AirVac PCBRM15 User manual

PCBRM15 &
PCBRM System 5.2

Customer: Date:
Machine Type:
Address:
Serial Number:
Contacts:
Phone: E-mail/Fax:
Phone: E-mail/Fax:
Phone: E-mail/Fax:
This is to certify that the Air-Vac Representative __________________________________ has installed the
above machine and that all items have been received or are noted below. The machine is in good working order,
and initial training was provided.
Customer Signature/Date:
Air-Vac Representative Signature/Date:
Issues:
Items Missing:
Please fax this completed document to:
Air-Vac Engineering [phone], Attn: Brian Czaplicki
AIR-VAC ENGINEERING COMPANY, INC.
INSTALLATION AND TRAINING

PCBRM15 & PCBRM System 5.2 User’s Manual Table of Contents
4005.00.906
Table of Contents
Part Number 4005.00.906
Rev 08.00
September 2022
Chapter 1: Introduction & General Overview
Chapter 2: Requirements & Machine Overview
Chapter 3: Set Up & Installation
Chapter 4: Processes & Applications
Chapter 5: Maintenance & Parts
Chapter 6: Troubleshooting
Chapter 7: Schematics

PCBRM15 & PCBRM System 5.2 User’s Manual Table of Contents
4005.00.906

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 1: Introduction/Overview
Part No. 4005.00.906 1-1
1: Introduction/Overview
1 Introduction/Overview ....................................................................................................................3
1.0 Welcome...........................................................................................................................................................3
1.1 PCBRM15 and PCBRM System 5.2 Overview...........................................................................................3
1.2 Contacts & Support........................................................................................................................................3
1.3 Warranty..........................................................................................................................................................4
1.4 Material Check List - PCBRM15 .................................................................................................................5
1.5 Material Check List - PCBRM System 5.2..................................................................................................6
1.6 Unpacking - PCBRM15 .................................................................................................................................7
1.7 Unpacking - PCBRM System 5.2..................................................................................................................8

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 1: Introduction/Overview
Part No. 4005.00.906 1-2

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 1: Introduction/Overview
Part No. 4005.00.906 1-3
1 Introduction/Overview
1.0 Welcome
Please read this User’s Guide carefully before initial set-up of the PCBRM15 or PCBRM System 5.2 to
insure the optimal start-up and maintenance of the equipment. This User’s Guide has been compiled in
accordance with ISO 9000 and the EC machine guideline regulations. It contains all information and
instructions that are necessary for safe and trouble-free operation of the PCBRM15 and PCBRM
System 5.2. Considerable time has been spent in an attempt to provide in-depth instructions in regards
to the unpacking, installation, verification, operation and maintenance of these systems.
1.1 PCBRM15 and PCBRM System 5.2 Overview
The PCBRM15 and PCBRM System 5.2 machines provide lead-free selective soldering and rework of
through-hole components and thermally challenging assemblies The PCBRM System 5.2 adds a 6500
watt preheater.
1.2 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
maintenance, 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 and Technical Support: [e-mail]

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 1: Introduction/Overview
Part No. 4005.00.906 1-4
1.3 Warranty
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 considered
“wear and tear” items which 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 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 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 following information:
Order number which the parts were shipped
Model and serial number of the product
Reason for warranty
Products cannot be returned to Air-Vac without authorization – please call for an RMA #.

