PVA BI2000 User manual

BI2000 Board Inverter
Owner’s Manual
Revision F
WHERE
PRECISION
DRIVES
PRODUCTION

BI2000 Board Inverter Manual
Revision F /February 2020 Page 2 of 37
This 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.
Precision 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.
This 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.
Copyright © 2020
Precision Valve and Automation, Inc.
All Rights Reserved.

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Table of Contents
Introduction...........................................................................................................6
PVA Contact Information........................................................................................................6
Document History.....................................................................................................................6
Safety .......................................................................................................................................... 7
Notices and Warnings ..............................................................................................................9
Personal Protective Equipment.............................................................................................9
Environmental ...........................................................................................................................9
Noise Levels ...........................................................................................................................9
Materials/Chemicals.........................................................................................................9
Transportation, Operation, and Storage..............................................................................9
Handling and Transportation .............................................................................................9
Storage................................................................................................................................9
Temperature and Humidity...........................................................................................10
Description of Components..................................................................................................10
Hazards Due to Contact ....................................................................................................10
Setup......................................................................................................................11
Installation.................................................................................................................................11
Air Pressure Regulator........................................................................................................... 12
Safety Devices and Guarding...............................................................................................13
Safety Circuit ...................................................................................................................13
Work Area Access............................................................................................................13
Door....................................................................................................................................13
Light Tower Operation ...........................................................................................................13
Interface Overview .................................................................................................................14
Operation.............................................................................................................. 15
Startup Procedure ..................................................................................................................15
Shutdown .................................................................................................................................15
Cycle Stop.................................................................................................................................15

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Auto Cycle ................................................................................................................................16
Manual Mode ............................................................................................................................16
Conveyor Operation ....................................................................................................... 17
Board Stops...................................................................................................................... 17
Rotate ................................................................................................................................18
SMEMA...............................................................................................................................18
PIP Status .........................................................................................................................19
Shutters ............................................................................................................................19
Conveyor Width Adjust ................................................................................................. 20
Setup Mode ............................................................................................................................. 20
Flip Process..........................................................................................................................21
Board Flip..........................................................................................................................21
Board Second Flip.......................................................................................................... 22
Conveyor Width .............................................................................................................. 22
Profile Naming ................................................................................................................ 23
Fault Recovery.................................................................................................... 24
Board Removal ....................................................................................................................... 24
Manual Board Removal ..................................................................................................... 24
Conveyor Board Removal............................................................................................. 24
Open Door or “Emergency Stop” Recovery Procedure.................................................. 25
Recovery Procedure for Board Processing Failure ................................................ 26
Recovery Procedure for a Rotation Error ................................................................. 26
Error Messages........................................................................................................................27
Maintenance ....................................................................................................... 28
Conveyor Belt Replacement................................................................................................ 28
Board Sensor Adjustment.................................................................................................... 28
Board Thickness Adjustment.............................................................................................. 29

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Rotary Adjustment ................................................................................................................ 30
Rotation Angle ................................................................................................................ 30
Soft Start Adjustment....................................................................................................31
Rotary Speed Adjustment.............................................................................................31
Width Adjustment .................................................................................................................. 32
Main Air Regulator ................................................................................................................. 33
Troubleshooting................................................................................................. 34
Notes .....................................................................................................................35
Warranty ...............................................................................................................36
Table of Figures ...................................................................................................37

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Introduction
Before you operate this system, read the operation and setup manual. This will help you to
become familiar with the product and ensure successful operation.
If any questions or problems arise, contact PVA’s Technical Support department.
PVA Contact Information
Main Office PVA
One Mustang Drive
Cohoes, NY 12047
Tel [phone]
Fax [phone]
Website: http://www.pva.net
Email: [e-mail]
Technical Support
Tel [phone]
Email: [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
Note: 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
Certain 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
•Wear safety glasses, gloves, and long-sleeved clothing when working with
automated industrial equipment.
•Read and understand all operating manuals before using this equipment.
•Do not disable the safety features of the machine.
•Lock-out and tag-out the air and power supplies before any service is done.
•Reduce the air pressure to 0 psi before any hoses are removed.
•Make sure all replacement parts are correctly rated for use.
•Always remain clear of all moving parts when the system is in operation.
Personal Protective Equipment
Operators 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
The audible noise level of the board invertor is below 65 dBA.
Materials/Chemicals
There are no dangerous materials or chemicals used in the operation of the machine.
Transportation, Operation, and Storage
Handling and Transportation
Handling and transportation should be done with minimal vibration and shock to the
system. An air-ride truck is recommended for roadway transport.
Storage
All 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
Operation 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
The 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.
The 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.
Any uses other than listed above could result in a dangerous condition and cannot be
protected against by the safety features installed on the system.
Figures 1 and 2: Functional Block Diagram and SMEMA Cables and Process Flow
Hazards Due to Contact
The 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. Plug 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. Connect 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.
Figure 3: Main Air Attachment
3. Close any access doors and engage the “Emergency Stop” button.
4. Turn the red air lockout valve to “SUP”.
5. Make sure any SMEMA cables are correctly connected.
6. Turn the main power to switch “ON”.

