AAT MEGA II CLEANER User manual

MEGA II CLEANER
Rev 2.0
10/15/2005
OPERATING MANUAL
Austin American Technology Corporation
12201 Technology Blvd., Suite 160
Austin, Texas 78727-6102
Tel [phone] Fax [phone]
Web site address: www.aat-corp.com

Copyright © 1984, 2005 Austin American Technology Corporation. All Rights Reserved.
Mega is a registered trademark of Austin American Technology Corporation. MegaSolv is a trademark of
Austin American Technology Corporation
Printed in U.S.A.
Foreign and U.S. Products of Austin American Technology Corporation are covered by Foreign and U.S.
patent or patents pending. No part of this Publication may be translated and/or reproduced or stored in a
data retrieval system, or transmitted in any form or by any means without the express written permission
of Austin American Technology Corporation. Information in this publication supersedes all previously
published material. Specification and price change privileges reserved.
All of the information contained herein is, to the best of our knowledge, correct. Users, however, should
independently evaluate the suitability of each product for their application. Austin American Technology
Corporation, makes no warranties as to the accuracy or the completeness of the information, and
disclaims any liability regarding its use.

Mega II Operating Manual Rev. 2.0 10/15/2005 i
Table of Contents
1.0 OPERATOR SAFETY SUMMARY
1.1 Symbols on the Equipment ............................................................................. 2
1.2 Additional Precautions .................................................................................... 3
1.3 MEGA II Safety Features ................................................................................ 4
2.0 INSTALLATION AND SET UP
2.1 Introduction ..................................................................................................... 5
2.2 Installation/Set Up ........................................................................................... 6
2.3 System Components ...................................................................................... 8
3.0 THE CLEANING PROCESS
3.1 Final Cleaning Cycle ..................................................................................... 13
4.0 OPERATOR INTERFACE
4.1 Using the Operator Interface ........................................................................ 15
4.2 Menu Modes ................................................................................................. 15
4.2.1 Menu Mode ............................................................................................ 15
4.2.2 Non-Menu Mode..................................................................................... 15
4.3 Entering/Changing Settings .......................................................................... 16
4.4 Menu Structure ............................................................................................. 17
5.0 OPERATION
5.1 Starting and Stopping the System ................................................................ 21
5.2 Menu Selections ........................................................................................... 21
5.2.1 Initiate Cycle 1-5..................................................................................... 21
5.2.2 View System Settings............................................................................. 22
5.2.3 View Cycle Setup ................................................................................... 22
5.2.4 View IAC Saturation ............................................................................... 22
5.2.5 View IAC Run Time ................................................................................ 23
5.2.6 View Cycle Count ................................................................................... 23
5.2.7 Change Cycle Setup 1-5 ........................................................................ 23
5.3 Maintenance Menu ....................................................................................... 25
5.3.1 Fill System Hold Tank ............................................................................ 25
5.3.2 Drain System Hold Tank ........................................................................ 25
5.3.3 System/Chem. Cleanup ......................................................................... 25
5.3.4 Rinse Drain Time.................................................................................... 25
5.3.5 Change IAC Saturation Time ................................................................. 26
5.3.6 Reset IAC Run Time .............................................................................. 26
5.3.7 Reset Cycle Counter .............................................................................. 26
5.3.8 Cycle Counter Lockout........................................................................... 26
5.3.9 Analog Conversion ................................................................................. 26
5.3.10 Enable/Set Password ............................................................................. 27