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 1: Introduction/Overview
Part No. 4005.00.906 1-5
1.4 Material Check List - PCBRM15
The following ‘Machine Section’ is a checklist of items shipped with all PCBRM15 units.
MACHINE TOOL KIT - 12050 SERIAL NUMBER#
DESCRIPTION
QUANTITY
PART NUMBER
CHECK
Ö
Sleeve Baffle
1
2004.01.102
Extractor Tool
1
EX-2
Set of fuses (packed in small plastic case):
- 15 amp
- 1/2 amp
- 3/4 amp
- 3/10 amp
1
2
2
2
2
9002.04.043
9002.04.038
9002.04.035
9002.04.040
5/32” Tee Handle Allen Wrench
1
12050B
1/4” Spintite Sprocket Wrench
1
12050A
Graphite Anti-Sieze
1
AS15
Bubble Level
1
12015
Allen Wrench Set
1
12055
3mm Allen Wrench
1
12050L
MACHINE ACCESSORIES
DESCRIPTION
QUANTITY
PART NUMBER
CHECK
Ö
Footswitch
1
12870
Bailer
1
SL5
Pot Cover
1
2004.01.108
Manual
1
2004.00.900
Ladel
1
9008.99.315
Spatula
1
9008.99.314
Gloves (pair)
1
12050M
SPARE PARTS
DESCRIPTION
QUANTITY
PART NUMBER
CHECK
Ö
Sleeve Baffle
1
2004.01.102
Pump Assembly
1
2004.01.040
Drive Belt (Hi Temp)
1
12467
Pump Bearings (set of 2)
1
9001.09.020
Thermocouple & Fitting (Process Temp.)
1
12801
Thermocouple & Fitting (Over Temp.)
1
12802
Temperature Controller (Process)
1
12860
Cycle Controller Board
1
12862
Solid State Relay, Pot
1
12865

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 1: Introduction/Overview
Part No. 4005.00.906 1-6
1.5 Material Check List - PCBRM System 5.2
The following ‘Machine Section’ is a checklist of items shipped with all PCBRM Systems.
MACHINE TOOL KIT - 12050 SERIAL NUMBER#
DESCRIPTION
QUANTITY
PART NUMBER
CHECK
Ö
Sleeve Baffle
1
12011
Extractor Tool
1
EX-2
Set of fuses (packed in small plastic case):
- 15 amp
- 1/2 amp
- 3/4 amp
- 3/10 amp
1
2
2
2
2
9002.04.043
9002.04.038
9002.04.035
9002.04.040
5/32” Tee Handle Allen Wrench
1
12050B
1/4” Spintite Sprocket Wrench
1
12050A
Graphite Anti-Sieze
1
AS15
Bubble Level
1
12015
Allen Wrench Set
1
12055
3mm Allen Wrench
1
12050L
Spatula
1
9008.99.314
MACHINE ACCESSORIES
DESCRIPTION
QUANTITY
PART NUMBER
CHECK
Ö
Footswitch
1
12870
Bailer
1
SL5
Pot Cover
1
12590
Manual
1
3006.00.903
Ladel
1
9008.99.315
Gloves (pair)
1
12050M
SPARE PARTS
DESCRIPTION
QUANTITY
PART NUMBER
CHECK
Ö
Sleeve Baffle
1
12011
Pump Assembly
1
12401
Drive Belt (Hi Temp)
1
12467
Pump Bearings (set of 2)
1
9001.09.020
Thermocouple & Fitting (Process Temp.)
1
12801
Temperature Controller (Process)
1
12802
Cycle Controller Board
1
12862
Solid State Relay, Pot
1
12865

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 1: Introduction/Overview
Part No. 4005.00.906 1-7
1.6 Unpacking - PCBRM15
Shipping Weight: - 170 lbs.
Shipping Dimensions (W x D x H): - 43” x 34” x 30”
IMPORTANT!!
DO NOT LIFT OR PULL HERE AT POINTS INDICATED,
DAMAGE TO SYSTEM MAY RESULT.
−Position module on a level surface which can provide adequate support for weight.
−Accessories are normally shipped in box with module. Please inspect carefully and check that
all items have been shipped.
−Save shipping box for any future shipping.
X
X
X

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 1: Introduction/Overview
Part No. 4005.00.906 1-8
1.7 Unpacking - PCBRM System 5.2
Shipping Weight: - 250 lbs.
Shipping Dimensions (W x D x H): - 67” x 35” x 52”
IMPORTANT!!
SUPPORT MUST BE PROVIDED IN CENTER. BASE PLATE WILL BEND. LIFT MACHINE WITH A
FORK LIFT AS SHOWN.
DO NOT LIFT OR PULL HERE.
DAMAGE TO SYSTEM MAY RESULT.
−Position module on a level surface which can provide adequate support for weight.
−Accessories are normally shipped in box with module. Please inspect carefully and check that
all items have been shipped.
−Save shipping box for any future shipping.
Lift Here
With Fork Lift
X
X
X
X
X
Fork
Fork
support

