PAV BI2000 User manual

202B
BI2000 Board Inverter
Owner’s Manual
Revision F
INNOVATION. PRECISION. EXCELLENCE.

BI2000 Board Inverter Manual
Revision F /January 2022 Page 2 of 37
203BThis document is based on information available at the time of its publication. While efforts
have been made to ensure the contents of this manual are accurate, the information
contained herein does not purport to cover all specific details or variations in hardware, or
to provide for every possible contingency in connection with installation, operation, or
maintenance. Features may be described herein which are not present in all hardware and
software systems. Precision Valve and Automation, Inc. assumes no obligation of notice to
holders of this document with respect to changes subsequently made.
204BPrecision Valve and Automation, Inc. makes no representation or warranty, expressed,
implied, or statutory with respect to, and assumes no responsibility for the accuracy,
completeness, sufficiency, or usefulness of the information contained herein. No warranties
of merchantability or fitness for purpose shall apply.
205BThis document, including the information contained herein, is the property of
Precision Valve and Automation, Inc. and is considered confidential and proprietary
information. It is delivered on the express condition that it not be used, disclosed, or
reproduced, in whole or in part, for any reason without prior written consent of
Precision Valve and Automation, Inc.
206BCopyright © 2020
207BPrecision Valve and Automation, Inc.
208BAll Rights Reserved.

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457BTable of Contents
391B Introduction...........................................................................................................6
401B PVA Contact Information........................................................................................................6
402B Document History.....................................................................................................................6
403B Safety .......................................................................................................................................... 7
404B Notices and Warnings ..............................................................................................................9
405B Personal Protective Equipment.............................................................................................9
406B Environmental ...........................................................................................................................9
429B Noise Levels ...........................................................................................................................9
430B Materials/Chemicals.........................................................................................................9
407B Transportation, Operation, and Storage..............................................................................9
431B Handling and Transportation .............................................................................................9
432B Storage................................................................................................................................9
433B Temperature and Humidity...........................................................................................10
408B Description of Components..................................................................................................10
434B Hazards Due to Contact ....................................................................................................10
392B Setup......................................................................................................................11
409B Installation.................................................................................................................................11
410B Air Pressure Regulator...........................................................................................................12
411B Safety Devices and Guarding...............................................................................................13
435B Safety Circuit ...................................................................................................................13
436B Work Area Access............................................................................................................13
437B Door....................................................................................................................................13
412B Light Tower Operation ...........................................................................................................13
413B Interface Overview .................................................................................................................14
393B Operation.............................................................................................................. 15
414B Startup Procedure ..................................................................................................................15
415B Shutdown .................................................................................................................................15
416B Cycle Stop.................................................................................................................................15

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417B Auto Cycle ................................................................................................................................16
418B Manual Mode ............................................................................................................................16
438B Conveyor Operation ....................................................................................................... 17
439B Board Stops...................................................................................................................... 17
440B Rotate ................................................................................................................................18
441B SMEMA...............................................................................................................................18
442B PIP Status .........................................................................................................................19
443B Shutters ............................................................................................................................19
444B Conveyor Width Adjust ................................................................................................. 20
419B Setup Mode ............................................................................................................................. 20
445B Flip Process..........................................................................................................................21
446B Board Flip..........................................................................................................................21
447B Board Second Flip.......................................................................................................... 22
448B Conveyor Width .............................................................................................................. 22
449B Profile Naming ................................................................................................................ 23
394B Fault Recovery.................................................................................................... 24
420B Board Removal ....................................................................................................................... 24
450B Manual Board Removal ..................................................................................................... 24
451B Conveyor Board Removal............................................................................................. 24
421B Open Door or “Emergency Stop” Recovery Procedure.................................................. 25
452B Recovery Procedure for Board Processing Failure ................................................ 26
453B Recovery Procedure for a Rotation Error ................................................................. 26
422B Error Messages ........................................................................................................................27
395B Maintenance ....................................................................................................... 28
423B Conveyor Belt Replacement................................................................................................ 28
424B Board Sensor Adjustment.................................................................................................... 28
425B Board Thickness Adjustment .............................................................................................. 29

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426B Rotary Adjustment ................................................................................................................ 30
454B Rotation Angle ................................................................................................................ 30
455B Soft Start Adjustment....................................................................................................31
456B Rotary Speed Adjustment.............................................................................................31
427B Width Adjustment .................................................................................................................. 32
428B Main Air Regulator ................................................................................................................. 33
396B Troubleshooting................................................................................................. 34
397B Notes .....................................................................................................................35
398B Warranty ...............................................................................................................36
399B Table of Figures ...................................................................................................37

