................................................................................. 10 FT
05-03-00047 TUBING, PTFE BLUE STRIPE 1/4" OD .................................................................................... 20 FT
SEE FIG 10.0 p.38 NOZZLE CABLE (2 FT) .......................................................................................................... 2
SEE FIG 10.0 p.38 NOZZLE CABLE (8 FT) .......................................................................................................... 2
06-02-00100-001 MAIN INTERFACE PRINTED CIRCUIT ASSEMBLY .................................................................... 1
06-03-00173 STANDARD PUMP ASSEMBLY ................................................................................................ 1
06-03-00187 PNEUMATIC VALVE ASSEMBLY .............................................................................................. 1
06-03-00215-NP5 ULTRASONIC GENERATOR .................................................................................................... 1
06-03-00422 ROTARY VALVE ASSEMBLY .................................................................................................... 1
06-03-00364 JET BLOCK ASSEMBLY 2000F ................................................................................................ 1
06-03-00463-005 330M DISPLAY ASSEMBLY ..................................................................................................... 1
06-03-00465 SOLENOID CONTROL VALVE ASSEMBLY................................................................................. 1
06-03-00577-001 330M JET CONTROL CARD.................................................................................................... 1
06-04-00313 ULTRASONIC NOZZLE ........................................................................................................... 1
10-00-00001 NYLON FERRULES FOR 1/4" SWAGELOCK FITTINGS (SET OF 10) ........................................... 2
10-00-00024 FLUX TANK FILTERS (SET OF 12) .......................................................................................... 1 BAG

* P/N 02-10016/17, a “break beam” PCB sensor is also available. Please specify if this option is required.

SPARES KIT, 2000F-610M LEVEL 1

P/N DESCRIPTION QUANTITY
01-00-00229 BULKHEAD FITTING, 1/4" ..................................................................................................... 6
02-10-00015/16* PCB SENSOR AND LENS COVER ........................................................................................... 1
05-01-00006 BELT FOR ROTARY VALVE ..................................................................................................... 2
05-03-00017 TYGON TUBING 1/16" .......................................................................................................... 2 FT
05-03-00040 TUBING, PTFE BLUE 5/16" OD .............................................................................................. 10 FT
05-03-00041 TUBING, PTFE BLUE 3/8" OD ................................................................................................ 10 FT
05-03-00043 TUBING, PTFE RED 5/16" OD................................................................................................ 10 FT
05-03-00044 TUBING, PTFE RED STRIPE 5/16" ......................................................................................... 10 FT
05-03-00045 TUBING, PTFE BLUE STRIPE 5/16" OD .................................................................................. 10 FT
05-03-00046 TUBING, PTFE RED STRIPE 1/4" ........................................................................................... 20 FT
05-03-00047 TUBING, PTFE BLUE STRIPE 1/4" OD .................................................................................... 20 FT
SEE FIG 10.0 p.38 NOZZLE CABLE (8 FT) .......................................................................................................... 2
06-03-00364 JET BLOCK ASSEMBLY 2000F ................................................................................................ 1
06-03-00465 SOLENOID CONTROL VALVE ASSEMBLY................................................................................. 1
06-03-00577-002 610M JET CONTROL CARD.................................................................................................... 2
10-00-00001 NYLON FERRULES FOR 1/4" SWAGELOCK FITTINGS (SET OF 10) ........................................... 2
10-00-00024 FLUX TANK FILTERS (SET OF 12) .......................................................................................... 1 BAG

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SPARES KIT, 2000F-610M LEVEL 2
P/N DESCRIPTION QUANTITY
01-00-00229 BULKHEAD FITTING, 1/4" ................................................................................................ 6
02-10-00015/16* PCB SENSOR AND LENS COVER ...................................................................................... 1
05-01-00006 BELT FOR ROTARY VALVE ................................................................................................ 2
05-03-00017 TYGON TUBING 1/16"...................................................................................................... 2 FT
05-03-00040 TUBING, PTFE BLUE 5/16" OD ......................................................................................... 10 FT
05-03-00041 TUBING, PTFE BLUE 3/8" OD ........................................................................................... 10 FT
05-03-00043 TUBING, PTFE RED 5/16" OD ........................................................................................... 10 FT
05-03-00044 TUBING, PTFE RED STRIPE 5/16"..................................................................................... 10 FT
05-03-00045 TUBING, PTFE BLUE STRIPE 5/16" OD ............................................................................. 10 FT
05-03-00046 TUBING, PTFE RED STRIPE 1/4" ...................................................................................... 20 FT
05-03-00047 TUBING, PTFE BLUE STRIPE 1/4" OD ............................................................................... 20 FT
SEE FIG 10.0 p.38 NOZZLE CABLE (8 FT) ..................................................................................................... 2
06-03-00173 STANDARD PUMP ASSEMBLY ............................................................................................ 1
06-03-00187 PNEUMATIC VALVE ASSEMBLY - POSITION 1 .................................................................... 1
06-03-00215-NP5 ULTRASONIC GENERATOR ............................................................................................... 1
06-03-00364 JET BLOCK ASSEMBLY 2000F ........................................................................................... 1
06-03-00465 SOLENOID CONTROL VALVE ASSEMBLY ............................................................................ 1
06-03-00467 PNEUMATIC VALVE ASSEMBLY - POSITION 2 .................................................................... 1
06-03-00577-002 610M JET CONTROL CARD ............................................................................................... 1
06-04-00313 ULTRASONIC NOZZLE ...................................................................................................... 2
10-00-00001 NYLON FERRULES FOR 1/4" SWAGELOCK FITTINGS (SET OF 10)....................................... 2
10-00-00024 FLUX TANK FILTERS (SET OF 12) ..................................................................................... 1 BAG