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 2: Requirements/Machine Overview
Part No. 4005.00.906 2-1
2: Requirements/Machine Overview
2 Requirements/Machine Overview ...................................................................................................3
2.1 Facility Requirements - PCBRM15..............................................................................................................3
2.2 Facility Requirements - PCBRM System 5.2 ..............................................................................................3
2.3 PCBRM15 - Module Overview .....................................................................................................................4
2.4 PCBRM15 and System 5.2 - Control Panel Overview ...............................................................................5
2.5 PCBRM15 - Carrier Overview .....................................................................................................................7
2.6 PCBRM System 5.2 – System Overview ......................................................................................................8
2.7 PCBRM System 5.2 PCB Carrier Overview.............................................................................................11

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 2: Requirements/Machine Overview
Part No. 4005.00.906 2-2

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 2: Requirements/Machine Overview
Part No. 4005.00.906 2-3
2 Requirements/Machine Overview
2.1 Facility Requirements - PCBRM15
•Physical Dimensions: 32”W x 26”D x 26”H
•Maximum Board Size: 22”W x 21”D
•Weight: 125 lbs. (with solder), 90 lbs. (without solder)
•Electrical Requirements:
- Machine (PCBRM15): 208/220VAC, 13 Amps, 50/60 Hz, Single Phase.
Plug = 15 Amp, 250VAC, Nema 6-15P.
- Heater Box (optional): 110/120VAC, 4 Amps, 50/60 Hz, Single Phase.
(PCBRM15)
- Machine (PCBRM15.Z): 208/220VAC, 13 Amps, 50/60Hz, Single Phase.
Plug = Continental Europe 16 Amp
- Heater Box (optional): 208/220VAC, 2 Amps, 50/60Hz, Single Phase
(PCBRM15.Z)
•Compressed Air (optional): 40-80 psi, 2 scfm, clean, moisture-free air (intermittent),
1/8 NPT(M) fitting required.
2.2 Facility Requirements - PCBRM System 5.2
•Max Operating Dimensions: 76”W x 38”D x 28”H
•Weight: 230 lbs. (with solder), 195 lbs. (without solder)
•Electrical Requirements:
- Machine (System 5.2) 208/220 Vac, 45 Amps-full load (overload protected to 55 Amps),
50/60 Hz, single phase, 6 awg 3 wire cord supplied.
- Heater Box (optional): 120 Vac, 4 amps, 50/60 Hz, single phase.
(System 5.2)
- Machine (System 5.2.Z) 208/220 Vac, 15 Amps-full load (overload protected to 20 Amps),
50/60 Hz, 3 phase, 2.5mm2x 5 wire cord provided.
- Heater Box (standard): 220 Vac, integral with machine power
(System 5.2.Z)
•Compressed Air (optional): 40-80 psi, 2 scfm, clean, moisture-free air (intermittent),
1/8 NPT(M) fitting required.
Miscellaneous
•35 lbs. of solder
•Level work area.
•Venting is recommended.

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 2: Requirements/Machine Overview
Part No. 4005.00.906 2-4
(I) - option
(J)
(C)
(D)
(A)
(H) - option
(B)
(F)
(G)
(B)
2.3 PCBRM15 - Module Overview
(A) X-Axis Carrier Rail - Cantilever carrier rail adjusts to hold PCB up to 22”W.
(B) PCB Carrier Arms - Carrier arms hold PCB up to 21” deep. PCB Stops with reference scale
provides one time set-up of repetitive assemblies.
(C) X-Axis Carrier Lock - Once PCB is aligned over flow well, the carrier is locked in place.
(D) Z-Axis Height Adjustment - Adjusts height of PCB in relation to the flow well.
(F) Solder Pot
(G) Solder Pump
(H) APS System- Blows low pressure air through holes in PCB of removed component to clear them of
solder.
(I) APS System Air Regulator – Sets air pressure.
(J) Emergency Stop – Shuts system down immediately if required.