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Introduction
209BBefore you operate this system, read the operation and setup manual. This will help you to
become familiar with the product and ensure successful operation.
210BIf any questions or problems arise, contact PVA’s Technical Support department.
PVA Contact Information
211BMain Office PVA
6 Corporate Drive
Halfmoon, NY 12065
214BTel [phone]
215BFax [phone]
216BWebsite: http://www.pva.net
217BEmail: [e-mail]
218BTechnical Support
219BTel [phone]
220BEmail: [e-mail]
Document History
Revision
Revision Date
Reason for Changes
REV F
February 2020
SoftStart Initial Setup Updated
REV E
January 2020
Template updated
REV D
September 2017
Screens updated
REV C
July 2016
Maintenance updated
REV B
June 2016
Template update and chain/conveyer added
REV A
January 2003
Initial release for Unitronics PLC
358BNote: All photographs and CAD model representations in this document are a “general
representation” of the system and its components. The actual appearance of the
system and its components can differ based upon customer specific configuration.

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Safety
221BCertain warning symbols are affixed to the machine and correspond to notations in this
manual. Before operating the system, identify these warning labels and read the notices
described below. Not all labels may be used on any specific system.
Always wear approved safety glasses when you operate or work near the
workcell.
Before you operate the system, read and understand the manuals provided
with the unit.
Never put hands or tools in areas with this symbol when the machine is in
operation. A dangerous condition may exist.
Read and understand the manuals provided with the unit before any repairs
or maintenance is done. Only a qualified individual should do service.
Use caution when there are pressurized vessels. Find and repair any leaks
immediately. Always wear appropriate safety equipment when you work
with pressurized vessels or vessels that contain chemicals
Shear hazard from moving parts. Avoid contact.
Do not remove protective guarding.
In situations where inattention could cause either personal injury or damage
to equipment, a warning notice is used.

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Do not smoke near the PVA UV cure machine. Always have a fire
extinguisher available for emergency use.
Before performing any repairs or maintenance to the system, turn off power
and lock out the power disconnect switch.
Warning notices are used to emphasize that hazardous voltages, current,
temperatures, or other conditions that could cause personal injury exist in
this equipment or may be associated with its use. Only qualified personnel
should enter areas designated with this symbol.
Laser light source present. Do not stare directly into the beam. Do not use in
the presence of highly reflective surfaces
Pinch hazard from moving parts. Avoid contact.
Hot surface. Avoid contact.
Warning, Ultraviolet (UV) light hazard. Do not look directly at the UV light
source.

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Notices and Warnings
•77BWear safety glasses, gloves, and long-sleeved clothing when working with
automated industrial equipment.
•78BRead and understand all operating manuals before using this equipment.
•79BDo not disable the safety features of the machine.
•80BLock-out and tag-out the air and power supplies before any service is done.
•81BReduce the air pressure to 0 psi before any hoses are removed.
•82BMake sure all replacement parts are correctly rated for use.
•83BAlways remain clear of all moving parts when the system is in operation.
Personal Protective Equipment
222BOperators must use eye protection because material contents are under pressure. Always
wear gloves when handling materials and solvents. Refer to MSDS sheets on the material
being dispensed for other precautions.
Environmental
Noise Levels
223BThe audible noise level of the board invertor is below 65 dBA.
Materials/Chemicals
224BThere are no dangerous materials or chemicals used in the operation of the machine.
Transportation, Operation, and Storage
Handling and Transportation
225BHandling and transportation should be done with minimal vibration and shock to the
system. An air-ride truck is recommended for roadway transport.
Storage
226BAll enclosures and connector covers should be closed tightly. The system should be
covered if dust or other airborne debris is present in the storage area.

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Temperature and Humidity
227BOperation and storage should be done at 40–105°F (4–41°C) and low humidity. Do not let
condensation collect on the machine. Install the system on a level surface, away from
standing water, possible over spray, and overhead leaks.
Description of Components
228BThe PVA Board Inverter can process and invert multiple boards. It is SMEMA (Surface
Mount Equipment Manufacturers Association) rated for easy integration into a production
line. The unit is designed to operate with PVA workcells.
229BThe operator can control the system with the user interface. The machine status and error
messages are displayed on the LCD screen and the light tower (optional). Operators must
be trained or have read the manual.
230BAny uses other than listed above could result in a dangerous condition and cannot be
protected against by the safety features installed on the system.
231B
41BFigures 1 and 2: Functional Block Diagram and SMEMA Cables and Process Flow
Hazards Due to Contact
232BThe board invertor is designed to minimize injury from contact with the machine. In certain
modes of operation, you can enter the work area while the module is in operation. Only a
qualified person should do this. Examine warning labels.

