Bravo 8105 User manual

Bravo 8105®
CONVECTION REFLOW SYSTEM
INSTALLATION GUIDE
Technical Manual P/N 111–00–0
Installation Manual P/N 3–9317–370–00–0

Bravo™ 8105 Installation Guide

2-9317-370-00-0 Bravo™ 8105 Installation Guide iii
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Preface
Overview
In this section This preface covers the following information:
Topic See Page
To Our Customers iv
Customer Support Structure vii
Before You Call viii

PREFACE
To Our Customers
iv Bravo™ 8105 Installation Guide Rev. 2
To Our Customers
This Guide The purpose of this guide is to help the customer obtain the greatest return on
investment. Speedline suggests that operators, supervisors, and technicians
responsible for operating and maintaining this equipment become familiar with the
contents of these Guides prior to using the equipment.
This Technical Manual includes safety information, a machine overview, an
applications overview, program development instructions, standard operating
instructions, advanced operating instructions, process troubleshooting, scheduled
maintenance overview, and a list of error messages and audible alarms with
solutions.
Other Guides
in the Set The following list of guides make up the entire information set:
†Not yet released
Guide Name Part Number
Bravo™ 8105 Installation Guide 3-9317-370-00-0
Bravo™ 8105 General Information Guide† 3-9317-371-00-0
Bravo™ 8105 Programming and Operations Guide 3-9317-372-00-0
Bravo™ 8105 Preventive Maintenance Guide 3-9317-373-00-0
Bravo™ 8105 Repair Guide† 3-9317-374-00-0
Bravo™ 8105 Options Guide† 3-9317-375-00-0
Bravo™ 8105 Drawings† 3-9317-376-00-0

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PREFACE
Customer Support Structure
2-9317-370-00-0 Bravo™ 8105 Installation Guide v
Customer Support Structure
Introduction Speedline has a number of offices throughout the world ready to support your
needs:
• Main Offices
• Regional Service Centers (USA)
• International Service Centers
Main Offices Office Location
Speedline Technologies, Inc.
Electrovert Main Sales and
Service Office
Technical Service Support Group
P.O. Box 709, Hwy. 5 South
Camdenton, MO 65020-0709
Fax: [phone]
Tel: [phone]
or call Toll Free @ Tel: [phone]
e-mail:
[e-mail]
Speedline Distribution Center Parts Sales
1605 Dundee
Elgin, IL 60120
Fax: [phone]
Local Tel: [phone]
Toll Free: 1-800-737-8110
Cookson Performance Solutions Training Center
580-A Tollgate Rd.
Elgin, IL 60123
Fax: [phone]
Local Tel: [phone]
Toll Free: 1-800-737-8110

PREFACE
Customer Support Structure
vi Bravo™ 8105 Installation Guide Rev. 2
Regional Service
Centers (USA) The following Service Centers are located throughout the United States:
Office Location
North East Regional Service
Center 472 Amherst St. Suite 6
Nashua, NH 03063
Fax:[phone]
Phone: [phone]
South East Regional Service
Center 1055 Windward Ridge Pkwy., Suite 140
Alpharetta, GA 30005
Fax: [phone]
Phone: [phone] ext. 16
North Central Regional Service
Center 580-A Tolllgate Road
Elgin, IL 60123
Fax: [phone]
Phone: [phone]
North West Regional Service
Center 2968 Scott Blvd.
Santa Clara, CA 95054
Fax:[phone]
Phone: [phone]
South West Regional Service
Center 1111 W. North Carrier Parkway
Grand Prairie, TX 75050
Fax:[phone]
Phone: [phone]

