MSI BEAHM 160-A User manual

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
[e-mail] • www.machinesolutions.com
Table Of Contents
List of Figures................................................................................................................................................3
List of Tables.................................................................................................................................................3
Purpose.........................................................................................................................................................4
Overview.......................................................................................................................................................4
Contents........................................................................................................................................................4
Installation....................................................................................................................................................4
Safety............................................................................................................................................................5
User Alerts....................................................................................................................................................5
Set Up and Configuration.............................................................................................................................6
System Controls and Features .....................................................................................................................6
Parameter Settings.......................................................................................................................................9
Temperature.............................................................................................................................................9
Heater Air Flow.........................................................................................................................................9
Pressure (210-A Only) ..............................................................................................................................9
Vacuum (210-A Only) ...............................................................................................................................9
System Operation.......................................................................................................................................10
Power On…………………………………………………………………………………………………………………………………………..10
Power Off………………………………………………………………………………………………………………………………………..…10
Cool Down………………………………………………………………………………………………………………………………..……….10
Maintenance...............................................................................................................................................11
Exchanging Thermal Nozzles..................................................................................................................11
Exchanging Thermal Nozzle ...................................................................................................................11
System Specifications 160-A/185-A and 210-A.....................................................................................11
Calibration (See Notes Below)...............................................................................................................12

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
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Tuning Temperature Controllers (Eurotherm Model 3216e)................................................................12
Critical Spare Parts (Contact Beahm Designs for pricing) .....................................................................12
Diagnostics (Troubleshooting)...............................................................................................................12
System Schematics.................................................................................................................................14
Servicing......................................................................................................................................................19
Heating Element.....................................................................................................................................19
Temperature Controller.........................................................................................................................20
Power Controller ....................................................................................................................................20
Warranty.....................................................................................................................................................20
Return Material Authorization ..............................................................................................................20
List of Figures
Figure 1.Standard Hot Air System (Model 160-A).......................................................................................6
Figure 2. Standard Hot Air System (Model 185-A)......................................................................................7
Figure 3. Balloon Development System (Model 210-A)..............................................................................7
Figure 4: Thermal Nozzles............................................................................................................................9
Figure 5: Nozzle Cover…………………………………………………………………………………………………………………….…….10
Figure 6: System Electrical Schematic 160-A.............................................................................................15
Figure 7: System Electrical Schematic 185-A and 210-A ...........................................................................17
Figure 8: System Pneumatic Schematic 160-A ..........................................................................................18
Figure 9: System Pneumatic Schematic 185-A and 210-A.........................................................................19
List of Tables
Table 1. 160-A Control and Display functions.............................................................................................6
Table 2.185-A and 210-A Control and Display functions ............................................................................7
Table 3.210-A Control and Display functions..............................................................................................8
Table 4.160-A/185-A, and 210-A System Specifications...........................................................................11
Table 5.Critical Spare Parts with descriptions...........................................................................................12
Table 6. Diagnostics and Troubleshooting ................................................................................................13

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
[e-mail] • www.machinesolutions.com
Purpose
The purpose of this document (Original Instructions) is to describe the electrical and software
design of the control system for the Hot Air Stations; Models 160-A, 185-A, and 210-A. This
document also includes operator instructions.
Overview
Beahm Designs Hot Air Stations are compact, bench‐top systems designed to deliver precisely
controlled heated air through a variety of multi‐port nozzles. Various shapes and sizes of thermal
nozzles are available to deliver a focused stream of controlled‐temperature air to a desired zone.
Process applications include heat fusing, shaping, tipping, heat shrinking, welding/bonding and
balloon forming and tubing expansion.
The A‐series Hot Air Stations provide stable, precise air temperature control using a high
accuracy controller with thermocouple monitoring and feedback.
Safety interlocks are provided between the electrical and pneumatic system to prevent
heater burnout during accidental loss of air pressure.
Contents
Included with the system are the following contents:
1. Heater remote and main control
2. IEC Power Cord
3. Compressed Air Supply Hose Assembly
Installation
Note: See Maintenance Section for facilities requirements
1. Place the system on a sturdy, and level surface.
2. Connect the remote heater enclosure to the main control unit.
3. Connect the power cord to the main control unit.
4. Connect the air supply hose to the system, and then to a clean, dry, and filtered
compressed air source.
5. Auto-tune Temperature Controllers (please refer to page 12 for procedure details).

