AirVac DRS27 User manual

DRS27

\\Avdata\assy instr\Work Instructions\Drs27\Shipping Instructions\Uncrating Drs 27 work Instruction 5-12-21.doc
1
Removing Drs 27 from crate
Product Line: Drs 27
Date: 9-10-20
Category: Shipping Crate
Distribution: WEB Work Instruction
1. Remove the front panel bolts and screws and the top panel bolts and remove panels
of the crate.
2. Remove all boxes from the crate.
3. Remove the shipping boards holding the bridge and side wings.
4. Remove the four bolts from the bottom two hold down boards.
5. Place two 2 x 4’s onto the two forks of the fork lift to lift the machine out of the crate.
Be aware of the power cord and the CPU holder when locating the forks under the
machine.
6. Lift the machine above the supports as shown before pulling machine from crate.
Do Not lift machine
here! Damage to the
machine will occur

DRS27 User’s Manual Table of Contents
0027.00.902
TABLE OF CONTENTS
0027.00.902
R08.00
Chapter 1: Introduction & Overview
Chapter 2: Unpacking, Installations & Facility Requirements
Chapter 3: Machine Function Verifications
Chapter 4: Software Overview
Chapter 5: Process Development Guide/Engineering Training
Chapter 6: Templates: Removal, Site Clean Replacement
Chapter 7: Operator Training
Chapter 8: Maintenance
Chapter 9: Schematics
Appendix

DRS27 User’s Manual Table of Contents
0027.00.902

DRS27 User’s Guide Chapter 1: Introduction/Overview
0027.00.902 1-1
1: Introduction/Overview
1Introduction/Overview.................................................................................................................. 3
1.0 GENERAL DESCRIPTION.................................................................................................................. 3
1.1 CONTACTS & SUPPORT ................................................................................................................. 3
1.2 WARRANTY - GENERAL .................................................................................................................. 4
1.3 HEATING ELEMENT LIMITED LIFE WARRANTY ..................................................................................... 4
1.4 SAFETY SYSTEM ........................................................................................................................... 5
1.4.1 GENERAL SAFETY ..................................................................................................................... 5
1.4.2 ADDITIONAL SAFETY PRECAUTIONS.............................................................................................. 6
1.4.3 LABEL DESCRIPTION AND PLACEMENT........................................................................................... 7
1.4.4 MACHINE WARNING LABELS ......................................................................................................... 7
1.4.5 DRS27 SYSTEM ALARMS .......................................................................................................... 9
1.5 MACHINE OVERVIEW.................................................................................................................... 10
1.5.1 FRONT PANEL CONTROLS......................................................................................................... 10
1.5.2 POWER START UP/POWER DOWN CONTROLS ............................................................................. 15
1.6 OPTIONS OVERVIEW .................................................................................................................... 16
1.6.1 SITE CLEANING SYSTEM (0029.03.012) .................................................................................... 16
1.6.2 PIVOTING IR PROBE WITH LASER POINTER (0029.11.043)........................................................... 16
1.6.3 DIRECT VIEW CAMERA ............................................................................................................. 17
1.6.4 UNIVERSAL INSERTION TOOL (AU6LGA47R)............................................................................... 17
1.6.5 PASTE-ON-DEVICE MICRO STENCIL ADAPTER (0024.24.111) ....................................................... 18
1.6.6 FLUX DIP PEDESTALS (PART NUMBER QUOTED PER DEVICE)............................................................. 18
1.6.7 FUME EXTRACTION MANIFOLD & HOSE ASSEMBLY (300.00.547) ................................................... 19

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DRS27 User’s Guide Chapter 1: Introduction/Overview
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1 Introduction/Overview
1.0 General Description
The DRS27 is a SMT Rework and Repair machine. It is designed to remove and replace surface mounted
and through-hole devices on printed circuit boards. This involves heating of the PCB using a radiant
panel type preheater located under the PCB and a hot gas heater / delivery system mounted over the
component to be reworked to provide heat to the component solder joints. A motorized Z (vertical) axis
and vision deployment system aid in reducing operator required activity and providing a level of process
control through partial automation.
1.1 Contacts & Support
Air-Vac is always willing to assist our customers with any technical or operating questions. If you have
any questions on machine parameters, correct nozzle requirements, options, procedures or mainte-
nance, please do not hesitate to call.
Air-Vac Engineering Company, Inc.
30 Progress Avenue, Seymour, CT 06483
Tel: [phone] - Fax: [phone]
http://www.air-vac-eng.com/
General Sales & Tooling Information: [email protected]
Technical Support: [email protected]
Download PDF of this manual: http://www.air-vac-eng.com/support.html
Web Support Documents: http://www.air-vac-eng.com/support.html

