Air-Vac PCBRM100 User Manual Download Page 157

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PCBRM100 User’s Guide

Chapter 6: Maintenance

4101.00.902

6-1

6: Maintenance

Maintenance......................................................................................................................... 3

6.0

-D

ROSS THE

OLDER

...................................................................................................... 3

6.1

HANGE THE

OLDER

TACK

...................................................................................................... 7

6.2

HECKING

OLDER

EVEL

........................................................................................................ 12

6.3

LEANING

OLDER

UMP

................................................................................................... 13

6.4

LEANING THE

REHEATER

ANELS

........................................................................................... 14

6.5

LEANING THE

ARREL

LEANING

OOL

...................................................................................... 14

6.6

AINTENANCE

UIDE

CHEDULE

............................................................................................... 15

6.7

ERIFICATION

VERVIEW

......................................................................................................... 16

6.8

LOW

ATE

ERIFICATION AND

DJUSTMENT

.............................................................................. 17

6.8.1

OZZLE

LOW

ONTROLLER

ERIFICATION AND

DJUSTMENT

.................................................... 17

6.9

EMPERATURE

ERIFICATION

.................................................................................................... 22

6.9.1

PPER

EATER

ERIFICATION

............................................................................................... 22

Summary of Contents for PCBRM100

Page 1: ...PCBRM100...

Page 2: ......

Page 3: ...Part Number 4101 00 902 Rev 02 00 9 10 2014 Chapter 1 Introduction Overview Chapter 2 Facility Requirements Chapter 3 Start Up Chapter 4 Software Overview Chapter 5 Process Development Chapter 6 Maint...

Page 4: ...PCBRM100 User s Guide 4101 00 902...

Page 5: ...ction Overview 3 1 0 CONTACTS SUPPORT 3 1 1 WARRANTY GENERAL 4 1 2 HEATER LIMITED LIFE WARRANTY 4 1 3 SAFETY SYSTEM 5 1 3 1 SAFETY INSTRUCTIONS RECOMMENDATIONS 5 1 3 2 ADDITIONAL SAFETY PRECAUTIONS 7...

Page 6: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 2...

Page 7: ...erating questions If you have any questions on machine parameters correct nozzle requirements options procedures or mainte nance please do not hesitate to call Air Vac Engineering Company Inc 30 Progr...

Page 8: ...r Warranty Products cannot be returned to Air Vac without authorization please call for an RMA 1 2 Heater Limited Life Warranty Air Vac Engineering Company warrants the heaters for a period of ninety...

Page 9: ...personnel Machine Operation All heated areas can be programmed to reach high temperatures Use caution near heated surfaces including the nozzle solder pot and the pre heater Always use the gas nozzle...

Page 10: ...ile it is moving Do not override safety interlocks Check area for any loose parts or tools that could cause mechanical interference Do not place anything on the top of the machine In the event of an e...

Page 11: ...AIR VAC does not supply the solder or flux products with the PCBRM100 system The end user of the system should follow proper handling and disposal instructions for the materials as supplied by their v...

Page 12: ...the PCBRM100 system This label describes the electrical and air requirements for the system The overall system requirements can be found in the facilities section of this manual It is located over th...

Page 13: ...ound on the covers of each such heated surface as well as next to heated surfaces Skin contact with these surfaces would result in a burn reaction and therefore presents an inherent po tential thermal...

Page 14: ...Introduction Overview 4101 00 902 1 10 Warns the user that dangerous conditions pinch point or crushing exist with the machine covers re moved Do not operate the machine with covers re moved These ar...

Page 15: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 11 1 3 5 Warning Label Placement Inside Cover Locations hidden normally Pinch Point Hot Surface and High Voltage Front of Machine...

Page 16: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 12...

Page 17: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 13 Left Side...

Page 18: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 14 Center Right Side...

Page 19: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 15 Rear...

Page 20: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 16...

Page 21: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 17 Outside Locations visible Pinch Point Hot Surface and High Voltage Main Machine and Preheater Right Side...

Page 22: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 18...

Page 23: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 19 Left Side...

Page 24: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 20 Center...

Page 25: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 21...

Page 26: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 22 Laser Warnings...

Page 27: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 23 Front...

Page 28: ...PCBRM100 User s Guide Chapter 1 Introduction Overview 4101 00 902 1 24 Rear...

Page 29: ...PCBRM100 User s Guide Chapter 2 Facility Requirements 4101 00 902 2 1 2 Facility Requirements 2 Facility Requirements 3...

Page 30: ...PCBRM100 User s Guide Chapter 2 Facility Requirements 4101 00 902 2 2...

Page 31: ...e to frequent power disturbances line filtering protection may be required Air Nitrogen Main Air Supply 90 120 psi 25 scfm clean dry air non condensing source Nitrogen supply option for pot inert 90 1...

Page 32: ...PCBRM100 User s Guide Chapter 2 Facility Requirements 4101 00 902 2 4...

Page 33: ...PCBRM100 User s Guide Chapter 3 Start Up 4101 00 902 3 1 3 Start Up 3 Start Up 3...