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Setup
WARNING: These procedures should be done by a qualified person in accordance with
this manual and applicable safety regulations. A “qualified person” is defined as “a
person or persons who, by possession of a recognized degree or certificate or
professional training, or who, by extensive knowledge, training, and experience, has
successfully demonstrated the ability to solve problems relating to the subject
matter and work.” (ref. ANSI/ASME B30.2-1983.)
Installation
1. 84BPlug the machine into an appropriate power source as shown by the Machine
Specific Information section of the Operating Guide or the legend plate on the
machine. The electrical service should be correctly grounded and the power source
“clean”. If there is high power equipment operating off the same source, a line
conditioner may be necessary. Machine errors can be caused by poor quality power.
WARNING: Failure to comply with electrical specifications can damage the machine
and injure personnel. Electrical hookup must be made by a qualified electrician and
comply with any local standards.
2. 85BConnect the ¼” NPT female fitting at the rear of the machine to a source of clean,
dry air. A hose of ¼” inside diameter is sufficient.
42BFigure 3: Main Air Attachment
3. 86BClose any access doors and engage the “Emergency Stop” button.
4. 87BTurn the red air lockout valve to “SUP”.
5. 88BMake sure any SMEMA cables are correctly connected.
6. 89BTurn the main power to switch “ON”.

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Air Pressure Regulator
1. 90BTo adjust the system air pressure, pull up on the regulator knob so the orange ring
can be seen.
43BFigure 4: Pull Up on the Regulator to Adjust
2. 91BTurn the knob clockwise to increase the pressure or counterclockwise to decrease
the pressure.
3. 92BWait for the pressure to adjust as shown on the dial.
4. 93BPush the regulator knob down to lock the pressure at the current value.
44BFigure 5: Push Down to Lock

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Safety Devices and Guarding
Note: The safety features should NEVER be bypassed, disabled or tampered with.
Precision Valve & Automation, Inc. is not responsible for any damages incurred
because of alteration or destruction of any safety features.
Safety Circuit
236BThe machine main power is controlled by the safety circuit with a safety relay and
additional safety devices. The safety relay has a redundant and self-checking circuit,
which means two parallel relay circuits work together electrically with the safety devices.
The tripping contacts of the relays are connected in series to make sure the safety circuit
will disconnect the power even if one of the relays fails. The self-checking circuit has
positive guided contacts, mechanically forced to operate together. If one of the redundant
relays fails, the power contacts are opened. The safety devices monitor the state of the
Emergency Stop button and other safety mechanisms. When one or more of the safety
devices have opened, the power is stopped.
Work Area Access
237BThe work area is enclosed with Lexan guarding or safety glass.
Door
238BThe top of the machine is protected by a door. The door is monitored by a non-defeatable
limit switch. The Door Bypass key is for maintenance access only.
Light Tower Operation
239BThree stacked indicator lights and a buzzer are used to indicate the status of the machine.
The lights are visible from all sides of the machine and operate as follows:
•94BThe green light is on when the machine is in Auto Cycle and producing parts. It is
off at all other times.
•95BThe amber light is on when the machine is in Auto Cycle, but cannot operate
because of an external material handling problem (no incoming parts or no room to
unload parts).
•96BThe red light is on steady when the machine is not in Auto Cycle due to operator
intervention. It will flash when the machine is in cycle, but the cycle has stopped
because of a machine problem. It will be off at all other times.
•97BThe buzzer will cycle with the red light during machine errors.