ii Rev. 2.0 10/15/2005 Mega II Operating Manual
6.0 PREVENTIVE MAINTENANCE
7.0 PARAMETERS FOR RESISTIVITY CONTROLLER
7.1 Mega II Cleaner: Wash-MegaSolv JB ........................................................... 31
7.1.1 Outputs................................................................................................... 31
7.1.2 Menus..................................................................................................... 31
8.0 PARAMETERS FOR RESISTIVITY CONTROLLER (RC1)
8.1 Mega II Cleaner: Wash-Water ...................................................................... 33
8.1.1 Outputs................................................................................................... 33
8.1.2 Menus..................................................................................................... 33
8.2 Recirculating Heater System Only ................................................................ 33
9.0 REPLACEMENT/SPARE PARTS
APPENDIX A SCHEMATICS
APPENDIX B OPTIONS
B.1 PURGE AND PRESSURIZATION OPTION ................................................ 51
B.1.1 Initial System Power 52
B.1.2 Post Start-Up Power 52
B.2 RECIRCULATION HEATER SYSTEM OPTION ......................................... 52
B.2.1 Operation 52
B.3 PREWASH / SOAK OPTION ....................................................................... 54
B.3.1 Solution Cross Over 55
B.3.2 Change Cycle Setup 1-5 58
B.3.3 PREWASH CYCLE 59
B.4 OPEN LOOP RINSE OPTION ..................................................................... 60
B.4.1 OPEN LOOP RINSE CYCLE 62
B.5 DATA LOGGING PROGRAM OPTION ...................................................... 63
B.5.1 200CR CONTROLLER PROGRAM- Help Files 64
B.5.2 Communications Port Setup 65
B.5.3 200CR Meter 67
B.6 ULTRASONICS CLEANING OPTION ......................................................... 67
B.6.1 Specifications 68
B.6.2 Change Cycle Setup 1-5 69
B.7 CHILLER ...................................................................................................... 70
B.8 COOLING COILS ........................................................................................ 74
APPENDIX C TERMS AND CONDITIONS

Mega II Operating Manual Rev. 2.0 10/15/2005 iii
List of Figures
Figure 1. Symbols on Equipment ............................................................................. 2
Figure 2. Installation ................................................................................................. 7
Figure 3. System Components ................................................................................. 9
Figure 4. Operator Interface Flow Chart ................................................................. 19
Figure B-1. 200CR Control Panel .............................................................................. 67
Figure B-2. Chiller ...................................................................................................... 70
Figure B-3. Chiller Option Airflow Direction ................................................................ 71
Figure B-4. Chiller Connections ................................................................................. 71
Figure B-5. Chiller Connections ................................................................................. 72
Figure B-6. Chiller Plumbing Connections ................................................................. 73
Figure B-7. Holding Tank and Cooling Coils .............................................................. 74
Figure B-8. Plumbing Connections for Cooling Coils ................................................. 75
Figure B-9. Cooling Coils in Hold Tank ...................................................................... 75

iv Rev. 2.0 10/15/2005 Mega II Operating Manual

Mega II Operating Manual Rev. 2.0 10/15/2005 v
List of Tables
Table 1. Available Phases ..................................................................................... 11
Table 2. Sequence of Events ................................................................................ 13
Table 3. Menu Selections ...................................................................................... 17
Table 4. Menu Structure ........................................................................................ 18
Table 5. Key Press Sequence to Run a Cycle ...................................................... 22
Table 6. Cycle Change Key Press Sequence ....................................................... 23
Table 7. Cleanup Function Key Selections ........................................................... 25
Table 8. Analog Conversions ................................................................................ 26
Table 9. Key Selections to Set the Password ....................................................... 27
Table 10. Spare Parts List ....................................................................................... 35

vi Rev. 2.0 10/15/2005 Mega II Operating Manual

Mega II Operating Manual Rev. 2.0 10/15/2005 1
1.0 OPERATOR SAFETY SUMMARY
The safety information in this summary is for the benefit of operating personnel.
Warnings and Cautions will also be found throughout the manual where they
apply.
Terms in This Manual
CAUTION statements identify conditions or practices that could result in
damage to the equipment or to other property.
WARNING statements identify conditions or practices that could result in
personal injury or loss of life.
Properly Install the Equipment
For safe operation, this equipment must be properly installed, following the
instructions in the INSTALLATION section of this manual.
Protectively Ground the Equipment
For electric-shock protection, this product must be protectively grounded as
part of the installation procedure. Use the green/yellow grounding conductor
provided for this purpose.
Connect to Earth-Referenced Power System Only
Note: This equipment must only be powered by a single-phase earth-
referenced power source in which the potential power never exceeds
240 volts.
Note: This equipment must never be connected to an “IT” power system with
an impedant neutral connection. During a supply system fault
condition, the equipment insulation system could be over-stressed,
creating an electric-shock hazard.