Page 34: ...PCBRM100 User s Guide Chapter 3 Start Up 4101 00 902 3 2...

Page 35: ...ttons are released Turn the key clockwise and hold until green power light illuminates Software Start Up If the PC is off open the front left PC cover and press the PC power button The software will b...

Page 36: ...fault operator is PCBRM Click Thumbs Up icon The default password is blank Click Thumbs Up icon A message will appear stating that the machine will perform a home operation all motorized axes will hom...

Page 37: ...t gas blades Note THIS IS THE ONLY LOCATION IN THE SOFTWARE FOR SETTING THE SOLDER POT TEMPERATURE THE SOLDER POT HEATER TEMPERATURE SETTING SHOULD BE BASED ON THE TEMPERATURE REQUIRED TO GET THE DESI...

Page 38: ...PCBRM100 User s Guide Chapter 3 Start Up 4101 00 902 3 6...

Page 39: ...4 Software Overview 4 Software Overview 3 4 0 WINDOWS TOOLS OVERVIEW 3 4 1 OPTIONS MENU FUNCTIONS 8 4 2 HISTORY MENU 41 4 3 SETUP 43 4 4 RESET OPERATOR 47 4 5 PROTECTED SYSTEM SECURITY ACCESS 49 4 6 T...

Page 40: ...PCBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 2...

Page 41: ...PCBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 3 4 Software Overview 4 0 Windows Tools Overview Software Main Screen...

Page 42: ...the top of the icon Note IF A BUTTON IS COMPLETELY GRAY THE FUNCTIONS ASSOCIATED WITH THAT BUTTON ARE DISABLED Edit Boxes Edit Boxes allow information to be entered by placing the cursor over the top...

Page 43: ...tivated The time mode and time delay value are not used Filled state A filled box indicates a third option For Example Clear Continue to Main Screen Checked Continue to Run Screen Filled Continue to T...

Page 44: ...hrough the list using the scroll bar to the right of the list box The operator can select any line within the list by moving the mouse to that line and clicking left button on that line To select an e...

Page 45: ...to display several lines of information on the screen After making a selection the list box collapses back down to one line For Example By clicking left button on the down arrow the board group list...

Page 46: ...PCBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 8 4 1 Options Menu Functions View of the Options Menu Close Allows the operator to close either an open board image or a profile...

Page 47: ...Chapter 4 Software Overview 4101 00 902 4 9 New The New option located on the Options menu will automatically clear the current profile from memory and display the teach screen The system is ready to...

Page 48: ...4 Software Overview 4101 00 902 4 10 Board Image New Located on the option menu will automatically clear any open profile or board image from memory and display the board image build The system is rea...

Page 49: ...e library organization The profile list can be adjusted by changing the group selection combination Clicking on the down arrow of a group list box will display a window with all the available options...

Page 50: ...PCBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 12 Board Image Open Scroll to find the customer group Select the correct board Click on Select...

Page 51: ...Software Overview 4101 00 902 4 13 Board Image 2 Operator view Click on part you want to rework Component will turn green Click the check box Check Select component process Click on the check box Cli...

Page 52: ...atically take the operator to the Open Profile Notes screen This screen is used to display general setup or process related information Clicking on the Ok button will take the operator to the Run scre...

Page 53: ...his screen allows the operator to process an application In general this screen provides the operator with messages heating and flow rate information thermocouple readings and the overall progress of...

Page 54: ...B allows the operator to quickly open a related profile soldering or desol dering without leaving the Run screen The Link Name is not automatically generated The operator must enter this information T...

Page 55: ...d and Device Group These groups E allow profiles to be organized using a combination of customer board and device name New groups can be easily created see Setup Group Categorizing profiles by group c...

Page 56: ...rview 4101 00 902 4 18 Board Image Save The Board Image Save option is used to save a NEW board image or resave an EXISTING board image The customer name and board image name will come up from the Ope...

Page 57: ...nctionality of the profile The operator has the option to move the new profile to a different group New link names can be added at any time Note THE ORIGINAL PROFILE REMAINS UNCHANGED AND COMPLETELY I...

Page 58: ...er 4 Software Overview 4101 00 902 4 20 Delete Profiles The Delete Profile screen allows the operator to delete files based on the Long Name similar to the Open option The operator will be prompted be...

Page 59: ...o be backed up B Select the profile s to be backed up one or more C Select the USB Memory Storage Device for the profiles to be backed up to Plug into computer D Click on the backup icon to backup Cli...

Page 60: ...The Restore option allows profile s to be restored from a USB Memory Storage Device Select the Restore source The files available for restore will appear Click the restore icon The profiles have been...

Page 61: ...ing profiles 1 Select a target profile or click on the select all profiles button 2 Highlight left single click profile long name s multiple selections allowed 3 Select a destination profile group 4 C...

Page 62: ...PCBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 24 About The About screen contains general information about Air Vac Engineering and the current software version...