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Air Pressure Regulator
1. To adjust the system air pressure, pull up on the regulator knob so the orange ring
can be seen.
Figure 4: Pull Up on the Regulator to Adjust
2. Turn the knob clockwise to increase the pressure or counterclockwise to decrease
the pressure.
3. Wait for the pressure to adjust as shown on the dial.
4. Push the regulator knob down to lock the pressure at the current value.
Figure 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
The 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
The work area is enclosed with Lexan guarding or safety glass.
Door
The 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
Three 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:
•The green light is on when the machine is in Auto Cycle and producing parts. It is
off at all other times.
•The 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).
•The 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.
•The buzzer will cycle with the red light during machine errors.

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State
Red
Amber
Green
Buzzer
Cycle Stop ON OFF OFF OFF
Auto Cycle OFF ON OFF OFF
In Cycle OFF OFF ON OFF
Machine Error FLASH OFF OFF FLASH
Figure 6: Light Tower & Buzzer Status
Interface Overview
The 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.
Figure 7: Pump Components

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Operation
Startup Procedure
1. Check the air pressure.
2. Close the door.
3. Engage the “Emergency Stop” button.
4. Use the main power red rotary switch to turn on the system power.
5. Disengage the “Emergency Stop”.
Shutdown
Do not shut down the machine down with parts in it.
1. Wait for all boards to clear the module.
2. Press “ESC” on the OIT. Wait for the Cycle Stop screen to appear.
3. Engage the “Emergency Stop” button.
CAUTION: If maintenance will be done, lockout and tagout the machine.
Cycle Stop
This 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.
Figure 8: Cycle Stop

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Auto Cycle
Auto 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. Select Auto Cycle from Cycle Stop.
2. Push the “ESC” button to leave Auto Cycle and return to Cycle Stop.
Figure 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. To change the settings shown in Auto Cycle, go to Setup Mode.
4. The Profile is shown above the screen name. Go to Setup mode to change the
profile.
5. The current conveyor speed is shown.
6. The text field shows information about board handling and processing.
7. The 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
In Manual mode, the operator has control of the conveyor, flipper, and SMEMA signals.
1. Select Manual mode from Cycle Stop.
2. Use the “Left”, and “Right” arrow buttons to scroll through the screens.

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Conveyor Operation
Figure 10: Manual Mode, Conveyor Speed
1. Use the Red Xor the Green Checkmark button to toggle the conveyor “On” or
“Off”.
2. Select 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
•To manually extend or retract the board stops, select the Red Xor the Green
Checkmark button.
Figure 11: Manual Mode, Board Stop

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Rotate
Figure 12: Manual Mode, Rotate
•To manually rotate the cage, push the “Square Arrow Button” on-screen. The arrow
direction shows the current position.
oWhen the arrow is Up the cage is in the home position (0 degrees)
oWhen the arrow is Down the cage is in the flip position (180 degrees)
SMEMA
You 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.
Figure 13: Manual Mode, SMEMA

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PIP Status
View the status of the part in place (PIP) input from the machine.
Figure 14: Manual Mode, PIP Status
Shutters
This screen only applies to systems with shutters. To manually open or close the shutters
select the Green Checkmark or Red X.
•Closed shutter:
•Open shutter:
Figure 15: Shutters

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Conveyor Width Adjust
This screen only applies to systems with automatic width adjust.
•To manually adjust the conveyor width, go to the Conveyor Width screen.
•Select the width value and use the keypad shown to enter a new width.
•Select the Target symbol to move the conveyor to the set width.
•Select the Home icon to home the conveyor.
Figure 16: Conveyor Width
Setup Mode
In 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. Select the Setup icon or the “ESC” button from Cycle Stop.
2. Use 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. Use the “Left”, and “Right” arrow buttons to scroll through the screens or the “F1”
and “ESC” hardware keys.
4. Push the “Home” button or the F3 key to return to Cycle Stop. When you leave
Setup mode, all changes will be saved.
The profile that will run in Auto Cycle is the one shown on the screen.