2 Rev. 2.0 10/15/2005 Mega II Operating Manual
1.1 SYMBOLS ON THE EQUIPMENT
The definition of each symbol used on the Cleaning System is as follows:
Figure 1. Symbols on Equipment
CAUTION and WARNING Notices on the Equipment
The following notices, together with additional explanatory information, address
hazards associated with improper use of the equipment.
CAUTION - DO NOT SIT, STAND, LEAN, OR APPLY EXCESSIVE WEIGHT TO
THE OPEN DOOR.
The door of the equipment is only intended to support the wash rack and its
contents. Overloading the door mounting hardware will damage the equipment,
resulting in improper door operation and the potential for water leaks. Severely
overloading the open door could also cause the equipment to tip over, resulting
in substantial damage and possibly personal injury.
WARNING - RISK OF FIRE. USE ONLY APPROVED SOLVENTS.
This equipment is designed primarily to use water and saponifier as the
cleaning agent. Addition or substitution of other cleaning agents, especially
liquids classed as FLAMMABLE, could result in fire or explosion. Incompatible

Mega II Operating Manual Rev. 2.0 10/15/2005 3
solvents could also lead to machine failure, including the malfunction of safety
seals, with its associated hazards. If other cleaning agents are desired, contact
AAT. Observe the water temperature limitations and exhaust flow rates set forth
in this section and in Specifications section.
1.2 ADDITIONAL PRECAUTIONS
Wipe Up All Spills
Wipe up all spills and drips promptly. This especially applies to solvents used in
semi-aqueous cleaning systems. Do not allow spilled liquid to remain on the
floor or on external surfaces of the equipment. Be sure that all absorbent
materials used for such cleaning procedures are properly rinsed out or placed in
a safety container designed for disposal of materials soaked with combustible
liquids.
WARNING: Due to the drying effect of the semi-aqueous cleaning agents on a
person’s skin, observe the following:
Wear Clean Protective Clothing
If solvent cleaning systems are used in conjunction with this equipment, wear
protective clothing such as an apron and gloves when handling items wet with
the cleaning agent.
Remove the solvent from the outer surface of protective clothing before handling
the clothing. Washing or wiping is usually sufficient.
If cleaning agent is spilled into eyes, flush thoroughly with copious amounts of
water for at least ten minutes. Consult the cleaning solvent’s Material Safety
Data Sheet for additional precautions and information.
Operate Equipment In Compliance With Local Regulations
The user(s) of this equipment must comply with operating procedures and the
training of operating personnel as mandated by local regulations.
Use the Proper Fuse
For continued fire protection, use only a controller rear-panel fuse of the proper
type, voltage rating, and current rating as specified for your product. The fuse
rating is marked adjacent to the fuse holder on the rear panel of the controller.
Replacement of internal fuses must only be performed by qualified service
personnel.
Do not Remove Covers or Panels
To avoid personal injury, do not remove the product covers or panels. Do not
operate the product without the covers and panels properly installed. Refer
servicing to qualified personnel.