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
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Safety
•Use of eye protection when working with compressed gases and heated materials is advised.
•The maximum observed Sound Pressure Level is below 70 dB(A).
Caution: high voltage. Remove power and use safety precautions when servicing.
Caution: hot surface. Contact may cause burn. Allow to cool before servicing.
Caution: pinch point. Keep hands and body parts clear while in operation.
User Alerts
Do not to use the equipment other than as prescribed. Examples: Do not attempt to sit on or climb on
the equipment, do not place heavy objects or containers of liquid on the machine, do not to insert any
foreign objects into the machine and do not attempt to bypass any guards or otherwise operate the
machine in any manner other than that in which it is explicitly intended.
This equipment is not for use with materials that can decompose or ignite below the maximum
operating temperature of the machine. Hazards are materials that outgas hazardous substances and or
ignite. This equipment is not for use in an ATEX environment.
Note: The equipment is not for use with materials that can decompose or ignite
below the maximum operating temperature of the machine. Hazards are
materials that outgas hazardous substances and or ignite. (260°C/500°F)

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
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Note: This equipment is not for use in an ATEX environment.
Set Up and Configuration
Proper sizing of the thermal nozzle is crucial to the optimizing process and repeatability. The
following guidelines are recommended methods; however, all applications vary, and several
iterations of tooling process development may be required and may not follow all of the
recommended guidelines.
1. Thermal Nozzle Diameter - The nozzle diameter should be .187” - .25” larger than the
material to be processed.
2. Thermal Nozzle Width - The width of the thermal nozzle should be sized equal or
slightly greater (approximately 1.0mm) than the length of the overlap of the materials.
3. System Options –Many optional accessories are available to enhance the functionality of the
system and improve process yield. Contact Beahm Designs sales department or visit our website
at www.machinesolutions.com for more information on available accessories and/or to request
a quote.
System Controls and Features
Located on the front panel of the Hot Air System(s) are the following controls and/or displays
and their functions:
Figure 1.Standard Hot Air System (Model 160-A)
160-A only (Starter System)
Description
Function

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
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1
Main power switch
Toggles system power and air on and off.
2
Heater Power Switch
Toggles heater power on and off.
3
Cooling Air Flow Adjust
Controls cooling air flow rate.
4
Cooling Air Toggle Switch
Toggles cooling air on/off
5
Heater Air Flow Meter
Controls heater air flow rate.
6
Temperature controller
Controls the temperature of the thermal nozzle.
Table 1. 160-A Control and Display functions
Figure 2. Standard Hot Air System (Model 185-A)
185‐A and 210‐A
Description
Function
1
Main power switch
Toggles system power and air on and off.
2
Heater Power Switch
Toggles heater power on and off.
3
Temperature controller
Controls the temperature of the thermal nozzle.
4
Heater Air Flow Meter
Controls heater air flow rate.
5
Cooling Air Flow Adjust
Controls cooling air flow rate.
6
Cooling Air Toggle Switch
Toggles cooling air on/off
Table 2.185-A and 210-A Control and Display functions

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
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Figure 3. Balloon Development System (Model 210-A)
210‐A only
Description
Function
1
Pressure regulator
Regulates the pressure at the PRESS/VAC. Port.
2
Pressure gauge
Displays the pressure at the PRESS./VAC. Port.
3
Vacuum Gauge
Display vacuum at the PRESS./VAC. Port.
4
Rotary Switch
Selects pressure or vacuum at PRESS./VAC. port
5
PRESS./VAC. port
Access port for the pressure and vacuum function.
Table 3.210-A Control and Display functions
Thermal nozzles are equipped to various Hot Air Systems. Designed to deliver precisely
controlled, heated air to your thermal application; these nozzles are machined to your
specification (Width and Diameter).
•Interchangeable nozzles.
•Offered in a variety of styles

