AirVac DRS25 User manual

DRS25

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

DRS25 User’s Manual
Table of Contents
0025.00.902
Table of Contents
DRS25 User Manual
Part Number 0025.00.902
Rev 06.00
March, 2021
Chapter 1: Getting Started
Chapter 2: Installation
Chapter 3: Machine Function Verifications
Chapter 4: Process Development for Engineers
Chapter 5: Operator Training
Chapter 6: Software Overview
Chapter 7: Troubleshooting
Chapter 8: Schematics
Chapter 9: Maintenance/Diagrams

DRS25 User’s Manual
Table of Contents
0025.00.902

DRS25 User’s Guide
Chapter 1: Introduction/Getting Started
0025.00.902 1-1
1: Introduction/Getting Started
1 Introduction/Getting Started............................................................................................................................................ 3
1.0 Warranty - General..................................................................................................................................................... 4
1.1 Heater Limited Life Warranty .................................................................................................................................... 4
1.2 Material Check List .................................................................................................................................................... 5
1.3 Options........................................................................................................................................................................ 6
1.4 Safety........................................................................................................................................................................... 9

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Chapter 1: Introduction/Getting Started
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DRS25 User’s Guide
Chapter 1: Introduction/Getting Started
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1 Introduction/Getting Started
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/
[e-mail]

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1.0 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 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, with-
out 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 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 #.
1.1 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, with-
out 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 (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 conditions under which they are run. Higher tempera-
tures 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, 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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1.2 Material Check List
The following items are shipped with all DRS25 systems.
User Manual 0025.00.902
Calibration Components Part Number Use
Flow Meter FLM5 Verify flow settings
Flow Meter Hose 9001.15.036
Flow Meter Fitting 9001.00.013
Temperature Calibration Nozzle NCAL1 Verify temperature settings
Vision Alignment Nozzle N27EZ27 Verify vision alignment
Vision Alignment Board 9002.14.017
Vision Alignment Component (QFP) 9002.14.005
Allen Wrench Set (Metric) 9008.99.766 Adjust vision alignment
Force Weight 0032.14.091 Verify load cell setting
Training Components Part Number Use
Practice Board 9002.14.044
PBGA676 (2) 9002.14.056 27 x 27mm BGA
Thermocouples (2) 9002.12.047
Operator Components Part Number Use
Nozzle Handling Tool 1022.02.040 Nozzle load/unload
Nozzle Stand GNS1 Holds nozzles
O-Ring Assortment (Silicone) ORASST Nozzle o-rings
Board Support Set 0025.01.010 Supports flexible boards
(2-12”, 2-6”, 4-9”, 2-standalone)
Grounding Clip 9002.01.065 Grounding
Vacuum Probe Tubing (6’) 9001.15.018 Parts handling
By-Pass Probe 3CP100 Parts handling
Probe Tip 29A3 Parts handling
Silicone Cups VASST Parts handling/nozzle vacuum cup
Syringe (5cc) TS5LL/PP Apply flux
Needle TS5LL-1 Apply flux
Maintenance Part Number Use
Filter Element 0001.11.101 Site clean filter
Allen Wrench Set (American) 12055
Fuse, 10 amp (2) 9002.04.108
Fuse, 4 amp (2) 9002.04.033
Fuse, ½ amp (2) 9002.04.038
Fuse, 12 amp (2) 9002.04.055
Anti-Seize (1 oz) AS15 Lubricate
Filter Element F1AE Vacuum filter
Steel Brush STB7 Clean vacuum ports
Installation Part Number Use
Black Adhesive Mounts (2) 9002.18.013 Supports diffuser hose

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1.3 Options
1.3.1 Site Cleaning System (0029.03.012)
Objective
• Removal of residual site solder without damaging the pads or solder mask. Eliminates the need
for traditional solder iron/solder wick process and associated issues (ie. manual intervention, me-
chanical contact of pads).
How It Works:
• Hot gas reflows the residual solder on the pads.
• While viewing through the microscope, the operator
moves the board with the x/y adjustment wheels to
clean the pads on the site.
• A vacuum sensor continuously adjusts the height of
the composite vacuum tip to provide non-contact
site cleaning.
Notes Of Interest:
• Non-contact site cleaning is critical for lead-free re-
work due to the significantly higher temperature re-
quired to reflow the residual site solder.
• Small, medium and large composite vacuum tips
provided.
• Custom designs available for hard to access areas.
1.3.2 Pivoting IR Probe with Laser Pointer (1012.02.017)
Objective
• Provides process repeatability by insuring
that the board is at the exact same target
temperatures each time before localized re-
flow begins.
How It Works:
• Operator is instructed to position the laser
pointer at the beginning of the process.
• The non-contact temperature sensor moni-
tors topside board temperature and auto-
matically triggers the localized reflow pro-
cess once the target temperature is
reached.

