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Pcbrm15 & PCBRM System 5.2 User’s Manual Chapter 6: Troubleshooting

Part No. 4005.00.906

6-3

6

Troubleshooting

6.0 Air-Vac Technical Service

Air-Vac is always willing to assist our customers with any technical or operating questions. If you have
any questions on machine parameters, correct nozzle requirements, options, procedures or
maintenance,

please do not hesitate to call.

Air-Vac Engineering Company, Inc.

30 Progress Avenue

•

Seymour, CT 06483

•

Tel: 203-888-9900

•

Fax: 203-888-1145

www.air-vac-eng.com

e-mail:

General Sales Information:

[email protected]

Technical Support:

[email protected]

6.1 Common Problems/Solutions

NOTE

A

LL

PCBRM

UNITS ARE TESTED PRIOR TO SHIPPING

.

T

EMPERATURE CONTROLLERS ARE

PROGRAMMED AND TESTED AT

500

°

F/260

°

C.

6.1.1 Machine will not turn on, or turns on for a short period and shuts off

1. Defective latching relay 12879.
2. Consult Air-Vac for further help.

6.1.2 Pump Motor will not run

1. Motor fuse blown

WARNING

DO NOT REPLACE MOTOR FUSE WITH ANY OTHER FUSE BESIDES

250V3AG,

3/10

AMP.

INCORRECT FUSING CAN RESULT IN DAMAGE TO SYSTEM

.

IF MOTOR FUSE STARTS TO BLOW

CONTINUOUSLY

,

SOLDER PUMP NEEDS TO BE REMOVED

,

DISASSEMBLED AND THOROUGHLY

CLEANED

.

2.  Footswitch not plugged in.
3.  SP2 – activated on temperature controller – see 0 #’s 3-5.
4.  Stand-by switch activated.
5.  Pump seized.
6.  Set point temperature set too low – solder not molten.
7.  Consult Air-Vac for further help.

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Summary of Contents for PCBRM15

Page 1: ...PCBRM15 PCBRM System 5 2 ...

Page 2: ......

Page 3: ..._ has installed the above machine and that all items have been received or are noted below The machine is in good working order and initial training was provided Customer Signature Date Air Vac Representative Signature Date Issues Items Missing Please fax this completed document to Air Vac Engineering 203 888 1145 Attn Brian Czaplicki AIR VAC ENGINEERING COMPANY INC INSTALLATION AND TRAINING ...

Page 4: ......

Page 5: ...f Contents Part Number 4005 00 906 Rev 08 00 September 2022 Chapter 1 Introduction General Overview Chapter 2 Requirements Machine Overview Chapter 3 Set Up Installation Chapter 4 Processes Applications Chapter 5 Maintenance Parts Chapter 6 Troubleshooting Chapter 7 Schematics ...

Page 6: ...PCBRM15 PCBRM System 5 2 User s Manual Table of Contents 4005 00 906 ...

Page 7: ... 906 1 1 1 Introduction Overview 1 Introduction Overview 3 1 0 Welcome 3 1 1 PCBRM15 and PCBRM System 5 2 Overview 3 1 2 Contacts Support 3 1 3 Warranty 4 1 4 Material Check List PCBRM15 5 1 5 Material Check List PCBRM System 5 2 6 1 6 Unpacking PCBRM15 7 1 7 Unpacking PCBRM System 5 2 8 ...

Page 8: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 1 Introduction Overview Part No 4005 00 906 1 2 ...

Page 9: ...ctions in regards to the unpacking installation verification operation and maintenance of these systems 1 1 PCBRM15 and PCBRM System 5 2 Overview The PCBRM15 and PCBRM System 5 2 machines provide lead free selective soldering and rework of through hole components and thermally challenging assemblies The PCBRM System 5 2 adds a 6500 watt preheater 1 2 Contacts Support Air Vac is always willing to a...

Page 10: ...placed repaired The title of the replaced parts will automatically pass to Air Vac Air Vac reserves the right to reject replacement under this warranty where in the sole opinion of Air Vac the defect is due to obvious misuse and or improper maintenance of the module or any part thereof The express and or implied warranty of Air Vac is limited to the replacement and or repair of any item defective ...

Page 11: ... 1 12050B 1 4 Spintite Sprocket Wrench 1 12050A Graphite Anti Sieze 1 AS15 Bubble Level 1 12015 Allen Wrench Set 1 12055 3mm Allen Wrench 1 12050L MACHINE ACCESSORIES DESCRIPTION QUANTITY PART NUMBER CHECK Ö Footswitch 1 12870 Bailer 1 SL5 Pot Cover 1 2004 01 108 Manual 1 2004 00 900 Ladel 1 9008 99 315 Spatula 1 9008 99 314 Gloves pair 1 12050M SPARE PARTS DESCRIPTION QUANTITY PART NUMBER CHECK Ö...

Page 12: ...0 5 32 Tee Handle Allen Wrench 1 12050B 1 4 Spintite Sprocket Wrench 1 12050A Graphite Anti Sieze 1 AS15 Bubble Level 1 12015 Allen Wrench Set 1 12055 3mm Allen Wrench 1 12050L Spatula 1 9008 99 314 MACHINE ACCESSORIES DESCRIPTION QUANTITY PART NUMBER CHECK Ö Footswitch 1 12870 Bailer 1 SL5 Pot Cover 1 12590 Manual 1 3006 00 903 Ladel 1 9008 99 315 Gloves pair 1 12050M SPARE PARTS DESCRIPTION QUAN...

