Tyco Electronics Raychem Interconnect AA-400 Mark IV User manual

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Contents
1 General Description 1
2 Safety 1
3 Installation 3
4 Operation 4
5 Accessories and Replacement Parts 5
6 Technical Specifications 5
Section Title Page
Raychem Interconnect a division of Tyco Electronics International Ltd. Printed in USA No.: TUS-44-3300 Revision: None Revision Date: February 16, 2000 Page: 2 of 8

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Control Unit
SECTION 1 GENERAL DESCRIPTION
Heat Gun
The CE 240-Vac AA-400 Mark IV
super heater is a compressed-air
heating tool—
one that offers precise control of the
heated air stream, especially in
confined areas. It operates with a
mains voltage of 240 Vac.
The AA-400 Mark IV performs
equally well in production, rework, and
prototype applications. Five different
reflector tips are available, providing a
wide range of air-flow patterns and
temperatures.
The needle-point tip is used for micro-
miniature connectors. This tip comes
standard with the AA-400 Mark IV.
The Mini SolderSleeve reflector tip is
used for installing SolderTact contacts
and SolderSleeve terminations in
confined areas. This tip comes standard
with the AA-400 Mark IV.
The low-flow-point tip is used for
installing small heat-shrinkable parts,
such as micro tubing and boots. This
tip must be ordered separately.
The SolderSleeve Reflector tip is used
for installing SolderSleeve shield
terminators and wire splice sleeves.
This tip must be ordered separately.
The boot and tubing reflector tip is
used for shrinking large-diameter
Thermofit tubing products and molded
heat-shrinkable components. This tip
must be ordered separately.
General Warning
Electrical Warning
Read Warning
Hot Surface
As with all electrical equipment, the
AA-400 Mark IV must be operated
properly. Carefully read and observe
all of the instructions and warnings in
this manual.
Incorrect use of the AA-400 Mark IV
can cause serious injury. This
equipment must be operated and
maintained only by fully trained and
qualified personnel.
Failure to follow the manufacturer’s
instructions may void the warranty of
this equipment.
The AA-400 Mark IV must be
operated in accordance with safe
working practices and local safety
codes and regulations.
SECTION 2 SAFETY
General
The control unit contains several
features:
• Mains power double-fused chassis
plug.
• Two-meter removable power cord.
• Pressure regulator and gauge for
adjusting air flow and temperature.
• Green HEAT ON indicator LED that
illuminates when power is applied to
the heating element.
• Automatic power cutoff switch to
protect the heating element if the air
flow is interrupted or turned down
below a safe operating pressure.
• A three-pin mains inlet connector
with two single-pole screwdriver-
release fuse cartridges to accept
five 20-mm fuses.
• A pressure-relief valve.
Do not use the AA-400 Mark IV for
any purpose other than its intended
function.
The AA-400 Mark IV carries an
International Protection (IP) Code of
IP30 for the control unit and IP20 for
the heat gun assembly. Never expose
the
AA-400 Mark IV to rain or moisture.
Labels and Warning Symbols
This tool carries a label (shown below)
that displays the product part number
(PCN), product description, electrical
rating information, air pressure infor-
mation, and wiring schematic drawing
number.
Warning symbols appear at right.
Raychem Interconnect a division of Tyco Electronics International Ltd. Printed in USA No.: TUS-44-3300 Revision: None Revision Date: February 16, 2000 Page: 3 of 8

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SAFETY (continued)
Safety Precautions and
General Warnings
• The heat gun must be placed on its
stand when not in use.
• A fire may arise if the 240-Vac AA-
400 Mark IV super heater is not used
with care.
• Be careful when using the AA-400
Mark IV in places where there are
combustible materials.
• Do not apply heat to the same area
for a prolonged period.
• Do not use this tool in the presence of
explosive atmosphere.
• Heat may be conducted to
combustible materials that are out of
sight.
• Place the AA-400 Mark IV on its
stand after use and allow it to cool
before storing it.
• Do not leave the AA-400 Mark IV
unattended when it is not in use.
Electrical
The AA-400 Mark IV-control unit is
connected directly to the AC mains
electrical supply through a double-fused
chassis plug and detachable power cord.
Before performing any electrical
maintenance or repair, always turn off
the equipment and unplug it from the
mains supply.
Do not open the control unit case or
heat gun case while the equipment is
connected to the mains supply.
The AA-400 Mark IV equipment must
be connected to an earthed power
supply.
It should not be hard-wired to a mains
supply.
Use only specified fuse types and
ratings.
Eye Protection
Safety glasses should be worn when
operating this tool. Avoid aiming the
heat gun nozzle’s hot air stream toward
your face.
Fire Prevention
Parts of the AA-400 Mark IV become
heated during normal usage. Avoid
aiming the heat gun nozzle’s hot air
stream at the unit’s hose, power cord, or
control unit.
Before disconnecting the operating
AA-400 Mark IV air supply, first allow
the heating element to cool. Failure to
observe this precaution will reduce the
element’s product life and could lead to
melting of the plastic in the heat gun
handle.
Always use the AA-400 Mark IV in a
well-ventilated area, away from any
flammable
materials, liquids, or fumes.
Be sure the AA-400 Mark IV is not
placed on flammable materials between
uses. Always place the heat gun in its
stand when not in use.
Emergency Shutoff
The AA-400 Mark IV is not equipped
with
an emergency shutoff system.
To turn the equipment off, first reduce
the air pressure to 0.21 MPa (30 psi) for
one minute. The green HEAT ON
indicator light will go off when the
pressure drops below approximately
0.31 MPa (45 psi), indicating power to
the heating element has been shut off.
After one minute at 0.21 MPa
(30 psi), reduce the air pressure to zero.
The equipment can be powered off by
unplugging the power lead from the
mains supply.
Hot Surfaces
Parts of the AA-400 Mark IV and the
product being worked on will become
heated during use. Always place the
heat gun in the stand when not in use.
Always provide adequate ventilation
and avoid overheating any products or
solder devices. Charring or burning of
tubing or wire insulation will produce
fumes that may cause eye, skin, nose, or
throat irritation.
Raychem Interconnect a division of Tyco Electronics International Ltd. Printed in USA No.: TUS-44-3300 Revision: None Revision Date: February 16, 2000 Page: 4 of 8