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PREFACE
Customer Support Structure
2-9317-370-00-0 Bravo™ 8105 Installation Guide vii
International
Service Centers The following centers serve the international community:
Office Location
Speedline Technologies, LTD Unit 1
Pincents Kiln Industrial Park
Reading Bershire RG317SD
Fax: [phone]
Phone: [phone]
Speedline Technologies, Gmbh Daimlerstrasse 1E
63303 Dreieich
Germany
Fax: [phone]
Phone: [phone]
Speedline Technologies, Italy Via Liguria 2/28
I-20068 Peschiera Borromeo (MI)
Italy
Fax: 39-2 - 5530. 8468
Phone: [phone]
Speedline Technologies, Singapore 150 Kampong Ampat
KA Centre # 05-08
Singapore 368324
Fax: [phone]
Phone: [phone]
Speedline Technologies, Taiwan 1F, No. 11 Ching Kuo Road
Taoyuan
Taiwan, ROC
Fax: [phone]
Phone: [phone]
Speedline Technologies, Mexico Carretera a Base Aerea Militar
KM.5 No - 5850 Edificio #11
Zapopan, Jalixco C.P.
45100 MEX
Fax: [phone]
Phone: [phone]

PREFACE
Before You Call
viii Bravo™ 8105 Installation Guide Rev. 2
Before You Call
Introduction To help Electrovert support your machine in a timely fashion, have the following
specific information available when calling in:
• System Software Version
• Serial Tag Information
Machine Serial Tag The machine serial tag is located on side of the rear electrical panel. It provides
important information that will be helpful in servicing your machine.

2-9317-370-00-0 Bravo™ 8105 Installation Guide 1
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Table of Contents
Preface
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
To Our Customers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Customer Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Before You Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Chapter 1. Safety Information
Hot Surface Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fire and Smoke Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mechanical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Breathing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inerting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Other Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lock-Out Tag-Out
Attach Facility Lock-Out Tag-Out Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Attach Machine Lock-Out Tag-Out Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Perform Required Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remove Lock-Out Tag Out Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 2. Bravo™ 8105 Machine Installation
Bravo™ 8105 Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Before Uncrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Crate and System Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Packing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installing Leveling Feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Location Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspection at Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Height and Leveling Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install Computer and Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Facility Utility Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Nitrogen Machine Option — Turn Nitrogen On. . . . . . . . . . . . . . . . . . . . . . . . . . 39

TABLE OF CONTENTS
2 Bravo™ 8105 Installation Guide Rev. 2
Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Facility Power Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Verification of Options in Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Doors, Panels and Hood Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Exhaust Setup and Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Conveyor Operation and Speed Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Photocell Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Blower Operation Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Test Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Nitrogen Machine Option — Verify Coolant Flow . . . . . . . . . . . . . . . . . . . . . . . . 68
Appendix A: Index

2-9317-370-00-0 Bravo™ 8105 Installation Guide 1-1
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Safety Information
Overview
Introduction Operation of this equipment exposes personnel to potential health and safety
hazards. Refer to the following information to ensure a safe operating
environment for machines and personnel.
Safety To ensure personal safety and avoid equipment damage, observe the following:
ATTENTION
The information provided in the safety section of this document is not intended to
supersede rules and regulations governing health and safety in the local area or at
the installation site. Whenever there is a conflict between the information in this
section and local information, the local rules and practices govern.
In this chapter This chapter consists of the following:
Topic Section
Potential Hazards A
Safety Precautions B
Lock-Out Tag-Out C

SAFETY INFORMATION
1-2 Bravo™ 8105 Installation Guide Rev. 2
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Section A: Potential Hazards
Overview
Introduction This section describes various hazards the operator may encounter while
operating an Bravo™ System. This section also describes warning tags installed
on the system and ways to avoid the hazards encountered.
In this section Refer to the following hazard descriptions
Topic See Page
Hot Surface Hazards 1 – 3
Flammable Hazards 1 – 4
Electrical Hazards 1 – 5
Mechanical Hazards 1 – 6
Breathing Hazards 1 – 7
Inerting Hazards 1 – 8
Other Hazards 1 – 9

