AirVac PCBRM100 User manual

PCBRM100

PCBRM100 User’s Guide
4101.00.902
TABLE OF CONTENTS
Part Number 4101.00.902
Rev 02.00
9-10-2014
Chapter 1: Introduction/Overview
Chapter 2: Facility Requirements
Chapter 3: Start Up
Chapter 4: Software Overview
Chapter 5: Process Development
Chapter 6: Maintenance
Chapter 7: Error Messages
Chapter 8: Schematics

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PCBRM100 User’s Guide Chapter 1: Introduction/Overview
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1: Introduction/Overview
1Introduction/Overview.................................................................................................................. 3
1.0 CONTACTS & SUPPORT ................................................................................................................. 3
1.1 WARRANTY - GENERAL .................................................................................................................. 4
1.2 HEATER LIMITED LIFE WARRANTY .................................................................................................... 4
1.3 SAFETY SYSTEM ........................................................................................................................... 5
1.3.1 SAFETY INSTRUCTIONS & RECOMMENDATIONS .............................................................................. 5
1.3.2 ADDITIONAL SAFETY PRECAUTIONS.............................................................................................. 7
1.3.3 LABEL DESCRIPTION AND PLACEMENT........................................................................................... 8
1.3.4 MACHINE WARNING LABELS ......................................................................................................... 9
1.3.5 WARNING LABEL PLACEMENT .................................................................................................... 11

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1 Introduction/Overview
1.0 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]

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1.1 Warranty - General
Air-Vac Engineering Company warrants its equipment for a period of one (1) year from date of shipment on all parts and-
materials required to repair the system except for component parts that are considered “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 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. The express and/or implied war-
ranty 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 warranty.
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 #.
1.2 Heater Limited Life Warranty
Air-Vac Engineering Company warrants the heaters 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 incoming air (wa-
ter and oil contamination) and overall process cycle. These products are considered a “consumable”
item. The length of useful service will vary based on the conditions under which they are run. Higher
temperatures and/or lower flows will cause shortened life.
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 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, deter-
mined 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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1.3 Safety System
The PCBRM100 system was designed with safety of the operator in mind. The operation and mainte-
nance of the system must be performed cautiously due to the nature of the hot surfaces, flux and mol-
ten solder involved in the assembly and rework of printed circuit cards.
NOTE:
WHEN OPERATING THE AIR-VAC PCBRM100 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 RECOM-
MENDATION IN ACCORDANCE WITH LOCAL CODES.
Other safety mechanisms include:
•A latching E-stop.
•Operator safety warning labels and markings are employed.
•Gas nozzle handling tools has been included and should be used when handling hot nozzles.
1.3.1 Safety Instructions & Recommendations
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.
Machine Operation
•All heated areas can be programmed to reach high temperatures. Use caution near heated surfaces
including the nozzle, solder pot and the pre-heater.
•Always use the gas nozzle handling tool when installing or removing nozzles.
•The solder pot, head, carrier and preheater systems are powered and are programmed to move
during operation. Use caution near these moving mechanisms.
•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.
CAUTION:
OPERATION OF THIS MODULE INVOLVES PUMPING OF MOLTEN SOLDER. ALL NORMAL SAFETY
PRACTICES MUST BE OBSERVED.
Personnel
•Safety glasses should be worn at all times. Wear protective gloves when working with solder.
Solder contains tin and lead, which are hazardous materials.
•Place any waste solder or dross in a heat resistant dross container.
•Always wash hands after working with solder.
•Use caution if wearing loose clothing while operating this machine as loose clothing can fall into
the molten solder. Always secure loose clothing before operating this equipment.
•Never eat, drink, or smoke while working on or near the machine.

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•Only trained operators and technicians should work on this equipment.
•Molten solder will cause severe burns. Use extreme caution when operating this equipment. Heat
resistant gloves are recommended particularly when placing and removing Flow Wells, removing
dross, adding solder or removal solder and during maintenance.
•Report any problem to supervisor.
Equipment
•Flow Wells must heat soak on pump housing before attempting to flow solder. Failure to heat
soak Flow Well can cause solder to solidify in the Flow Well openings.
•Flux vapors result from soldering or desoldering. Fresh air must be provided. A venting system
or fume extraction system is recommended.
•Slowly increase flow rate to reach proper flow for the flow well. Do not increase flow rate if
opening solidifies. Allow flow well to heat soak slowly.
•Do not allow solder to flow outside the confines of the solder pot.
•Do not cool flow well with liquid (water). Use only ambient air environment to cool flow well.
•During operation do not allow PCB to seal against flow well.
•Keep all covers on. Do not open machine covers unless you are at the Main Menu Screen for
basic maintenance.
•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 Stop button located on the front of the
machine. Locate this Emergency Stop 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 Stop button to stop operation.
•The machine should not be operated unless the flow well is in place.
•Heat resistant gloves should be worn when placing and removing flow wells, removing dross,
and adding or removing solder.
•The machine should not be moved when the solder is molten.
•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.
Maintenance
•Only qualified personnel are allowed to work on the machine.
•As a basic rule, disconnect the main 220 Vac power before servicing the machine or when the ma-
chine is taken off line.
•Only use the tools for their defined purpose.
•Never remove or disable any safety feature or software.
•Make sure that all electrical devices are leakage current protected and are stored and used in dry,
dust-free surroundings.
•The machine contains static sensitive devices. Use caution to avoid static discharge when handling
machine parts.
•Use original spare parts only.

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1.3.2 Additional Safety Precautions
•Upper heater housing protects the upper heating element - marked with hot label.
•Preheater surfaces 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.
•Pot, carrier, head and preheater motion can cause injury to the operator.
Handling of Hazardous Solder and Flux Products
AIR-VAC does not supply the solder or flux products with the PCBRM100 system. The end user of the
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 (ie. GNS1 Nozzle Stand).
To install a nozzle, reverse the above procedure.

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1.3.3 Label Description and Placement
The following placards are affixed to the PCBRM100 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. It is located over the main disconnect switch on the
right side of the machine.
Air-Vac Engineering
Seymour, CT 06483 USA
Part No:
Serial No:
Mfg Dt:
Power:
V
A ø
Hz
Air:
PSI

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1.3.4 Machine warning labels
Label
Indication
The Caution - Hot Surface labels found on the
PCBRM100 system are intended to prevent injury to
the operators and users of the system. The solder
pot, top heater and preheater of the system are re-
quired to reach temperatures well above 60°C. Labels
are found on the covers of each 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 hot surfaces well above 60 0C.
The Solder pot, 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 electrical equip-
ment with voltages above 60 Volt.
Labels are found beside all removable covers where
electrical equipment is mounted and it is used to indi-
cate a possible shock hazard.
This label indicates the presence of a Laser diode
module with Laser class 3R.
Do not stare into the beam. Direct viewing into the
beam or reflected beam can cause permanent eye
damage.
(Po = 5 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.
High power warning labels advise personnel of poten-
tial shock issues when the machine covers are
opened.
CAUTION HIGH VOLTAGE
DISCONNECT POWER
BEFORE OPENING
CAUTION – HOT SURFACE

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Warns the user that dangerous conditions (pinch
point or crushing) exist with the machine covers re-
moved. Do not operate the machine with covers re-
moved. These are visible if a cover is removed.

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1.3.5 Warning Label Placement
Inside Cover Locations (hidden normally)
Pinch Point, Hot Surface and High Voltage
Front of Machine

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Left Side

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Center
Right Side

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Rear

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