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
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Figure 4: Thermal Nozzles
Parameter Settings
Temperature
Depress and hold the up or down arrow key of the temperature controller to scroll to
the desired temperature. After 2 seconds the new value will be accepted and the
temperature will ramp to the new set point.
Heater Air Flow
Rotate the flow meter knob clockwise or counterclockwise until the meter displays the
desired value.
Pressure (210-A Only)
Rotate the regulator knob clockwise or counterclockwise until the pressure gauge
displays
the desired value.
Vacuum (210-A Only)
a. The vacuum strength is coupled with the pressure setting. A pressure value of
80 psi will generate maximum vacuum of the system specification.
b. With vacuum switched on, rotate the pressure regulator knob clockwise or
counterclockwise until the vacuum gauge displays the desired value.

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
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System Operation
Power On
1. Switch MAIN POWER on.
2. Set heater air flow to 20-40 SCFH.
3. Switch HEATER POWER on.
a. When the temperature is not within +/- 3 degrees of the set point the error
message “TEMPERATURE ERROR” will be displayed.
4. Position components to be processed within the thermal nozzle for a timed duration.
5. Remove the components from the thermal nozzle and position them at the end of the
Cooling air nozzle. Depress the foot switch or toggle, the panel switch will start the flow
of air.
Power Off
1. Switch HEATER POWER off.
2. Place the Nozzle Cover (shown below in Figure 5) over the Thermal Nozzle appliance, to
prevent heat related burns and/or injuries.
3. Let the heater cool for approximately 5 minutes.
4. Switch MAIN POWER off.
Note: Failure to let heater completely cool down will result in a shortened heater lifecycle.
Figure 5: Nozzle Cover

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
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Maintenance
Caution: pinch point/crush hazard. Keep fingers, hands, and clothing clear of moving parts.
1. Use 99% isopropyl alcohol to wipe down the outside of the machine. Do not attempt to clean
the inside of the machine. Machine should not be washed down.
2. Cleaning should be with a soft dry cloth only.
Warning
Note: Ensure the machine is unplugged for any servicing or maintenance work.
Note: Perform these steps ONLY when the machine is at room temperature.
Exchanging Thermal Nozzles
Note: Perform the following steps ONLY when the nozzle is at room temperature.
Exchanging Thermal Nozzle
1. Loosen the set screw at the top of the nozzle adapter.
2. Slide the nozzle while simultaneously removing the thermocouple connector.
3. Install the replacement nozzle/thermocouple connector.
4. Tighten the set screw in the adapter.
Operational Requirements
System Specifications 160-A/185-A and 210-A
Description
Range
Resolution
Accuracy
160-A, 185-A, and 210-A
*1. Temperature
200‐750° F
1.0 deg.
+/‐.25% F.S.
*2. Air Flow
5‐50 SCFH
5.0 SCFH
+/‐ 4% F.S.
210-A Only
1. Pressure
0‐100 psi
2.0 psi
+/‐3.5% F.S.
2. Vacuum
ATM‐18 inHg
5.0 inHg
+/‐5% F.S.
Table 4.160-A/185-A, and 210-A System Specifications
*Instrument specification does not represent specification at tooling output.