Page 63: ...down any active devices vacuum air flow etc The Windows Desktop screen will be displayed DRS25 Machine E Stop Button The E Stop button will de power the machine It should only be used in the case of...

Page 64: ...screen is organized into the following sections Numeric Process Information Profile Event Alert Foot Switch Messages Graph Process Information Event Time Event Counter Process Time Button Functions So...

Page 65: ...h process temperature flow rate force and thermocouples Nozzle and Preheater System The Nozzle System upper heater graphically displays the following control parameters Nozzle flow rate percentage set...

Page 66: ...number positioned between the set point and actual displays When a thermocouple channel is controlling the process a T C Control message will be displayed at the bottom of the screen This message will...

Page 67: ...ated with component force placement force re moval or force adjustment The Force System graphically displays the following control parameters Force target set point green A Force actual applied force...

Page 68: ...nt and Foot Switch Messages B This section of the Run screen displays system foot switch messages or pre programmed event alert messages Messages are used to inform the operator when machine interacti...

Page 69: ...Information This section of the Run screen displays the Temperature vs Time graph Event Time D Time remaining in the current event Event Counter E Current and maximum profile event counters Process T...

Page 70: ...PCBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 32 Function Buttons G This section of the Run screen displays the function buttons that are available to the operator G...

Page 71: ...un screen and return the operator to the Main screen Nozzle Vacuum The Nozzle Vacuum button will activate or deactivate the nozzle vacuum When this function is active the button background will be dis...

Page 72: ...Z and Vision motor axis Dry Run Activating this will allow the profile to run without heat Skip Nozzle Align Activating this will allow the profile to skip the nozzle align task Update Pump Velocity A...

Page 73: ...ode Board Serial Number Tracking I This section of the Run screen allows a board serial number to be tracked and recorded in the cycle history file The operator has the option to enter this informatio...

Page 74: ...s that are available to the operator Load Process Link File Menu Option The Load Process Link File menu J allows the operator to toggle between the soldering desolder ing and site cleaning profiles Th...

Page 75: ...folder Clicking on the small blue button K will export the chart data to the export folder Export directory C Program Files Air Vac Engineering Platform Export Run This information can be retrieved at...

Page 76: ...d and stored using an 8 digit file sequence number Clicking on the green button will present a file browse window allowing the operator to select chart data files from one of the following folders C P...

Page 77: ...king on Control Thermal Profile Analysis Printing will display the following screen Clicking on the green button will present a file browse window allowing the operator to select chart data files from...

Page 78: ...e reviewed such as maximum joint temperature maximum package tem perature time over set temperature etc To change set temperature input desired temperature in box To view specific slopes move vertical...

Page 79: ...s Guide Chapter 4 Software Overview 4101 00 902 4 41 4 2 History Menu The History menu has two options Cycle and Alarm Cycle History A History file entry is recorded each time the operator cycles a pr...

Page 80: ...Chapter 4 Software Overview 4101 00 902 4 42 Alarm History The software continuously monitors the controlling sub systems If an alarm condition occurs for any process or hardware issue an Alarm file e...

Page 81: ...ol parameters These options are only available to high priority operators Preheater Idle Selecting the Signal Idle from the Setup menu will present the operator with the Idle Control screen These sett...

Page 82: ...e type the desired group name into the group edit box A Click on the New Add Entry button to insert the new group into the existing list B To delete a group the operator must first highlight the group...

Page 83: ...apter 4 Software Overview 4101 00 902 4 45 Limits and Defaults This screen is used is primarily used to modify the default profile groups used by the Open profile option The process temperature limits...

Page 84: ...all screens Caution should be taken when defining these operators All critical machine parameters or process profiles can be adjusted Low priority Operator Operators can only run existing profiles an...

Page 85: ...Overview 4101 00 902 4 47 4 4 Reset Operator Click on the Reset Operator Log Off option on the menu bar the Operator Login screen will be displayed Log in again followed with your security access code...

Page 86: ...CBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 48 Operator is PCBRM click Thumbs Up icon to continue Thumbs Down icon to exit software Password is blank click Thumbs Up icon to continu...

Page 87: ...ystem Security Access To access the Protected System Menu the operator must click on the Air Vac logo with the right mouse button The menu background color will change to red The menu options will be...

Page 88: ...M100 User s Guide Chapter 4 Software Overview 4101 00 902 4 50 Options functions are the same as in the main menu Control functions are the same as in the main menu History function includes Machine T...

Page 89: ...ity as the standard operator idle option Signal Idle same as Main menu from the Setup menu will present the operator with the Signal Idle Control screen These settings are global and will control the...

Page 90: ...PCBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 52 Adjustments...

Page 91: ...set for each air flow percentage reference and calibrated to a certified flow meter The Flow Sensor and Flow Con troller have individual dial indicators and are adjusted individually starting at 100...

Page 92: ...ter 4 Software Overview 4101 00 902 4 54 Force Adjustment This screen is used to provide adjustment and calibration to the force system This activity is performed at the factory and normally does requ...