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1.2 Warranty - General
Air-Vac Engineering Company warrants its equipment for a period of one (1) year from date of shipment on
all parts, materials and labor costs required to repair the system except for component parts that are consid-
ered “wear and tear” items that are warranted for ninety (90) days. These include, but are not limited to,
heaters, belts, lights, vacuum cups and tubing.
Air-Vac agrees to repair or replace any or all such equipment that may prove to be defective within the war-
ranty period, without expense, excluding shipping to the owner. This warranty shall not apply to any products
that have been repaired or altered except by Air-Vac Engineering. Services under warranty shall not affect
an extension of the warranty period, nor will a new warranty period be granted for the parts, which were re-
placed/repaired. The title of the replaced parts will automatically pass to Air-Vac.
Air-Vac reserves the right to reject replacement under this warranty where, in the sole opinion of Air-Vac, the
defect is due to obvious misuse and/or improper maintenance of the module or any part thereof. The express
and/or implied warranty of Air-Vac is limited to the replacement and/or repair of any item defective in material
and/or workmanship. Other damages, if any, direct or consequential are expressly excluded from this war-
ranty.
Air-Vac shall be liable under this warranty only if 1) Air-Vac receives notice during the appropriate warranty
period (90 days or 1 year as applicable); 2) The products are operated in accordance with the supplied
documentation; and 3) Such products are, to Air-Vac’s satisfaction, determined to be defective.
When contacting Air-Vac for warranty inquiries, please provide the Order Number that the parts were
shipped, Model and Serial Number of the product and the Reason for Warranty. Products cannot be returned
to Air-Vac without authorization – please call for an RMA #.
1.3 Heating Element Limited Life Warranty
Air-Vac Engineering Company warrants the heating elements for a period of ninety (90) days from date of
shipment. Air-Vac agrees to repair or replace any or all such equipment that may prove to be defective within
the warranty period, without expense, excluding shipping to the owner. This warranty shall not apply to any
products that have been repaired or altered except by Air-Vac Engineering. Services under warranty shall not
affect an extension of the warranty period, nor will a new warranty period be granted for the parts, which
were replaced/repaired. The title of the replaced parts will automatically pass to Air-Vac.
Air-Vac reserves the right to reject replacement under this warranty where, in the sole opinion of Air-Vac, the
defect is due to obvious misuse and/or improper maintenance of the module or any part thereof.
Heating element life is affected by several factors, temperature, airflow, condition of in-
coming air (water and oil contamination) and overall process cycle. These products are
considered a “consumable” item. The length of useful service will vary based on the condi-
tions under which they are run. Higher temperatures and/or lower flows will cause short-
ened life.
The express and/or implied warranty of Air-Vac is limited to the replacement and/or repair of any item defec-
tive in material and/or workmanship. Other damages, if any, direct or consequential are expressly excluded
from this warranty.
Air-Vac shall be liable under this warranty only if 1) Air-Vac receives notice during the warranty period; 2) The
products are operated in accordance with the supplied documentation; and 3) Such products are, to Air-
Vac’s satisfaction, determined to be defective.
When contacting Air-Vac for warranty inquiries, please provide the Order Number that the parts were
shipped, Model and Serial Number of the product and the Reason for Warranty. Products cannot be returned
to Air-Vac without authorization – please call for an RMA #.