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
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Calibration (See Notes Below)
1. It is recommended that calibration be performed by a certified service, preferably
with the system in the location of use. Calibration procedures are the domain of these
service providers.
2. Calibration refers to the process of verifying that each of the systems’ instruments
that control a process parameter is within manufacturers’ specification.
3. Calibration DOES NOT refer to the process of measuring the temperature at the
center of the tooling and “matching” the value to the temperature controller set point.
4. The measured value at the tooling (thermal nozzle) may not match the temperature
controller setpoint and the delta is dependent on nozzle style and dimensions as well as
method of measurement.
a. Calibrate the temperature controller annually.
b. Calibrate the pressure gauge annually.
c. Verify the flow meter annually.
Tuning Temperature Controllers (Eurotherm Model 3216e)
Note: Auto-tuning can be performed at any temperature set point within the system
operating specifications, however, best results are attained at temperatures about
500°F
a. Depress the scroll button until ATUN appears.
b. Depress the Up-arrow button until ON appears.
c. System will resume normal operation automatically after approximately 2
minutes.
Critical Spare Parts (Contact Beahm Designs for pricing)
Item
P/N
Description
1
1348043-001
GRADE A GAUGE
2
1343250-001
3‐way pneumatic valve
3
1150440-001
Temperature Controller
Table 5.Critical Spare Parts with descriptions
Diagnostics (Troubleshooting)
Issue
Possible Causes
Solution
1
Temperature not stable
Thermal Nozzle
replaced.
Thermocouple loose
Auto‐tune
Re‐install thermocouple

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
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2
S.br
Break in thermocouple wire
Thermocouple failure
Verify all connections from
controller to remote TC jack
Replace thermocouple
3
No heat at nozzle
Heater air flow too low
Defective heating element
Defective power control
Increase air flow
Replace heating element.
Contact Beahm Designs
4
.Err code in display
Temperature controller
software failure.
Replace temperature
controller.
5
System will not power on.
IEC power cord not fully
connected.
Verify installation.
Table 6. Diagnostics and Troubleshooting
Facility Requirements (160-A, 185-A, and 210-A)
1. Voltage: 120-240 VAC 50/60 Hz.
2. Wattage: 500 max.
3. Compressed Air: 100-125 psi, 1.0 SCFM, filtered 50 micron or greater, oil and water
free.

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
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System Schematics

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
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Figure 6: System Electrical Schematic 160-A

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
[e-mail] • www.machinesolutions.com

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
[e-mail] • www.machinesolutions.com
Figure 7: System Electrical Schematic 185-A and 210-A

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
Tel: [phone] • Fax: [phone]
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Figure 8: System Pneumatic Schematic 160-A

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
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Figure 9:System Pneumatic Schematic 185-A and 210-A
Servicing
Note: Disconnect system main power and air before servicing any part of the product.
Heating Element
1. Remove the top cover of the remote heater enclosure.
2. Disconnect the two electrical quick-disconnects.
3. Disconnect the air line from the rear of the heater boot by carefully pulling it rearward.
4. Loosen the rear set screw on the left side of the heater mount block.
5. Push the heater airline to the side and then carefully slide the heating element rearward until
it is fully clear of the mount block.
6. Install the replacement heater with the tab oriented down, inserting it fully into the mount
block.
7. Re-install the air fitting into the heater boot.
8. Re-connect the electrical connections.
9. Install the top panel.

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Machine Solutions Inc. 2951 W. Shamrell Blvd. Flagstaff, Arizona 86005 USA
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Temperature Controller
Contact Beahm Designs for further diagnostics and instructions.
Power Controller
Contact Beahm Designs for further diagnostics and instructions.
Warranty
Beahm Designs Inc. (BDI) products are backed by a 1 year warranty on parts and labor. Warranty is void
for any product returned if BDI determines that:
a. The asserted defect is not present,
b. The asserted defect is attributed to misuse, improper installation, alteration (label
removal and/or destruction, opening or removing external covers without authorization
by Beahm Designs Inc.), mishandling and/or mishaps.
c. The product was not sold to customer as new.
Return Material Authorization
Product may not be returned to Beahm Designs Inc. without first contacting BDI Aftermarket for a
Return Material Authorization (RMA) number. If it is determined that the Product may be defective, you
will be given an RMA number and instructions for Product return. End Users are required to include a
copy of the RMA receipt inside the return box, in order to receive replacement product under the
warranty. All unauthorized returns i.e., one for which an RMA number has not been issued, will be
returned at the customers expense. To request an RMA, please contact us at 928-556-3109 or email
[e-mail]
For additional information on Beahm Designs, Hot Air Systems, please visit
http://machinesolutions.com/our-products/