Page 93: ...ividual calibration points should not be made Adjustments are available to influence the automatic adjustment decision logic contact Air Vac fac tory technicians To start the calibration sequence the...

Page 94: ...roperties All machine properties control setup parameters are connected to this screen Machine properties associated with different peripherals to be quickly adjusted Click on the plus sign to expand...

Page 95: ...pter 4 Software Overview 4101 00 902 4 57 Machine Maintenance This screen offers access to all machine the interface control signals This screen is normally used to test individual control signals dia...

Page 96: ...PCBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 58...

Page 97: ...le is broken down into individual events and is numbered 1 XXX 8 Each event contains a task or group of tasks that will be executed when the event comes up in the Run Screen 16 A task is a combination...

Page 98: ...n 12 Motor Motion This group allows the movement of the axes listed Clicking on the blue Motor Axis bar brings up a motor panel 13 OK Exit Screen Exits Teach screen and temporarily saves any changes m...

Page 99: ...to an image command nozzle component etc Message Example Use nozzle NTXXX with photo of nozzle attached FootSwitch Event is footswitch or time based Show 1st Image Automatically show first image max...

Page 100: ...that nozzle alignment is always done NOTES for 1 3 Use for automatic laser squaring of nozzle 1 Noz Length Y mm min 0 mm max 175 mm Width of nozzle in correct orientation 2 Noz Margin Y mm min 30 mm...

Page 101: ...e Skip Request Skip Message Restart Event Primary use is to restart barrel cleaning if a force error occurs discuss Allow Restart Event Nozzle Heating Z Axis HotGas Heater Flow Control min 0 max 100 G...

Page 102: ...lades Left SolderPot Hot Gas C min 0 max 600 Left blade set temperature Left SolderPot Hot Gas Low Left blade low flow rate 4SCFM max flow rate if Left SolderPot Hot Gas High Left blade high flow rate...

Page 103: ...reaches target temp Average TC If you see 2 or more TC channels to measure board temp Temperature C min 0 max 300 Target board temp 150 C typical Maximum Delay sec min 0 max 1000 Maximum time in prehe...

Page 104: ...om Alignment zoom based on size of part Use Z HotGas Must be checked if Z hot gas nozzle is used moves nozzle to align position Use FootSwitch If unchecked Timed Delay sec min 0 max 300 If checked All...

Page 105: ...skips approach height and proceeds directly to place position If checked FootSwitch unchecked board approach height not used for hot air hot only removal Timed Delay sec min 0 max 300 Approach height...

Page 106: ...only removal time based on time recorded during develop ment using footswitch Place Position mm 12 50mm optimal height above bottom heating blades Place Position Velocity min 1 max 100 Board Z speed...

Page 107: ...02 4 69 Board Depart Height Process Use Depart Height If checked Depart Height mm min 200 max 0 Distance board will depart Depart Height Velocity min 1 max 100 Speed board will depart Event Message un...

Page 108: ...e Removal FootSwitch Function always performed nozzle lifts and retracts 2 Max FootSwitch Delay sec min 0 max 300 Max time solder flows after footswitch in cluding nozzle lifting 3 Solder Pump Off Aft...

Page 109: ...Z HotGas LED min 0 max 100 HALOGEN LIGHTS 100 Return To Center Position Tip will return to center position when done Close Camera When Done Camera image will close at end of barrel clean process Stop...

Page 110: ...Use footswitch Timed Delay sec min 0 max 300 Approach height mm min 1 max 50 DO NOT USE Approach Height Velocity min 1 max 100 Event Message unchecked Board Placement Process Place Position mm 12 500m...

Page 111: ...force touch If checked Use auto adjust will automatically adjust tip height above board dur ing barrel cleaning Depart Height mm Distance in mm tip will retract after initial force touch 1 5mm Depart...

Page 112: ...ize X mm Define barrel cleaning area Size Y mm Example DIMM X 11 Y 130mm Nozzle Size X mm Barrel clean tip is 5 0mm Nozzle Size Y mm Use 4 0 to provide 1 0mm overlap If checked Uses component dimensio...

Page 113: ...Right Camera If checked activate right camera only Soldering Process Soldering Process Soldering Process Z HotGas LED Halogen lights 100 Board Approach Height Process Use Approach Height If checked n...

Page 114: ...User s Guide Chapter 4 Software Overview 4101 00 902 4 76 Use Place Position If checked footswitch for development time for actual Mm 1 0 2 0 Velocity 10 Message Solder Immersion Board Depart Height...

Page 115: ...s Process Use Z HotGas If checked see removal section Plus Depart Height 30mm Inspection Manual Object Inspection Inspect barrels after barrel clean process Front Inspect LED Red front LED S 100 Back...

Page 116: ...rol Thermocouple Wait Channel Channel 1 TC01 typically taped to board and used to control board temp in the pre heater and to maintain board temperature throughout the process maintain function Other...

Page 117: ...To Safe Height NOTREQUIRED If checked Return To Start Position General Device Signal Control Name drop down menu SiteCleanVacuum Barrel clean vacuum NozzleVacuum Not used ProbeVacuum Not used Status d...