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SAFETY INFORMATION
Hot Surface Hazards
2-9317-370-00-0 Bravo™ 8105 Installation Guide 1-3
Hot Surface Hazards
Introduction During normal operation, some components of this equipment operate at
temperatures up to 300 °C (572 °F). The operator must use extreme caution and
wear the recommended safety garments prior to coming in contact with hot
surfaces or components. Closely follow and adhere to the warnings in this
document which pertain to hot surfaces.
Safety To ensure personal safety and avoid equipment damage, observe the following:
Hot Surface
The conveyor, conveyor rails, rail guards and boards moving through the system
are burn hazards and can cause severe skin burns.The heat–exposed surfaces of
the system (rails, conveyor surfaces, etc.) can become very hot.
Hot Surface
Use extreme caution when working around or with hot components. Allow hot
components to cool before handling whenever possible. Always wear heat
resistant gloves and protective clothing on or around the active system. Do not
touch the cover of the system or handle finished boards without wearing
protective gloves. Allow time for the system to cool prior to servicing. If
operations require working on any part of the system while it is still hot,
protective clothing is required. If in doubt whether something is hot or not,
assume it is hot and take the necessary steps to avoid a burn hazard. Never place
any foreign materials on the machine.
Photograph The following Photograph shows the hot surface warning tag.
Figure 1–1

SAFETY INFORMATION
Fire and Smoke Hazard
1-4 Bravo™ 8105 Installation Guide Rev. 2
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Fire and Smoke Hazard
Introduction There are two (2) inherent fire hazards present in the reflow system.
Safety Use good housekeeping techniques and follow the operating instructions and the
suggested maintenance schedule to avoid fires. Keep flammable materials and
solvents clear of the Bravo™ System. Never stop the system with boards in the
machine.
Flammable
Motors:
Fire and Smoke Hazard. Under normal circumstances, motors tend to create
sparks during operation. Should a serious problem ever develop in a motor,
sparking may ignite flammable materials.
Flammable
Heaters:
Fire and Smoke Hazard. If boards are stationary inside the system, the high
temperatures created by the heaters may cause the boards to ignite. Additionally,
if a board drops onto a heater, it may ignite.

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SAFETY INFORMATION
Electrical Hazards
2-9317-370-00-0 Bravo™ 8105 Installation Guide 1-5
Electrical Hazards
Introduction Installation of this equipment involves exposure to situations which may result in
electrical shock if procedures are not properly followed. Pay close attention to
warnings of this nature throughout the context of this Guide.
Electrical work should only be performed by a qualified electrician.
Prior to applying power for the first time, ensure that the system is properly
grounded.
The power panels and terminal blocks of the reflow system present an electrical
hazard. High voltages are present on various parts of the system.
Safety To ensure personal safety and avoid equipment damage, observe the following:
Electrical Hazard
Installation of this equipment involves exposure to High Voltage. High Voltage
can shock, burn, or cause death. Use extreme caution when performing voltage
and amperage tests on live voltage. These procedures must be performed only by
an authorized electrician, electrical engineer, or service technician familiar with
testing live voltage.
Electrical Hazard
When performing tests using AMP meters, volt meters, or ohm meters, electrical
shock hazard is present. These procedures must be performed only by an
authorized electrician, electrical engineer, or service technician familiar with
testing live voltage.
Photograph The following Photograph shows the electrical hazard warning tag:
Figure 1–2

SAFETY INFORMATION
Mechanical Hazards
1-6 Bravo™ 8105 Installation Guide Rev. 2
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Mechanical Hazards
Introduction Stop all moving parts when making adjustments or performing maintenance.
When the system is running, avoid moving mechanisms. Use caution when
working on or near moving parts and wear safety gear.
Safety To ensure personal safety and avoid equipment damage, observe the following:
Entanglement Hazard
All moving parts of the Bravo™ System represent potential hazards. Use caution
and avoid having hands or fingers caught in any moving mechanism. Long hair,
jewelry, and other parts of loose attire could be caught in moving mechanisms
and cause injury.
Photograph The following Photograph shows the pinchpoint warning tag:
Figure 1–3

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SAFETY INFORMATION
Breathing Hazards
2-9317-370-00-0 Bravo™ 8105 Installation Guide 1-7
Breathing Hazards
Introduction The lubricants used on the moving parts of the machine contain chemicals that
may be harmful if contacted directly or for a prolonged period of time. Refer to
the manufacturer MSDS (Material Safety Data Sheet) for information and safety
precautions concerning their products and system exhaust specifications.
Safety To ensure personal safety and avoid equipment damage, observe the following:
Respirator
All operators should be provided with an NIOSH or MSHA approved Respirator to
provide effective protection from airborne residue resulting from certain
saponifiers, defoamers, descalers, cleaning solvents or other chemicals used
during operation.
CAUTION
Noxious fumes are created during the normal heating process of reflow soldering.
The gases and vapors emitted from the solder and flux are contained in the reflow
chamber and should be avoided. Inhaling noxious vapors may cause headaches,
eye redness, stomach aches and breathing problems.