4 Rev. 2.0 10/15/2005 Mega II Operating Manual
CAUTION: HIGH VOLTAGE present within this equipment. Service by
authorized personnel only.
CAUTION: Do not attempt to service the circuitry of this equipment without
first disconnecting it from the power supply.
1.3 MEGA II SAFETY FEATURES
• Process Tank lid must be closed and latched before the cleaning cycle
can begin
• Solvent replenishment is automated; operator is never in contact with
solvent during normal operation
• After completion of an adequate drying cycle, the process tank is clean,
dry, free of solvents
• High level float in the process tank stops the cleaning cycle if:
- The process tank never fills to capacity
- The holding tank solution is empty or low
- The PreWash solution drum is empty or low
- The Rinse incoming water pressure is low
Note: During the Fill mode, should any of the circumstances above occur,
the system will attempt the appropriate function for 5 minutes. At
that time the “PT High Level Error” message is displayed and the cycle
is stopped.
An additional safety feature of the Mega®II is the Purge and Pressurization
option, which is required when ignitable gases or vapors are present. Purging
reduces the concentration of any potentially flammable gases or vapors present
in the equipment enclosure. For more information on this option see B.1
PURGE AND PRESSURIZATION OPTION.
WARNING - RISK OF FIRE. USE ONLY APPROVED SOLVENTS
This equipment is designed primarily to use water, MegaSolv™or IPA solvents
as the cleaning agent. When using FLAMMABLE solvents special precautions
must be taken to minimize any risk of fire or explosion. Incompatible solvents
could also lead to machine failure, including the malfunction of safety seals and
associated hazards. Consult the solvent MSDS for handling information and
precautions. If other cleaning agents are desired, contact AAT.

9600 Operating Manual Rev. 3.4 10/15/2005 5
2.0 INSTALLATION AND SET UP
2.1 INTRODUCTION
Austin American Technology's Mega® II is a revolutionary new closed-loop,
solvent regenerative, electronic assembly cleaning system with ION detection
and statistical process control capability. This has been made possible by the
development of a new solvent system and associated cleansing ION exchange
resins for solvent purification and reuse. The Mega II cleaner constantly
monitors the resistivity of a special recyclable, non-ozone depleting, non-
flammable, safe organic solvent with outstanding solubility and surface tension
properties. In the Mega II cleaner system, the solvent (Megasolv™ JB) is
recirculated through a unique ion-exchange process in which the soils dissolved
from the electronic assemblies are transferred into an Ion Absorption Chamber
(IAC) and a “cleaned” solvent (free of contamination) is obtained repeatedly for
each cleaning cycle. Megasolv JB was formulated to, and is successful in,
preventing “white residue” which is common when using many other solvent
types such as IPA. The system can also be used with 100% water and mixture of
water and IPA for other cleaning applications.
The process is fully automated and controlled at all times utilizing a
Programmable Logic Controller (PLC), while ionic contamination levels are
monitored by a resistivity controller. By applying the Onsager Theory as it
relates to the conductance of ions in solution, the ionic contamination of each
batch of circuit assemblies is directly obtained by resistivity detection. The
complete cleaning cycle (wash, rinse and dry) is engineered so that it requires
only one process chamber, eliminating the need for additional materials
handling or transferring, and offers an extremely small foot print.
The operator interface is conveniently located and easy to use. Up to five
cleaning profiles with varying time and set point parameters may be stored and
recalled at the push of a button. Maintenance parameters are set by entering a
code number. A two line display indicates status throughout the cleaning
process, as well as alarm and warning conditions. Two RS232 outputs are
available for data transfer and statistical process control software is available in
a Windows format. Data includes wash and rinse cycle time, cleanliness levels,
and chemistry temperature.
The Mega II offers numerous safety features. The process chamber is always
empty when not in use and must be closed and latched before the cleaning cycle
begins. Solvent replenishment is automated; the operator is never in contact
with the solvent during normal operation. At the completion of the cleaning
cycle the process tank drains into the integral holding tank at a controlled rate
(minimizing drag-out); at the completion of the drying cycle the process
chamber is clean, dry, free of solvents and ready for the operator to remove the
cleaned assemblies.