Page 118: ...PCBRM100 User s Guide Chapter 4 Software Overview 4101 00 902 4 80...

Page 119: ...velopment 4101 00 902 5 1 5 Process Development 5 Process Development 3 5 0 PROFILE BOARD 3 5 1 PROCESS ADVICE 4 5 2 REMOVAL AND BARREL CLEANING MASTER 6 5 3 REPLACEMENT AND SOLDERING MASTER 16 5 4 BO...

Page 120: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 2...

Page 121: ...profile board must be created Thermocouples TC s should be attached to the top of the board bottom side joints and temperature sensitive adjacent components if any Care should be taken to identify gro...

Page 122: ...process setting in the run screen The programmed pump process setting is shown to let the operator know the magnitude of change they are making The override setting applies for as long as the opera to...

Page 123: ...A barrel cleaning restart function is part of every removal and barrel cleaning process You will need the restart function if an error message occurs for any reason during barrel clean ing You will be...

Page 124: ...top and bottom heaters Event 8 Turns off heaters for next step Event 9 Load board and verify TC is in channel 1 Event 10 Turns heaters back on for process settings Event 11 Purges flow well and aligns...

Page 125: ...100 User s Guide Chapter 5 Process Development 4101 00 902 5 7 Event 1 Parks robot and turns on preheaters Event 2 Adjusts object dimensions for next step Event 3 Lets operator install and align flow...

Page 126: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 8 Event 4 Loads nozzle and turns on pot Hg heaters Event 5 Park pot y and camera y stabilization Event 6 Idles pump...

Page 127: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 9 Event 7 Resets object dimensions and stabilizes top and bottom heaters Event 8 Turns off heaters for next step...

Page 128: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 10 Event 9 Load board and verify TC is in channel 1 Event 10 Turns heaters back on for process settings...

Page 129: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 11 Event 11 Purges flow well and aligns part Event 12 Sets solder flow to process setting and preheats board...

Page 130: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 12 Event 13 Activates maintain bottom Hg and removal process Event 14 Install site clean nozzle...

Page 131: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 13 Event 15 Turn on site clean vacuum Event 16 Preheat nozzle Event 17 Site clean site and inspect...

Page 132: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 14 Event 18 Second site clean process and option to skip Event 19 Second inspection and skip options...

Page 133: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 15 Event 20 Heaters and vacuum off Event 21 Unload board Event 22 Park robot...

Page 134: ...aters Event 5 Park pot y and camera y stabilization Event 6 Idles pump Event 7 Resets object dimensions and stabilizes top and bottom heaters Event 8 Turns off heaters for next step Event 9 Load board...

Page 135: ...100 User s Guide Chapter 5 Process Development 4101 00 902 5 17 Event 1 Parks robot and turns on preheaters Event 2 Adjusts object dimensions for next step Event 3 Lets operator install and align flow...

Page 136: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 18 Event 4 Loads nozzle and turns on pot Hg heaters Event 5 Park pot y and camera y stabilization Event 6 Idles pump...

Page 137: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 19 Event 7 Resets object dimensions and stabilizes top and bottom heaters Event 8 Turns off heaters for next step...

Page 138: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 20 Event 9 Load board and verify TC is in channel 1 Event 10 Turns heaters back on for process settings...

Page 139: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 21 Event 11 Purges flow well and aligns part Event 12 Sets solder flow to process setting and preheats board...

Page 140: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 22 Event 13 Activates maintain bottom Hg and soldering process Event 14 Heaters off...

Page 141: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 23 Event 15 Unload board Event 16 Park robot...

Page 142: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 24 5 4 Board Image Scan Click on the Air Vac logo to go to hidden menus...

Page 143: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 25 Load board into carrier Enter board dimensions in mm Press the Start button Verify that the board lines up with the cross hairs...

Page 144: ...00 User s Guide Chapter 5 Process Development 4101 00 902 5 26 Press Scan to start If board is larger than available travel then you will be prompted to rotate the board Rotate board 180 and press Con...

Page 145: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 27 When finished type name of board picture then click Save...

Page 146: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 28 5 5 Board Image Build Open New Enter customer properties board properties and board sizes in mm...

Page 147: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 29 After all above parameters are entered select Set...

Page 148: ...apter 5 Process Development 4101 00 902 5 30 Click on the Search for Board Background Image button Scroll to find picture for board then click on Select Board picture replaces green background and enl...

Page 149: ...M100 User s Guide Chapter 5 Process Development 4101 00 902 5 31 Click component location properties Click the check box to create a new component The component will appear in the top left of board im...

Page 150: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 32 Enter all parameters for the component all sizes are in mm...

Page 151: ...100 User s Guide Chapter 5 Process Development 4101 00 902 5 33 Click and drag the component to the desired location on the board Click on the X and Y motor move buttons to move the board under the ca...