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SECTION 3 INSTALLATION
Remove any packing and inspect the
AA-400 Mark IV for damage. Check
that all items have been supplied.
Contact Raychem for assistance or
missing parts if necessary.
Electrical
The provided power cable uses the
following color codes:
Earth – Green/Yellow
Neutral – Blue
Live – Brown
Installation Procedure
Step 1
Attach the fitting on the control unit to a
clean, dry, oil-free compressed-air
source capable of supplying a minimum
of 113.3 l/m at 0.31 MPa (45 psi). The
240-Vac AA-400 Mark IV is supplied
with one of the more common quick-
disconnect air fittings; however, it may
be necessary to replace it with one that
will mate with your particular fittings.
CAUTION
Failure to use clean, dry, oil-free air will
result in severe damage to the AA-400
Mark IV.
Step 2
After connecting the AA-400 Mark IV
to an appropriate air supply, connect the
electrical mains power cord to the
control unit IEC receptacle. Connect the
previously installed IEC plug to a
correct wall receptacle. The AA-400
Mark IV should never be hard-wired to
a mains power supply.
Step 3
Adjust the air-pressure control knob for
a gauge reading of 0.35 MPa (50psi).To
unlock the knob, raise the red plastic
ring below the control knob. Turn the
knob clockwise to increase the air
pressure and flow.
Note
The heating element is powered on only
when the air pressure supplied to the
gun assembly exceeds approximately
0.28 MPa (40 psi). A pressure switch
cuts off power to the element when the
air pressure drops below this point,
protecting the heat gun assembly from
damage due to overheating. The green
HEAT ON indicator light is illuminated
whenever power is applied to the
heating element. This light goes off
when the pressure switch cuts off power
to the element.
Step 4
Within 30 seconds of nozzle air flow,
the air flow temperature should reach
260°C. After a full minute it should
stabilize at the operating temperature.
See Figure 1 below for the air
temperature ranges reached with
various air pressure and voltage
combinations.
CAUTION
Air passing through the eight small
holes in the nozzle cools the plastic heat
gun assembly handle. UNDER NO
CIRCUMSTANCES SHOULD THESE
SMALL HOLES BE CLOSED.
Step 5
To turn the unit off, first reduce the air
pressure to 0.21 MPa (30 psi) for one
minute. The green HEAT ON indicator
light will go off when the pressure
drops below approximately 0.31 MPa
(45 psi), indicating that power to the
heating element has been shut off. After
one minute at 0.21 MPa (30 psi), reduce
the air pressure to zero.
CAUTION
Failure to follow this shutdown
procedure may cause premature
element failure or heat damage to the
plastic heat gun assembly housing.
The power cable that comes with the
AA-400 Mark IV is not fitted with an
IEC plug. It is the responsibility of the
user to install the appropriate plug that
meets local and national requirements.
300
350
400
450
500
550
600
205 210 215 220 225 230 235 240 245 250 2
Vac
Temperature Degrees C
0.28 MPa (40 psi)
0.31 MPa (45 psi)
0.35 MPa (55 psi)
0.38 MPa (55 psi)
Figure 1. Output Air Temperature
The AA-400 Mak IV must be correctly
earthed. Failure to do so could cause
injury to the user.
WARNING
Unpacking
Raychem Interconnect a division of Tyco Electronics International Ltd. Printed in USA No.: TUS-44-3300 Revision: None
Revision Date: February 16, 2000 Page: 5 of 8