6 Rev. 3.4 10/15/2005 9600 Operating Manual
The cleaning cycle (wash, rinse and dry) in the Mega II is extremely fast and
effective (10-20 minutes, estimated average). The hot vortex dryer option uses
an inline heater with solid state control, flow protection, and is set for maximum
drying efficiently.
The Mega II wash and rinse cycles incorporate a highly effective spray under
immersion process, with strategically located venturi nozzles for maximum
cleaning efficiency. The agitation can be controlled to handle sensitive wire
bonded substrates or hard to clean, tight tolerance flip chip technology. An
ultrasonics assist is available for tough cleaning requirements.
2.2 INSTALLATION/SET UP
The Mega II is easy to install.
1. Place the unit in the desired location. Connect the system to a standard
grounded 110V AC power outlet, and a dry, oil-free compressed air or
nitrogen line providing 80 PSI at 10 CFM. Connect the exhaust line if
necessary. Exhaust should be 500 CFM.
CAUTION: If flammable or combustible materials are used, ignitable
concentrations of gases or vapors may accumulate thus requiring
special precautions. See the SAFETY section of this manual.
2. Fill the holding tank with 20 gallons of the desired cleaning solution.
3. Fill the holding tank via the process tank by following these steps:
a. Open the Process Tank Lid
b. Open the lower chassis front panel and open the valve to allow flow of
liquid from process tank to holding tank.
c. Slowly fill the process tank with fluid by pouring through the opening.
Do not put more than 20 gallons in the system or an overfill condition
may occur.
d. Close the valve and the process tank lid.
Note: Cycle will not start if lid is not closed and latched.
e. Initiate a cycle, timed or resistivity, to fill the plumbing lines, pump
and Ionic Absorption Chamber (IAC).
f. System may require additional fluid once the system is completely
filled - (Pump, IAC, etc.) and operated due to evaporative losses.
Note: When a low level in the Holding Tank occurs, add no more than 5
gallons to refill, using this same procedure.

9600 Operating Manual Rev. 3.4 10/15/2005 7
Figure 2. Installation

8 Rev. 3.4 10/15/2005 9600 Operating Manual
2.3 SYSTEM COMPONENTS
Refer to Figure 3. System Components for location of these components.
•E-STOP -Controls electrical power to the system. In = OFF, Out = ON.
Note: Some components maintain power when the E-stop is off. Unplug the
unit from outlet to remove all power.
•OPERATOR INTERFACE (OP) - Self-prompting display and controls to
allow the operator to initialize or change operating parameters and to
operate the system.
•RESISTIVITY CONTROL MODULE (RC) - Provides the signal for the
Mega II Process Control System and displays the resistivity level of the
cleaning solution through the resistivity sensor.
•PROCESS TANK - Wash Tank for PCB cleaning with the following
features:
LATCH - Secures lid in position.
OVERFLOW PORT/TUBE - Prevents process tank overfill. This line
drains directly into the wash fluid holding tank.
AGITATION NOZZLES - Provide for circulation of cleaning solution
during the wash cycle.
FILLING TUBE - Transfers cleaning solution from the holding tank to
the process tank.
Note: Since the filling operation is a timed function, if the cycle is
interrupted during the fill, the cycle will need to be re-initiated.
DRAIN PORT - Accommodates drainage of the process tank into the
holding tank.
AIR KNIFE - Dries the cleaned parts.
•PARTS BASKET AND RACK- Place items to be cleaned in this holder.
Custom basket available.
•EXHAUST PORT - Provides connection for venting of fumes from the
system.
•GROUNDING CONNECTION - Provides ESD protection. 1 me ground
strap should be used.
•HOLDING TANK - Storage for cleaning solution (20-gal. capacity).
•GRAVITY FILL VALVE - Enables user to fill the system holding tank
by pouring cleaning solution into the process tank.
•POWER FILL VALVE - This valve used in conjunction with the Auto
Fill Mode.
•POWER DRAIN VALVE - This valve used in conjunction with the Auto
Drain Mode.
•CASTERS - Brakes on front two wheels only.