Page 152: ...rocess Development 4101 00 902 5 34 Click on Activate manual teach camera alignment button The camera screen will come up and the joysticks will activate Align the yellow outline correctly over the si...

Page 153: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 35 Click on the red teach cross hair button for X and Y This will store the exact location...

Page 154: ...lopment 4101 00 902 5 36 Click component process properties 1 Click on the Search for component process button 2 Select correct component groups 3 Select profile 4 Click select button to attach profil...

Page 155: ...Development 4101 00 902 5 37 If a profile has images attached and they need to be updated use the Event image properties section Select the event Select correct image Click on update event image You...

Page 156: ...PCBRM100 User s Guide Chapter 5 Process Development 4101 00 902 5 38 The updated images will be logged under the Component location properties Event Images section...

Page 157: ...SOLDER LEVEL 12 6 3 CLEANING THE SOLDER PUMP 13 6 4 CLEANING THE PREHEATER PANELS 14 6 5 CLEANING THE BARREL CLEANING TOOL 14 6 6 MAINTENANCE GUIDE SCHEDULE 15 6 7 VERIFICATION OVERVIEW 16 6 8 FLOW R...

Page 158: ...PCBRM100 User s Guide Chapter 6 Maintenance 4101 00 902 6 2...

Page 159: ...r 6 Maintenance 4101 00 902 6 3 6 Maintenance 6 0 De Dross the Solder Pot Click on the Move Solder Pot To Cleaning Position icon Pot will move forward for easy access Board carrier will de power so it...

Page 160: ...100 User s Guide Chapter 6 Maintenance 4101 00 902 6 4 The left and right bottom convective heating blades are spring loaded so they can be moved CAUTION USE GLOVES TO MOVE BLADES OUT OF THE WAY Left...

Page 161: ...6 5 1 Move all dross off the flat surface into the surrounding gutter 2 Remove the two dross basket covers at the rear of the pot with the cover tool 3 Push the dross from the gutter through the two r...

Page 162: ...et handles to remove the baskets Deposit dross in approved hazardous container CAUTION BASKET HANDLE WILL BE HOT USE GLOVES IMPORTANT REPOSITION THE LEFT AND RIGHT CONVECTIVE HEATING BLADES AROUND THE...

Page 163: ...Chapter 6 Maintenance 4101 00 902 6 7 6 1 Change the Solder Stack Click on the Move Solder Pot To Cleaning Position icon Pot will move forward for easy access Board carrier will de power so it can be...

Page 164: ...100 User s Guide Chapter 6 Maintenance 4101 00 902 6 8 The left and right bottom convective heating blades are spring loaded so they can be moved CAUTION USE GLOVES TO MOVE BLADES OUT OF THE WAY Left...

Page 165: ...If it needs to change contact Air Vac CAUTION HOT CAREFULLY REMOVE THE STACK WITH GLOVES DO NOT USE PLIERS TO GRAB THE TOP OF THE STACK AS IT MAY CAUSE DAMAGE IMPORTANT CAREFULLY CLEAN ANY SOLDER ON...

Page 166: ...PCBRM100 User s Guide Chapter 6 Maintenance 4101 00 902 6 10 The bottom of the solder stack must be clean and free of solder especially around the edges...

Page 167: ...enance 4101 00 902 6 11 Install the new solder stack Loosely tighten the four bolts with the socket wrench Let the stack heat soak for two minutes Re tighten the bolts DO NOT OVERTIGHTEN IMPORTANT REP...

Page 168: ...pter 6 Maintenance 4101 00 902 6 12 6 2 Checking Solder Level Remove one dross basket using the basket handle CAUTION HOT USE GLOVES Solder should contact the bottom side of the dross gutter as shown...

Page 169: ...6 13 6 3 Cleaning The Solder Pump 1 Remove the motor cover not shown 2 Remove the pump belt 3 Remove the pump nut 4 The entire pump assembly can be removed 5 Remove screws to disassemble pump Clean i...

Page 170: ...erature Use alcohol and a lint free wipe to clean the preheater surfaces 6 5 Cleaning the Barrel Cleaning Tool Unscrew the barrel cleaning tool to access the solder collector Remove solder from the co...

Page 171: ...6 Maintenance Guide Schedule Daily De dross the pot Clean flux from cameras and lights Weekly Clean the preheaters carrier and plexiglass enclosure Monthly Clean the pump NOTE PUMP MAY NEED TO BE CLEA...

Page 172: ...the verification procedures be done sequentially as outlined in this section Machine verification should be done After initial setup Anytime the system is physically moved or disconnected At regularly...

Page 173: ...the Nozzle Flow Sensor which controls the Computer Digital Flow Display Nozzle flow verification is required for initial installation or any time the machine is disconnected and or moved 6 8 1 Nozzle...

Page 174: ...the Flow Adjustment Screen The airflow will activate after 1 4 seconds 6 Wait 45 seconds before making any adjustments 7 Check the 100 scribe line on the flow meter If the flow meter reads too high o...

Page 175: ...r not on the sliding bar position B 9 If the flow meter reads too low increase make 2 clicks on the right side of the track bar not on the sliding bar position B Once the 100 Flow Controller value has...