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1.3.3 Universal Insertion Tool (AU6LGA47R)
• Mechanically self-centers any square or rectangular de-
vice for accurate pick up.
• Used in conjunction with component shuttle.
1.3.4 Paste-On-Device Micro Stencil Adapter (0024.24.111)
• Component-specific micro stencil applies solder paste
directly to the component spheres.
• Pasted device in stencil is placed in micro stencil
adapter, which is used in conjunction with the compo-
nent shuttle to pick the pasted device.
Notes Of Interest:
• Air-Vac does not supply the component-specific micro
stencils. Recommended supplier is Mini Micro Stencil
(760-591-3804).
• Micro stencil installed into adapter for direct pick from
shuttle.
1.3.5 Flux Dip Pedestals (FASET1)
• Stainless steel fluxing pedestals with precision-machined
depth provides controlled application of tacky flux directly to
the solder spheres on the device.
• Used in conjunction with the component shuttle.
Notes Of Interest:
• Various sizes and depths available.
Recommended depth is 50% of ball
height.

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1.3.6 Ergonomic Workstation with CPU Holder (1003.05.010)
Objective
• Provides a self-contained work cell environment for the machine and operator.
Features:
• 60”W x 36”D ultra-sturdy construction with anti-static laminate surface.
• Workstation includes CPU Holder.
Options:
• Monitor Stand (1003.05.005)
• Nozzle Stand (1003.05.006)
• Locking Drawer (1003.05.007)
1.3.7 Direct View HD Camera with HD Monitor (0025.03.016)
Objective
• Provides operator viewing of the site cleaning
process and placement/reflow.
How it works:
• Video is activated by operator.
Focus/zoom/lighting adjustments are made to
optimize clarity.

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1.4 Safety
The DRS25 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.
NOTE: When operating the AIR-VAC DRS25 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 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.
1.4.1 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 per-
sonnel.
Machine Operation
• Both the top and bottom heating elements can be programmed to reach high temperatures. Use
caution near heated surfaces including the nozzle and the bottom heater.
• Always use the gas nozzle handling tool when installing or removing nozzles.
• The nozzle and vision systems are powered by stepper motors and are programmed to move dur-
ing operation. 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
• 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 DRS25 safety features 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
DRS25 machine parts.
• Use original spare parts only.

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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.
Handling of Hazardous Solder and Flux Products
AIR-VAC does not supply the solder or flux products with the DRS25 system. The end user of the
DRS25 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 (1022.02.040)
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.
• Turn the nozzle locking jaws counter clockwise and the nozzle fingers will open to free the nozzle.
• 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.

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1.4.3 Label Description and Placement
The following metal placards are affixed to the DRS25 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.
Warning Label Description and Placement
The warning and hot surface labels found on the DRS25 system are
intended to prevent injury to the operators and users of the DRS25 system.
Warning HOT – the upper heater and diffuser plates of the system are required to reach temperatures
well above 100°C. Labels are found on the covers of each heated surface.
High power and static-sensitive warning labels advise personnel of potential issues when the machine
covers are opened.
AIR-VAC ENGINEERING COMPANY, INC.
SEYMOUR, CONNECTICUT 06483
•
U.S.A.
DRS25
Serial Number
Voltage 220 VAC +/- 5%, 50/60Hz, 30A
Air/Nitrogen Pressure 90-130 PSI
CAUTION – HOT SURFACE AVOID
CONTACT WITH DIFFUSER PLATE
CAUTION HIGH VOLTAGE
DISCONNECT POWER
BEFORE OPENING
CAUTION
CONTENTS SUBJECT TO DAMAGE BY
STATIC ELECTRICITY
DO NOT OPEN
EXCEPT AT APPROVED
STATIC-FREE WORK STATION

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1.4.4 DRS25 System Alarms
The following alarms to the DRS25 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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2: Installation
IMPORTANT! If the Optional Workstation has been purchased, please assemble it first using the
instructions in Section 2.1.
2 Installation.......................................................................................................................................................................... 3
2.0 Unpacking................................................................................................................................................................... 3
2.1 Facility Requirements................................................................................................................................................. 4
2.2 Pneumatic Connections: Top and Bottom Heater ...................................................................................................... 5
2.3 Electrical Connections................................................................................................................................................ 6
2.4 Powering Up the Machine/PC and Login .................................................................................................................. 8
2.5 Voltage Verification.................................................................................................................................................. 10
2.6 Pressure Verification ................................................................................................................................................ 13
2.7 Direct View Camera & Mount Assembly Installation (option) ................................................................................ 14
2.8 IR Sensor Installation (option) ................................................................................................................................. 15
2.9 Site Solder Removal System Installation .................................................................................................................. 16
2.10 Workstation Assembly............................................................................................................................................... 17

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