9600 Operating Manual Rev. 3.4 10/15/2005 9
Figure 3. System Components

10 Rev. 3.4 10/15/2005 9600 Operating Manual

Mega II Operating Manual Rev. 2.0 10/15/2005 11
3.0 THE CLEANING PROCESS
The Mega II Cleaner was designed for precision cleaning requirements. The
system uses a control process that monitors the ionic contamination of the
cleaning solution while recirculating through an Ionic Exchange Process that
removes these contaminates.
The Mega II Cleaner can be programmed for two modes of operation:
•Setpoint (SP) Mode - Cleans to resistivity setpoint entered by user.
•Timed Mode - Cleans for a timed interval entered by the user.
See Table 2. Sequence of Events for an overall picture of the cleaning cycle.
Each phase of the cycle is explained in the following:
Table 1. Available Phases
Phase Explanation
PREWASH PHASE:
(Optional)
An optional pre-wash cycle, which acts as a first pass cleaning cycle. A separate
pumping/plumbing system is used to transfer the solution to the process tank. After
the cycle is finished the solution is pumped back into the drum, thereby limiting
“cross over” and increasing the life of the final Wash solution. See pg. 33 for
specifications and programming.
FILL PT (SET): The cleaning solution is transferred from the holding tank to the process tank.
ULTRASONICS PHASE:
(Optional)
This option allows for up to a maximum of 999.9 seconds of ultrasonics cleaning.
The solution present in the process tank is not recirculated through the IAC and is
not monitored for its resistivity. Ultrasonic frequencies are used to agitate tough to
clean contaminants. See pg. 67 for specifications and programming.
MIN. WASH TIME (ADJ.): The solution is recirculated in the minimum wash phase to clean the contaminants
from the parts and into solution. In this phase the Mega II does not recirculate
through the IAC and does not monitor the resistivity of the solution. This phase is a
timed function and provides agitation to remove contaminants from the parts.
Higher time settings may be required for baked-on flux while lower time settings
can be used for removal of finger oils and other contaminants that dissolve into
solution quickly.
SP PHASE - WASH (ADJ.): Resistivity is monitored in this phase, however, the fluid is not recirculated through
the IAC. The system looks for a minimum resistivity drop in the solution.
If, over a 10 second time period, the resistivity of the solution drops more than the
specified setting, the system remains in this mode and takes another sample over
the next 10 second time period. This indicates that removal of contaminants from
the parts into solution is still occurring. If the resistivity of the solution drops an
amount less than or equal to the specified setting, the cycle moves to the next
mode of operation. This indicates that removal of the contaminants from the parts
is almost complete. See Final Cleaning Cycle-Sequence of Events, page 16.
SP PHASE - CLEAN (ADJ.): Once the parts have been washed, the system then starts to clean the solution
through the IAC until it reaches the setpoint entered. The parts are now cleaned to
setpoint and the cycle progresses to the next phase.

12 Rev. 2.0 10/15/2005 Mega II Operating Manual
In all phases of the cleaning cycle, the top line of the OP display indicates which
phase the cycle is in as well as the setpoint (if any) of the phase. The bottom line
shows the status (time or resistivity).
TIMED WASH (ADJ.): As stated, the timed wash phase is a timed cycle; once the time elapses the phase
is complete. The system still monitors the resistivity of the solution. If the resistivity
is higher than the SP Clean setting, the solution is not recirculated through the IAC.
If below the setting it recirculates through the IAC. This process keeps the fluid at a
steady resistivity level, thereby controlling ever increasing resistivity levels when
longer timed wash settings are desired. If the setting for the timed phase is low,
then the resistivity may never reach setpoint because it is not cleaning to setpoint.
DRAIN PT (SET): Drains the solution from the process tank to the holding tank.
OPEN LOOP RINSE PHASE:
(Optional)
This option allows for a repeatable number of rinses. Both the timer and the
counter set the number of repeat rinse cycles. The rinse water in the process tank
is not recirculated through the IAC and is not monitored for its resistivity. After
recirculating through the process tank the used rinse water is pumped to drain and
the Dry phase is initiated.
DRY TIME (ADJ.): Air knives are turned on in this phase to dry the parts. If the hot vortex dryer option
is ordered and activated, the compressed air or nitrogen is heated, which dries the
parts quicker.
Caution: Many cleaning solutions take a long time to dry in ambient air.
COOL DOWN (SET): If the hot vortex dryer option is a part of the system, this phase is used to cool the
heater and air knife before the cycle is complete.
Table 1. Available Phases
Phase Explanation