Cookson Speedline Technologies Electrovert Bravo... Operating manual

Bravo 8105®
CONVECTION REFLOW SYSTEM
PREVENTIVE MAINTENANCE GUIDE
Bravo™ 8105 Technical Manual P/N 110–00–0
Bravo™ 8105 Preventive Maintenance Guide P/N 3–9317–373–00–0

Bravo™ 8105 Preventive Maintenance Guide

2-9317-373-00-0 Bravo™ 8105 Preventive Maintenance Guide i
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Preface
Overview
In this section This preface covers the following information:
Topic See Page
To Our Customers ii
Customer Support Structure iii
Before You Call vi

PREFACE
To Our Customers
ii Bravo™ 8105 Preventive Maintenance 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
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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
iv Bravo™ 8105 Preventive Maintenance 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
2-9317-373-00-0 Bravo™ 8105 Preventive Maintenance Guide v
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
vi Bravo™ 8105 Preventive Maintenance 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.

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Table of Contents
Preface
To Our Customers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Customer Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Before You Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Chapter 1: Safety Information
Section A: Potential Hazards
Hot Surface Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fire and Smoke Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mechanical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Breathing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Other Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heavy Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Skin Irritation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section B: Safety Precautions
Recommended Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Lock-Out Tag-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
No Smoking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fire Extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flammables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sound Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Perimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Protective Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exhaust Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Document Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Good Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section C: Lock Out Tag Out
Attach Facility Lock-Out Tag-Out Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Attach Machine Lock-Out Tag-Out Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Perform Required Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove Lock-Out Tag Out Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TABLE OF CONTENTS
viii Bravo™ Preventive Maintenance Guide Rev. 2
Chapter 2: Technical Data
Section A: Facility Requirements and Specifications
Exhaust Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ElectricalInformation. .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. 19
Standard Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Start Up Power Requirements Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Process Ready Power Requirements Table. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical Codes and Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Underwriters Laboratory (UL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Section B: Machine Components
Forced Convection Heating Module Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Convection Blower Specifications Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Forced Convection Air Cooling Module Table . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cooling Blower Specifications Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Conveyor Module Standard Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Conveyor Module Options Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Conveyor Specifications Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section C: System Dimensions
Physical Characteristics Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 3: Preventive Maintenance Schedule
Safety Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Section B: Weekly PM Schedule
Weekly PM Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Section C: Monthly PM Schedule
Monthly PM Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Section D: Quarterly, Semi–Annual and Annual Maintenance PM Tables
Quarterly, Semi–Annual and Annual Maintenance PM Tables . . . . . . . . . . . . . . . 31
Quarterly Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Semi–Annual Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Annual Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 4: Weekly Preventive Maintenance Procedures
Rail Width Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Limit Switch Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Analog Transducer Wire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Photocell(s) Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Chapter 5: Monthly Preventive Maintenance Procedures
Electrical Cabinet Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Vacuum Hood Exhaust Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cleaning Machine Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspect Chamber Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Blower Inspection and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Exhaust Vent Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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TABLE OF CONTENTS
2-9317-373-00-0 Bravo™ 8105 Preventive Maintenance Guide ix
Pin Chain Conveyor (Option) Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Automatic Oiler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cross–Shaft Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Tools or Materials Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Chapter 6: Quarterly, Semi–Annual and Annual Maintenance Preventive Main-
tenance Tables
Mesh Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Section B: Semi–Annual Maintenance
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Torquing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Section C: Annual Maintenance
Blower and Fan Speeds Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Conveyor Speed Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Conveyor Speed Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Conveyor Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

TABLE OF CONTENTS
x Bravo™ Preventive Maintenance Guide Rev. 2

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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 Preventive Maintenance Guide Rev. 2
1
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
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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
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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
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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
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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
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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
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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.