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240BState 241BRed 242BAmber 243BGreen 244BBuzzer
245BCycle Stop 246BON 247BOFF 248BOFF 249BOFF
250BAuto Cycle 251BOFF 252BON 253BOFF 254BOFF
255BIn Cycle 256BOFF 257BOFF 258BON 259BOFF
260BMachine Error 261BFLASH 262BOFF 263BOFF 264BFLASH
45BFigure 6: Light Tower & Buzzer Status
Interface Overview
265BThe operator interface terminal (OIT) has touch screen icons and buttons on the display
that are related to the shown icons. A keyboard or keypad will be shown when a related
value or text field is selected.
46BFigure 7: Pump Components

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Operation
Startup Procedure
1. 98BCheck the air pressure.
2. 99BClose the door.
3. 100BEngage the “Emergency Stop” button.
4. 101BUse the main power red rotary switch to turn on the system power.
5. 102BDisengage the “Emergency Stop”.
Shutdown
267BDo not shut down the machine down with parts in it.
1. 103BWait for all boards to clear the module.
2. 104BPress “ESC” on the OIT. Wait for the Cycle Stop screen to appear.
3. 105BEngage the “Emergency Stop” button.
CAUTION: If maintenance will be done, lockout and tagout the machine.
Cycle Stop
268BThis is the default machine state. All other modes are accessed from this screen. To shut
down the machine or select a different operating mode, you must return to Cycle Stop.
47BFigure 8: Cycle Stop

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Auto Cycle
270BAuto Cycle is the normal operating mode for the PVA board inverter. In Auto Cycle, the
machine operates as part of a production line and interfaces with any adjacent machines.
1. 106BSelect Auto Cycle from Cycle Stop.
2. 107BPush the “ESC” button to leave Auto Cycle and return to Cycle Stop.
48BFigure 9: Auto Cycle
Note: The board inverter will wait for the boards to exit if there are boards in the
inverter when the “ESC” button is pushed.
3. 108BTo change the settings shown in Auto Cycle, go to Setup Mode.
4. 109BThe Profile is shown above the screen name. Go to Setup mode to change the
profile.
5. 110BThe current conveyor speed is shown.
6. 111BThe text field shows information about board handling and processing.
7. 112BThe SMEMA indicators show the signals being sent and received. Output from the
system are in the box, external signals are outside of the box.
Manual Mode
272BIn Manual mode, the operator has control of the conveyor, flipper, and SMEMA signals.
1. 113BSelect Manual mode from Cycle Stop.
2. 114BUse the “Left”, and “Right” arrow buttons to scroll through the screens.

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Conveyor Operation
49BFigure 10: Manual Mode, Conveyor Speed
1. 115BUse the Red Xor the Green Checkmark button to toggle the conveyor “On” or
“Off”.
2. 116BSelect the Direction: button to toggle between L to R (left to right) or R to L
(Right to Left). The default direction is downstream.
Board Stops
•117BTo manually extend or retract the board stops, select the Red Xor the Green
Checkmark button.
50BFigure 11: Manual Mode, Board Stop

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Rotate
51BFigure 12: Manual Mode, Rotate
•118BTo manually rotate the cage, push the “Square Arrow Button” on-screen. The arrow
direction shows the current position.
o119BWhen the arrow is Up the cage is in the home position (0 degrees)
o120BWhen the arrow is Down the cage is in the flip position (180 degrees)
SMEMA
276BYou can view the status of the SMEMA input from the machine selected. To toggle the
SMEMA output on and off, push the related light on the screen.
277B
52BFigure 13: Manual Mode, SMEMA

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PIP Status
278BView the status of the part in place (PIP) input from the machine.
53BFigure 14: Manual Mode, PIP Status
Shutters
280BThis screen only applies to systems with shutters. To manually open or close the shutters
select the Green Checkmark or Red X.
54BFigure 15: Shutters

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Conveyor Width Adjust
282BThis screen only applies to systems with automatic width adjust.
•123BTo manually adjust the conveyor width, go to the Conveyor Width screen.
•124BSelect the width value and use the keypad shown to enter a new width.
•125BSelect the Target symbol to move the conveyor to the set width.
•126BSelect the Home icon to home the conveyor.
55BFigure 16: Conveyor Width
Setup Mode
284BIn setup mode, the operator can set the options for the PVA board inverter. The profile
name is shown at the top of the screen. You will make changes to the profile shown.
1. 127BSelect the Setup icon or the “ESC” button from Cycle Stop.
2. 128BUse the Use the + - Page icons or the F2 and F4 keys to scroll through the profiles.
The profile name is shown at the top of the screen. You can have a maximum of 30
profiles.
3. 129BUse the “Left”, and “Right” arrow buttons to scroll through the screens or the “F1”
and “ESC” hardware keys.
4. 130BPush the “Home” button or the F3 key to return to Cycle Stop. When you leave
Setup mode, all changes will be saved.
285BThe profile that will run in Auto Cycle is the one shown on the screen.