SPARES KIT, 2000F-610M LEVEL 3

P/N DESCRIPTION QUANTITY
01-00-00229 BULKHEAD FITTING, 1/4" .............................................................................................. 6
02-10-00015/16* PCB SENSOR AND LENS COVER .................................................................................... 1
05-01-00006 BELT FOR ROTARY VALVE .............................................................................................. 2
05-03-00017 TYGON TUBING 1/16" ................................................................................................... 2 FT
05-03-00040 TUBING, PTFE BLUE 5/16" OD ....................................................................................... 10 FT
05-03-00041 TUBING, PTFE BLUE 3/8" OD ......................................................................................... 10 FT
05-03-00043 TUBING, PTFE RED 5/16" OD......................................................................................... 10 FT
05-03-00044 TUBING, PTFE RED STRIPE 5/16" .................................................................................. 10 FT
05-03-00045 TUBING, PTFE BLUE STRIPE 5/16" OD ........................................................................... 10 FT
05-03-00046 TUBING, PTFE RED STRIPE 1/4" .................................................................................... 20 FT
05-03-00047 TUBING, PTFE BLUE STRIPE 1/4" OD ............................................................................. 20 FT
SEE FIG 10.0 p.38 NOZZLE CABLE (8 FT) ................................................................................................... 2
06-02-100-001 MAIN INTERFACE PRINTED CIRCUIT ASSEMBLY ............................................................. 1
06-03-00173 STANDARD PUMP ASSEMBLY ......................................................................................... 1
06-03-00187 PNEUMATIC VALVE ASSEMBLY - POSITION 1 .................................................................. 1
06-03-00215-NP5 ULTRASONIC GENERATOR ............................................................................................. 1
06-03-00422 ROTARY VALVE ASSEMBLY ............................................................................................. 1
06-03-00364 JET BLOCK ASSEMBLY 2000F ......................................................................................... 1
06-03-00463-004 610M DISPLAY ASSEMBLY .............................................................................................. 1
06-03-00465 SOLENOID CONTROL VALVE ASSEMBLY.......................................................................... 1
06-03-00467 PNEUMATIC VALVE ASSEMBLY - POSITION 2 .................................................................. 1
06-03-00577-002 610M JET CONTROL CARD............................................................................................. 1
06-04-00313 ULTRASONIC NOZZLE .................................................................................................... 2
10-00-00001 NYLON FERRULES FOR 1/4" SWAGELOCK FITTINGS (SET OF 10) .................................... 2
10-00-00024 FLUX TANK FILTERS (SET OF 12) ................................................................................... 1 BAG

* P/N 02-10016/17, a “break beam” PCB sensor is also available. Please specify if this option is required.

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11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 42
 WARRANTY – SONOFLUX PRODUCTS

LIMITED WARRANTY
Sono–Tek warranties SonoFlux PCB Fluxing Systems (“Product”) against defects in material and workmanship for a period of 12
months from the date of shipment. The following items are not covered by this warranty:
– conveyor fingers (for models supplied with finger conveyor)
– conveyor drive motor(s) and transport chains (for models supplied with chain/pin or finger conveyor)
– conveyor drive pulleys, sprockets, gearboxes, etc (for models supplied with chain/pin or finger conveyor)

This 12 month warranty is subject to the following conditions:

– In the event of a Product, or part of a Product, proving to be defective, the obligation of Sono–Tek shall be limited to the
supply of a repaired or replacement Product, or part of a Product, at its sole discretion. If a Product appears to be
defective, Purchaser must notify Sono–Tek immediately to obtain instructions to rectify the problem. Parts or Products must
only be returned to Sono–Tek after a Return Authorization number has been issued, and must be shipped freight pre–paid.
– Repairs or replacements necessitated by misuse, abuse or improper operation or application of a Product are not covered
by this warranty.
– Damage caused by unauthorized repair to, or alteration of a Product is not covered by this warranty.
– Installation labor is not covered by this warranty.
– Items of an expendable nature including, but not limited to, polypropylene and Teflon liquid tubing, liquid tubing fittings
and ferrules, air tubing, air tubing fittings, filters and ultrasonic nozzle power cables are not covered by this warranty.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, AND WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED. SONO–TEK CORPORATION ACCEPTS NO LIABILITY FOR
CONSEQUENTIAL OR INCIDENTAL DAMAGES HOWSOEVER CAUSED.

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 43

 Sono-Tek reserves the right to make changes to the
product(s) described herein without notice. No liability is
2012 Route 9W, Bldg. 3, Milton, NY USA 12547
assumed as a result of their use or application. No rights
Phone: (845) 795-2020
under any patent accompany the sale of any patented
Fax: (845) 795-2720 product. Copyright © 2010 Sono-Tek Corp. All rights
E-mail: info@sono-tek.com reserved.
Website: www.sono-tek.com Printed in the USA P/N 11-01-00140 V1.8

11-01-00140 V1.8 SonoFlux 2000F Manual of Operations Page 44