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1.4 Safety System
The DRS27 system was designed with safety of the operator in mind. The operation and maintenance
of the system must be performed cautiously due to the nature of the hot surfaces and the hazardous
chemicals involved in the assembly and rework of printed circuit cards.
DANGER
•SAFETY HAZARD. DO NOT modify this equipment, or disable or bypass safety interlocks. Such
actions may expose personnel to highly hazardous and possibly lethal conditions.
WARNING
•Only skilled and experienced Air-Vac Engineering trained personnel should perform service and
maintenance on this equipment.
•If toxic gases/chemicals are used with the equipment, the experienced personnel must also be
familiar with the applicable local, state and federal codes on handling such gases or chemicals
and be trained accordingly.
NOTE: When operating the AIR-VAC DRS27 system, follow all local codes for safe operation
of the machine. Disposal of materials used in the processing of Printed circuit boards must
be done in compliance with each Manufacturers recommendation in accordance with local
codes.
Other safety mechanisms include:
•A latching Emergency Off. This removes power from all machine functions and devices. The PC and
monitor will remain powered. To reset, rotate the EMO knob to unlatch. Turn the key switch all the
way to the right and release to restart. Restart the DRS27 software.
•Operator safety warning labels and markings are employed.
•Gas nozzle handling tools has been included and should be used when handling hot nozzles.
1.4.1 General Safety
Machines and tools of Air-Vac can only be used with maximum efficiency and safety by well trained
personnel. Do not attempt to operate or maintain this system without proper training from
qualified personnel.
Personnel
•Wear protective gloves when working with hot boards or gas nozzles. Solder can contain tin and
lead, which are hazardous materials.
•Use caution if wearing loose clothing while operating this machine as loose clothing can fall into the
work area. This is a fire hazard as well as an entanglement hazard in moving axis. Always secure
or remove loose clothing before operating this equipment.
•Never eat, drink, or smoke while working on or near the machine.
•Only trained operators and technicians should work on this equipment.
•Hot surfaces will cause severe burns. Use extreme caution when operating this equipment. Heat
resistant gloves are recommended particularly when handling hot components of the machine like
nozzles, circuit boards and during maintenance if hot surfaces are being handled.
•Report any problem to supervisor.

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Equipment
•Flux vapors result from soldering or desoldering. Fresh air must be provided. A venting system or
fume extraction system is recommended.
•Keep all covers on. Do not open machine covers unless you are at the Main Menu Screen for basic
maintenance, or to verify machine voltage (authorized personnel only).
•Keep hands clear of moving parts. Do not reach into the machine while it is moving.
•Do not override safety interlocks.
•Check area for any loose parts or tools that could cause mechanical interference.
•Do not place anything on the top of the machine.
•In the event of an emergency, press the Red Emergency Off button located on the front of the ma-
chine. Locate this Emergency Off button before operating this machine.
•Shut off electrical power and unplug machine when servicing any area of the machine.
•If a malfunction should arise, depress the Emergency Off button to stop operation.
•Wear protective gloves when working with hot boards or gas nozzles.
•Refer to material safety data sheet of solder, flux, or any other product used in conjunction with the
machine. Follow all warning labels and instructions.
•Follow proper handling and disposal instructions for the materials as supplied by their vendors.
Machine Operation
•Both the top and bottom heating elements can be programmed to reach high temperatures. Use cau-
tion near heated surfaces including the nozzle and the bottom heater.
•Hot surfaces are noted with labels but exposure to hazards is inevitable due to the nature of the
process. Do not touch hot surfaces. Proper training is essential. Contact Air-Vac for additional train-
ing sessions if required.
•Always use the gas nozzle handling tool when installing or removing nozzles.
•The nozzle and vision systems are powered by motors and are programmed to move during opera-
tion. Use caution near these two moving areas.
•Observe the legal and specific national regulations concerning accident prevention and protection of
the environment.
•Observe the general safety regulations concerning working with solder and flux. Fume extraction
should be seriously considered.
Maintenance (see Maintenance Chapter of Manual)
1.4.2 Additional Safety Precautions
•Upper heater housing protects the upper heating element - marked with hot label.
•Bottom heater plate surface can be hot – protective covers are marked with hot label.
•Flux vapors can be hazardous to operators - fume extraction should be employed.
•Flux liquid is flammable and hazardous to operator health and safety.
•Nozzle and vision motion can cause injury to the operator.
•Sound levels are below 70 dba levels except for use of the nozzle cold air bypass at 100% flow (75
dba) and the optional bottom spot heater at high flow (78 dba). These are intermittent items that can
be a small percentage of actual on time. If these are used they should be evaluated against local
regulation to determine if any additional noise protection is required.

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Handling of Hazardous Solder and Flux Products
AIR-VAC does not supply the solder or flux products with the DRS27 system. The end user of the
DRS27 system should follow proper handling and disposal instructions for the materials as supplied by
their vendors.
Nozzle Changeover: Safety Equipment Requirements
When changing out the part-specific gas nozzle, use the special nozzle removal tools (GNT1, GNT4 )
that are supplied in the tool kit of the system whenever handling a hot nozzle.
Removing a nozzle:
•Hold the hot nozzle with the nozzle removal tool and pull out of nozzle locking jaws.
•With the hot nozzle held firmly in the removal tool, place the nozzle in a container that can handle the
heat of the nozzle.
To install a nozzle, reverse the above procedure.
1.4.3 Label Description and Placement
The following metal placards are affixed to the DRS27 system: This label describes the electrical and air
requirements for the system. The overall system requirements can be found in the facilities section of
this manual.
1.4.4 Machine warning labels
Label
Indication
The Caution - Hot Surface labels found on the DRS27
system are intended to prevent injury to the operators
and users of the system. The top heater and prehea-
ter of the system are required to reach temperatures
well above 60°C. Labels are found on the covers of
each heated surface as well as next to heated sur-
faces.
Skin contact with these surfaces would result in a
burn reaction and therefore presents an inherent po-
tential thermal danger to the operators.
CAUTION – HOT SURFACE