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 2: Requirements/Machine Overview
Part No. 4005.00.906 2-5
(L)
(M)
(K)
(C)
(E)
(F)
(G)
(I)
(J)
(B)
(A)
(Q)
(P)
(R)
(O)
(N)- option
(Q)
(H)
(D)
2.4 PCBRM15 and System 5.2 - Control Panel Overview
(A) Digital Temperature Controller - Microprocessor provides two programmable set points: Process
Temperature and Standby/Interlock Temperature. Digital readout of actual temperature is accurate
within +/-1% of full scale. (Thermocouple is located at bottom of solder pot).
(B) Solder Flow Rate Control – Process flow rate can be varied and controlled during the duration
cycle. There are three Solder Flow Rate Controls: Ramp Up, Process, and Ramp Down. The Flow Rate
Control adjusts the pumping speed of the solder to produce a level flowing wave through the Flow Well.
Too low of speed will not pump the solder against the pcb contacting all the component leads. Too high
a setting will cause solder to flood the board surface.
(C) Solder Duration Control – The length of the time solder flows in one cycle can be set. The
process cycle can be started by either depressing the START ON the Footswitch or pressing the
CYCLE Start-switch.
•(D) Mode Switch - Automatic Mode – With the Timer Switch in the Automatic Mode, specific
timing logic is available up to 60 seconds and is adjusted and set by the Duration Control. The
settings between 1 and 5 give the range used for most applications. If the cycle needs to be
interrupted, pressing the STOP ON of the Footswitch will stop the cycle.
•(D) Mode Switch - Continuous Mode – With the Mode Switch in Continuous, the Duration
Control Logic and Cycle Start Switch are now by-passed. Solder will flow until the STOP pedal
is depressed. Solder flow will not resume until the STOP pedal is released. The Continuous
Mode is operator controlled.
Note:
THE CENTER POSITION OF THE MODE SWITCH (D) IS “OFF”.

PCBRM15 & PCBRM System 5.2 User’s Manual Chapter 2: Requirements/Machine Overview
Part No. 4005.00.906 2-6
(L)
(M)
(K)
(C)
(E)
(F)
(G)
(I)
(J)
(B)
(A)
(Q)
(P)
(R)
(O)
(N)- option
(Q)
(H)
(D)
(E) Main Power Switch – ON/OFF provides electrical power to the systems.
(F) Relatch Switch – Resets Main Power after unit is turned off or Emergency stopped.
(G) White Light – Indicates Main Power is on.
(H) Transformer Breakdown Light – Indicates failure of transformer coil isolation.
(I) Green Light – Indicates solder is molten and the machine is ready to cycle.
(J) Cycle Switch – Activates the Cycle Duration with Mode Switch in Automatic Mode.
(K) Temperature Controller – Controls temperature of solder.
(L) Ramp Up Flow Rate - Adjusts motor start speed of the pump, either quickly or slowly. To increase
ramp time, turn knob counter-clockwise. To decrease, turn clockwise.
(M) Ramp Down Flow Rate - Adjusts motor stop speed of the pump, either quickly or slowly. This can
help to produce a better solder joint. To increase ramp time, turn the knob counter-clockwise, to
decrease turn clockwise.
Note:
FLOW RATE INFLUENCES THE TOTAL DURATION/PROCESS CYCLE. RAMP DOWN FLOW RATE
INFLUENCES THE TIME WHEN THE AIR IS ACTIVATED FOR THE AIR CLEANING SYSTEM (APS
OPTION). FOR SOLDERING, SET RAMP DOWN TO "0". FOR DESOLDERING, SET TO "10".
(N) Flow Well Heater Box (option) – When external heaters are required for heating large flow wells.
(O) Heater Control Right (high/low) – Adjusts right flow well heater from low to high temp.
(P) Heater Control Left (high/low) – Adjusts left flow well heater from low to high temp.
(Q) Left & Right Plugs – Plug heater for flow wells here.
(R) ON/OFF Switch