Page 176: ...is being displayed on the software screen This meter represents the ac tual flow rate sensor output from the flow controller 14 The blue meter should bounce between 99 101 If the blue meter is not wi...

Page 177: ...icon to save changes and exit the Flow Adjustment screen IMPORTANT DISCONNECT THE BLUE FLOW METER HOSE FROM THE FLOW VERIFICATION FITTING AND RECONNECT THE BLUE UPPER HEATER HOSE FAILURE TO RECONNECT...

Page 178: ...PRIOR TO RUNNING THE TOP HEATER WILL CAUSE THE TOP HEATER ELEMENT TO FAIL 6 9 1 Upper Heater Verification 1 Install NCAL 5 temperature verification nozzle into the machine 2 Plug the nozzle thermocou...

Page 179: ...peratures and flow rates and will plot the Upper Heater temperature red line and the NCAL 5 Nozzle Temperature green line 6 After verification is complete click on the Calibrate box so it is solid Nex...

Page 180: ...PCBRM100 User s Guide Chapter 6 Maintenance 4101 00 902 6 24...

Page 181: ...s 4101 00 902 7 1 7 Error Messages 7 Error Messages 3 7 0 COMPLETE ALARM LISTING 3 7 1 TC01 EXCEEDED SENSOR PROCESS LIMITS 5 7 2 BOARD CARRIER POSITION MAX USER MOTION SAFETY CHECK 6 7 3 EXCEEDED MAX...

Page 182: ...PCBRM100 User s Guide Chapter 7 Error Messages 4101 00 902 7 2...

Page 183: ...rror Messages Some error messages can be easily corrected by the operator Other error messages will require assistance from Air Vac 7 0 Complete Alarm Listing The complete alarm listing can be accesse...

Page 184: ...s Guide Chapter 7 Error Messages 4101 00 902 7 4 All machine alarms and their current status are shown In this case there is a board carrier position max error Contact Air Vac with any questions on e...

Page 185: ...ror Messages 4101 00 902 7 5 7 1 TC01 Exceeded Sensor Process Limits TC01 is a control thermocouple Currently a thermocouple is not plugged in to channel 1 Plug in the TC and tape it to the board Clic...

Page 186: ...apter 7 Error Messages 4101 00 902 7 6 7 2 Board Carrier Position Max User Motion Safety Check The board carrier slide drawer has not been pushed all the way in Push the slide drawer in Click on the e...

Page 187: ...Control Delay The maximum allowable time in preheat has been reached and the board did not reach preheat target tem perature The process will abort and the carrier will Home Verify that the TC is pro...

Page 188: ...PCBRM100 User s Guide Chapter 7 Error Messages 4101 00 902 7 8 7 4 Low Pressure Message Indicates that pressure regulators are not seeing minimum required air flow...

Page 189: ...C1 Hot Gas L3 3D1 184 Hot Gas Htrs L2 185 76 TB2 79 78 77 154 369 TB3 78 82 B2 Breaker 2 pole 81 4 A 181 182 369 Chys Gnd 2B1 Start Switch L 2B1 Start Switch N 74 73 Start Switch L Start Switch N 74 7...

Page 190: ...ET 24V RET 24V RET 24V RET N AC NEUTRAL 13 243 240 238 239 Motor PS PS 3 235 237 153 TB1 24 5 RET COM 15V 15V COM 15V 118 117 116 115 150 114 113 152 151 152 116 115 114 113 114 113 27 249 10B1 5B3 23...

Page 191: ...33 142 258 259 265 63 64 N2 Nozzle Common 1D3 65 1 2 1 2 1 2 1 2 UH1 TC UH1 TC LN2 TC LN2 TC 1 1 2 2 TBL 3 141 TB27 142 TB59 134 TB58 132 TB26 1 One 2 Two 119 369 TB60 CH GND HEAT HEAT T C T C NOZZLE...

Page 192: ...TB54 136 TB53 145 TB51 146 TB52 Power Panel DOUT 2 18 Up Preheater LS F13 15A F13 15A F13 15A 140 139 138 108 109 110 5B3 276 56 54 52 108 109 110 279 280 DOUT 3 19 Low Preheater LS F12 15A F12 15A F...

Page 193: ...11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Wago DI Light RS LIght Gnd RS 339 338 381 382 383 384 385 386 387 388 389 24V Ret Motor P S LS...

Page 194: ...3 OVER TEMP CONT 8 NC 7 COM 6 NO 5 167 123 168 124 268 269 270 R Y 271 DIN 0 Upper Preheater OTC 275 DIN 2 Lower Preheater OTC 273 12C2 12C2 Lower Preheater Ret RS Upper Preheater Ret RS 5B4 12C2 276...

Page 195: ...le OP 1 NO Pot OP 1 C Pot OP 1 NO Lower Preheater OP 1 C Lower Preheater OP 1 NO Upper Preheater OP 1 C 210 213 GN 211 214 BK 212 215 R Pot L Preheat Lower Left HG Nozzle 232 232 231 231 229 229 228 2...