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This label indicates hot surfaces well above 60 0C.
The hot gas head and the pre-heater are required to
reach temperatures well above 60 0C. Hot surface
warning labels are found on the covers of each such
heated surface as well as next to heated surfaces.
Skin contact with these surfaces would result in a
burn reaction and therefore presents an inherent po-
tential thermal danger to the operators.
This label indicates the presence of a Laser diode
module with a Class 2 Laser.
Do not stare into the beam. Direct viewing into the
beam or reflected beam can cause permanent eye
damage.
(Po = 1 mW, _ = 650 nm)
This label indicates the presence of an area that pre-
sents a pinch point hazard when motion occurs.
Keep hands and all objects clear of this area.
This label indicates there are static sensitive compo-
nents inside. Appropriate handling should be used.
High power warning labels advise personnel of poten-
tial shock issues when the machine covers are
opened.
CAUTION HIGH VOLTAGE
DISCONNECT POWER
BEFORE OPENING

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1.4.5 DRS27 System Alarms
The following alarms to the DRS27 system will halt the process until the problem has been corrected and
the alarm is cleared:
This alarm type occurs when one of the following conditions is detected:
Machine Hardware Alarms
* SerialPort_Failure
Z_Axis_Motor_Comm_Restart
Vision_Axis_Motor_Comm_Restart
Nozzle_TempControl_Comm_Restart
Left_Preheat_TempControl_Comm_Restart
Right_Preheat_TempControl_Comm_Restart
Center_Preheat_TempControl_Comm_Restart
DeviceIO_Communication_Restart
Low_Pressure_Air_Regulator
Low_Pressure_N2_Regulator
Process Alarms
Nozzle_Temperature_Limit,
Nozzle_TC_Error,
Left_Preheater_Temperature_Limit,
Left_Preheater_TC_Error,
Right_Preheater_Temperature_Limit,
Right_Preheater_TC_Error,
Center_Preheater_Temperature_Limit,
Center_Preheater_TC_Error,
Below_Minimum_Nozzle_Flow_Rate,
Nozzle_Flow_Sensor_In_Position_Failed,
Exceeded_Max_FootSwitch_Delay,
Exceeded_Max_TC_Control_Delay,
TC1_Not_Connected,
TC2_Not_Connected,
TC3_Not_Connected,
TC4_Not_Connected,
TC5_Not_Connected,
TC6_Not_Connected,
TC7_Not_Connected,
TC8_Not_Connected,
Site_Clean_Tool_Clogged
* Computer must be rebooted to clear.
The various alarms are explained in further detail in the Software section.

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1.5 Machine Overview
1.5.1 Front Panel Controls

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USB Port
Start Switch: Turns machine on/off
Power Light: Indicates machine is turned on
Lights: Turns external lights on/off
Ground
Upper Heater Flow Calibration Port

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E-Stop
Probe Vacuum Port
Ground
Joy Stick Control: Controls positioning of
x/y-axis, z-axis, theta, and zoom mode,
determined by select button.
Select: Sets joystick control of:
X/Y-axis: vision alignment camera con-
trol, corners, edge and center position-
ing
Z-axis: nozzle control, up, down posi-
tioning
Theta: nozzle control, clockwise,
counterclockwise positioning
Zoom: vision alignment camera magnifi-
cation control
Rapid: Used to select rapid function
of joystick. Default=off. When
pressed, joystick pilot light will be
blinking.
Joy Stick Pilot Light:
Off - Indicates joy stick is not active
On - Indicates joy stick is active\
Blinking – Indicates Rapid function is activated

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Teach:
Inactive
Nozzle Vacuum: On/Off
Inactive
Z Axis: Indicates joy stick control of z-axis
Zoom alignment
camera (vision):
Indicates joy stick
control of camera
zoom
Theta (Nozzle): Indicates joy stick
control of nozzle rotation.

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Nozzle Y-Axis Adjustment
Nozzle X-Axis Adjustment
Nozzle XY Axis Lock