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SECTION 4 OPERATION
WARNING
Never leave the 240-Vac AA-400 Mark
IV super heater running unattended.
Step 1
With the heat gun nozzle cool and
power disconnected to the AA-400
Mark IV, install the appropriate
reflector tip (needle point, SolderSleeve,
Mini SolderSleeve, low flow, or boot
and tubing) required for your
application. Refer to Section 1 of this
manual and Step 6 in this section for
details on the available reflector tips.
Step 2
Follow Steps 1–3 of the Installation
Procedure (see Section 3) to prepare the
AA-400 Mark IV for operation. When
not using the heat gun, place it in its
stand to avoid possible heat damage to
the surrounding area.
CAUTION
Avoid aiming the hot air stream at the
control unit, hose, or power cord.
Step 3
If the air temperature appears to be too
high for your particular application,
increase the air pressure. If the air
temperature is still too high at the
maximum
pressure setting, it will be necessary to
reduce the voltage with a variable
transformer capable of handling a
400-watt load.
Step 4
If the air temperature appears to be too
low for your particular application,
decrease the air pressure.
If the air temperature is still too low at
the minimum pressure setting, check the
mains source voltage.
CAUTION
If it is necessary to use a variable
transformer to correct for a low-voltage
problem, do not exceed the 240-Vac
rating.
Step 5
For SolderSleeve applications, the end
of the nozzle or attached reflector
should be about 7 to 12 mm away from
the device. The hot air stream should be
directed at the solder band. Closer
placement of the nozzle tip can result in
browning of the tubing or spurting of
the melted solder.
Step 6
The needle-point, low-flow-point,
SolderSleeve, and Mini SolderSleeve
reflector tips are designed to slip over
the small-diameter end of the nozzle.
The
needle-point tip reduces the heated air
flow rate and air stream by about 50
percent. The low-flow tip reduces the
heated air flow rate about 70 percent in
a similar fashion. The SolderSleeve
reflector tip distributes all of the heated
air around the slot opening for uniform
heating of standard- size SolderSleeve
devices. The Mini SolderSleeve
reflector tip concentrates the hot air
flow in a small area for smaller
SolderSleeve devices.
The boot and tubing tip is designed to
slip over the large-diameter end of the
nozzle, so that the cooling air emitted
from the eight small holes mixes with
the hot air. This reduces the air
temperature to approximately 93°C and
significantly increases the air flow rate,
for recovering Thermofit heat-
shrinkable molded parts and tubing.
Step 7
To turn the AA-400 Mark IV off, follow
Step 5 of the Installation Procedure.
CAUTION
Never disconnect an operating AA-400
Mark IV from its air supply without first
allowing the element to cool, as
directed in Step 5 of the Installation
Procedure (see Section 3). Failure to
observe this procedure will reduce
the element’s product life and could
lead to melting of the gun assembly
plastic handle.
Raychem Interconnect a division of Tyco Electronics International Ltd. Printed in USA No.: TUS-44-3300 Revision: None Revision Date: February 16, 2000 Page: 6 of 8

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SECTION 5 ACCESSORIES AND REPLACEMENT PARTS
Accessories and Replacement Parts Part Number
SolderSleeve Reflector 979646
Needle-Point Tip 979647
Boot and Tubing Tip 979691
Mini SolderSleeve Reflector 979663
Low-Flow-Point Tip 979672
Stand 979649
Input Air Filter 979673
SECTION 6 TECHNICAL SPECIFICATIONS
Power supply 240 Vac, 2A, 50–60 Hz
Power consumption 363 watts
Fuses 2 x 2A (5 x 20 mm)
Power supply cable length 2 meters
Lamp 240 Vac, green
Air connection requirements 1/4 NPT (female)
Maximum air pressure 0.41 MPa (60 psi)
Minimum air pressure 0.31 MPa (45 psi)
Minimum air flow 113.3 l/m (4 cfm)
Raychem Interconnect a division of Tyco Electronics International Ltd. Printed in USA No.: TUS-44-3300 Revision: None
Revision Date: February 16, 2000 Page: 7 of 8

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Important: All information, including illustrations, is believed to be reliable. Users, however,
should independently evaluate the suitability of each product for their application. Raychem
makes no warranties as to the accuracy or completeness of the information, and disclaims any li-
ability regarding its use. Raychem’s only obligations are those in the Raychem Standard Terms
and Conditions of Sale for this product, and in no case will Raychem or its distributors be liable
for any incidental, indirect, or consequential damages arising from the sale, resale, use, or mis-
use of the product. Specifications are subject to change without notice. In addition, Raychem re-
serves the right to make changes—without notification to Buyer—to processing or materials that
do not affect compliance with any applicable specification.
SolderSleeve, SolderTact, and Thermofit are trademarks of Tyco Electronics International Ltd.
Raychem Interconnect Division
A Division ofTyco Electronics International Ltd.
Raychem Interconnect Division
Worldwide Headquarters
300 Constitution Drive
Menlo Park, CA 94025-1164
United States
Tel [phone]
[phone]
Fax [phone]
www.raychem.com
Europe Headquarters
Raychem Limited
Faraday Road
Dorcan, Swindon
Wiltshire SN3 5HH
United Kingdom
Tel [phone]
Fax [phone]
Raychem Interconnect Division A division of Tyco Electronics International Ltd. Printed in USA No.: TUS-44-3300 Revision: None Revision Date: February 16, 2000 Page: 8 of 8