Page 196: ...ND MOTOR SENSE 1 GND 24V 24V RET RS 485 B RS 485 A SENSE 1 SIG 5 VDC SENSE 2 GND SENSE 2 SIG 5 VDC CH B 5V CH A INDEX GND Motor Pot Y SWITCH 1 SWITCH 2 1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7...

Page 197: ...0C6 Z Preheat Home Prox 321 19D3 323 10C6 320 539 544 542 527 543 11B4 2B6 14B5 2B6 2A6 18B1 14C5 11B4 2A6 541 236 240 366 367 371 370 320 539 544 542 527 543 NC MOTOR SENSE A SENSE B SENSE C SENSE SE...

Page 198: ...S LS 24V Motor P S LS 15 V ret P S LS 5 24 Ret LS 28V Ret Motor P S LS 24 5 V RS 28 V Motor P S LS 15 V P S LS 4C1 5D1 5B3 5B3 Main Power LED Main Power LED Ret 577 576 2D3 3D1 5B3 3D1 325 1 2 3 1 2 3...

Page 199: ...G OUT 750 511 750 560 18C1 5B4 13C1 13C1 5B4 5B4 14B3 13C1 13C1 Dout 1 17 Spare 3 Way Valve 5B4 DOUT 6 22 Nozzle High Flow 13C1 13C1 18C1 Dout 6 14 CAL SOL 13C1 Dout 7 15 LASER 13D1 13C1 13C1 13D1 13D...

Page 200: ...4 6 ref STRN 4 2 Vd sig 461 462 463 464 15B1 15B1 15B1 15B1 466 467 468 469 15C1 15C1 15C1 15C1 471 472 473 474 15C6 15C6 15C6 15C6 476 477 478 479 15B6 15B6 15B6 15B6 501 502 503 504 505 506 507 508...

Page 201: ...EGULTOR 15V 15V COM 15V 3C3 7A4 11C4 11C4 11C4 11B5 11C4 11C3 11C4 11C4 11C4 11C4 11C4 11C4 11C4 11B5 11B5 2C6 12C2 12C2 2C6 2C6 2B6 14D1 11C3 14B2 3D3 2C6 11C3 11C3 LL Hot Gas Heater Low Flow 234 203...

Page 202: ...10 12 446 445 DOUT 7 15 LASER 9D6 15V PS 15V COM PS 15V PS 243 244 384 5 24 Ret RS 24 5 V RS 5B4 5V PS 24V Pneumatics 13B1 24VB 426 24VDC 2 428 24V RET 3 429 EARTH GND 430 24V RETB 427 11C2 11C2 11C2...

Page 203: ...3 12B3 12B3 12A3 12A3 12B3 12B3 12B3 12B3 Carrier Arms 12C3 12C3 12C3 12C3 1 2 Y R 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 BK W R GN BK W R GN 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 BK W R GN BN BK R O BL GN Y V Loa...

Page 204: ...t Gas Tool 489 PWM 3 5 Z HG LED s 488 11A3 11A3 PWM 3 7 Z HG LED s Y N STABEL TC R 12C5 12C5 N STABLE TC 499 LED Light Front 435 438 PWM 2 1 Inspection LED 1 437 PWM 2 3 Inspection LED 1 436 11B3 11B3...

Page 205: ...ng com 171 172 593 Computer Network Port 19C6 USB A USB A USB A USB A USB A Network 594 Panel Mount 19C6 Monitor USB A USB A Monitor 220 Vac 220 Vac Dout 7 39 LT Green L 11C5 Dout 5 37 LT Yellow L 11C...

Page 206: ...W BK GN 8D1 5 V Joystick 5V Ret Joystick 8D2 537 536 DIN 1 17 Z Rapid Joystick Y W R W BN O W Left Right Joystick BL Left Right Front Back 514 DOUT 4 20 X Y Joystick Enable DOUT 2 10 Z Joystick LED D...

Page 207: ...ronics Motor Drivers POE POE POE POE NET NET NET NET POE POE POE NET Cisco POE Router 100 240 Vac Power Cisco Router 1A3 173 NET USB B USB A USB HUB 4 USB HUB 5 USB HUB 6 USB HUB 7 USB B INPUT 17B4 US...

Page 208: ...583 TB68 584 TB69 610 625 TB70 584 583 1 2 TS 8 3 4 5 6 8 7 1 2 3 4 5 7 6 8 BK W 588 BL W 585 Ain 0 8 Laser Solder Level Dout 4 36 Laser SL Laser Dout 6 38 Laser SL Zero 11C5 11C5 11A4 R W 589 BL 566...

Page 209: ...Field Label 1301 WIP 4101 00 900 B ddb Drawn By Elect Schem PCBRM 100 Revision Table 4101 00 900 B Joe Koutrakos 21 21 AIR VAC Engineering Inc 30 Progress Ave Seymour CT 06483 Initial Release Revisio...

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