SAFETY INFORMATION
Inerting Hazards
1-8 Bravo™ 8105 Installation Guide Rev. 2
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Inerting Hazards
Introduction Nitrogen can smother if the gas is not properly exhausted. Nitrogen has two
distinct hazards associated with its use, asphyxiation and compressed gas
hazards.
Asphyxiation Hazard Symptoms. The warning signs of asphyxia are dizziness, headache, fainting, and
nausea. If you feel any of these symptoms, move to an area that is ventilated
with fresh air immediately.
Compressed Gas
Hazard Compressed Nitrogen - Excessive pressure could cause explosion of Nitrogen
Flow Meters.
Do not connect the Nitrogen Flow Control unit to a nitrogen source that exceeds
690 kPa (100 psi). Exploding flow meters are a potential hazard to workers
stationed in front of the control panel. Compressed gas can cause projectiles, gas
burns to exposed areas of the body, and asphyxiation. It is recommended that
nitrogen is delivered at a regulated pressure, at least 103 kPa (15 psi) less than
the supply line pressure.

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SAFETY INFORMATION
Other Hazards
2-9317-370-00-0 Bravo™ 8105 Installation Guide 1-9
Other Hazards
Introduction Additional hazards include weight considerations when moving or adjusting the
equipment and possible exposure to lead.
Safety To ensure personal safety and avoid equipment damage, observe the following:
CAUTION
To avoid damage to the equipment, adjust the fork lift forks to their widest
position. Use fork extensions on forks if the forks do not extend at least seven (7)
feet.
Heavy Objects When attempting to move heavy equipment or components, it is imperative to
use the proper rigging equipment. Do not attempt to move skids or large
assemblies without the use of a fork lift or other rigging equipment. Hand lifting
will cause serious personal injury.
Skin Irritation When using certain chemicals such as lubricants or solvents, it is important to
follow the MSDS (Material Safety Data Sheet) guidelines for proper handling and
usage. Wear appropriate clothing and safety articles when using descaler and
saponifier solutions. Skin or eye irritation can occur if not handled properly.
CAUTION
Exposure to lead in any form may cause serious heath hazards. Breathing lead
dust, which is nearly invisible, can cause lead poisoning.

SAFETY INFORMATION
1-10 Bravo™ 8105 Installation Guide Rev. 2
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Section B: Safety Precautions
Recommended Precautions
Introduction Refer to the following general precautions and recommendations.
Safety To ensure personal safety, observe the following:
ATTENTION
Please refer to specific chemical manufacturer Material Safety Data Sheet
(MSDS) for specific use, handling, and safety procedures for chemical and
cleaning agent applications.
Safety Lock-Out Tag-
Out Procedures Post electrical safety tag-out and lock-out procedures in the work place and
ensure that all electrical, service, and maintenance personnel are familiar with the
appropriate procedures. Mark and label all power supply sources used for the
equipment to ensure that the lock-out and tag-out process is easily accomplished.
See Section C: on page 13.
No Smoking Post No Smoking signs in the work area and provide measures for enforcement.
Fire Extinguisher Keep an approved fire extinguisher near the machine at all times. Familiarized all
personnel with the operation and use of the fire extinguisher.
Flammables Never store flammable material on or around the Bravo™ machine. Exposing
flammables to heating elements or hot surfaces presents a fire hazard due to the
operating temperature of the machine.
Electrical Precautions During operation, ensure that the interlocks and protective panels are closed and
remain secure.
Before working on any electrical circuit, shut down the main power, lockout /
tagout the source, and check that power is Off with a voltmeter at the main
power disconnect switch.
Electrical work should only be performed by qualified electricians and
maintenance personnel. Always shut Off main power before performing any
repairs on electrical circuits.
Prior to applying power to the machine for the first time, ensure that the machine
is properly grounded.
Do not disable safety interlocks or panels that restrict access to possible
energized circuits.