Page 13: ...ons W x D x H 43 x 34 x 30 IMPORTANT DO NOT LIFT OR PULL HERE AT POINTS INDICATED DAMAGE TO SYSTEM MAY RESULT Position module on a level surface which can provide adequate support for weight Accessories are normally shipped in box with module Please inspect carefully and check that all items have been shipped Save shipping box for any future shipping X X X ...

Page 14: ...VIDED IN CENTER BASE PLATE WILL BEND LIFT MACHINE WITH A FORK LIFT AS SHOWN DO NOT LIFT OR PULL HERE DAMAGE TO SYSTEM MAY RESULT Position module on a level surface which can provide adequate support for weight Accessories are normally shipped in box with module Please inspect carefully and check that all items have been shipped Save shipping box for any future shipping Lift Here With Fork Lift X X...

Page 15: ...ine Overview 2 Requirements Machine Overview 3 2 1 Facility Requirements PCBRM15 3 2 2 Facility Requirements PCBRM System 5 2 3 2 3 PCBRM15 Module Overview 4 2 4 PCBRM15 and System 5 2 Control Panel Overview 5 2 5 PCBRM15 Carrier Overview 7 2 6 PCBRM System 5 2 System Overview 8 2 7 PCBRM System 5 2 PCB Carrier Overview 11 ...

Page 16: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 2 Requirements Machine Overview Part No 4005 00 906 2 2 ...

Page 17: ...pressed Air optional 40 80 psi 2 scfm clean moisture free air intermittent 1 8 NPT M fitting required 2 2 Facility Requirements PCBRM System 5 2 Max Operating Dimensions 76 W x 38 D x 28 H Weight 230 lbs with solder 195 lbs without solder Electrical Requirements Machine System 5 2 208 220 Vac 45 Amps full load overload protected to 55 Amps 50 60 Hz single phase 6 awg 3 wire cord supplied Heater Bo...

Page 18: ...o 21 deep PCB Stops with reference scale provides one time set up of repetitive assemblies C X Axis Carrier Lock Once PCB is aligned over flow well the carrier is locked in place D Z Axis Height Adjustment Adjusts height of PCB in relation to the flow well F Solder Pot G Solder Pump H APS System Blows low pressure air through holes in PCB of removed component to clear them of solder I APS System A...

Page 19: ...nst the pcb contacting all the component leads Too high a setting will cause solder to flood the board surface C Solder Duration Control The length of the time solder flows in one cycle can be set The process cycle can be started by either depressing the START ON the Footswitch or pressing the CYCLE Start switch D Mode Switch Automatic Mode With the Timer Switch in the Automatic Mode specific timi...

Page 20: ... the pump either quickly or slowly To increase ramp time turn knob counter clockwise To decrease turn clockwise M Ramp Down Flow Rate Adjusts motor stop speed of the pump either quickly or slowly This can help to produce a better solder joint To increase ramp time turn the knob counter clockwise to decrease turn clockwise Note FLOW RATE INFLUENCES THE TOTAL DURATION PROCESS CYCLE RAMP DOWN FLOW RA...

Page 21: ... to solder wave Adjust to width of board X Axis Carrier Lock Locks carrier in place once board is aligned over flow well Board Locks Locks board in carrier arms Y Axis Board Lock Sets y axis position of board Z Axis Adjustment Adjusts height of carrier board in relationship to the flow well X Axis Lock preheater Sets x axis position of carrier board to flow well Arm Lock s Lock carrier arms on x a...

Page 22: ...r 2 Requirements Machine Overview Part No 4005 00 906 2 8 Cleaning Hood option Flow Well Heater Control option Compliant Arm Locks Preheater X Rail Handle Flow Well Z Axis Positioning Knob X Axis Stop preheater 2 6 PCBRM System 5 2 System Overview ...

Page 23: ...verview Part No 4005 00 906 2 9 Temperature Monitor Box E Stop Switch Audible Alarm Type K Thermocouple Temperature Indicator PCB Power Receptical Microswitch Interface Receptical Z Axis Positioning Knob Microswitch Interface Plug Top Heater Controls Bottom Heater Controls ...

Page 24: ... PCBRM System 5 2 User s Manual Chapter 2 Requirements Machine Overview Part No 4005 00 906 2 10 Preheater Chassis Fuses Y Axis Preheater Lock Knob Z Axis Adjust Wheel Y Axis Preheater Slides Heat Shield Main ...

Page 25: ...2 11 2 7 PCBRM System 5 2 PCB Carrier Overview X Axis Rail X Axis Stop preheater Micro switch to activate Temp Monitor Box X Axis Stop flow well X Axis Stop preheater PCB In Preheater Fume Nozzles Y Axis Board Location Board Lock Knobs Flow Well Compliant Arm Lock PCB Carrier Arm Compliant Arm Locks ...

Page 26: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 2 Requirements Machine Overview Part No 4005 00 906 2 12 ...

Page 27: ...lation 3 3 1 Leveling Module 3 3 2 PCBRM15 Carrier Arms Installation 4 3 3 PCBRM System 5 2 Carrier Arms Installation 7 3 4 PCBRM System 5 2 X Axis Stops Set Up Function 8 3 5 PCBRM System 5 2 Z Axis Stop Set Up Function 9 3 6 PCBRM System 5 2 Preheater Safety Stop 10 3 7 Optional Fume Extraction Manifold Assembly Installation 11 ...

Page 28: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 3 Set Up Installation Part No 4005 00 906 3 2 ...

Page 29: ...LLOWING SAFETY GLASSES SHOULD BE WORN AT ALL TIMES DO NOT MOVE MODULE WHILE SOLDER IS MOLTEN DISCONNECT POWER BEFORE SERVICING MODULES CAUTION LEVELING OF MODULE SHOULD NOT BE ATTEMPTED WITH MOLTEN SOLDER IN THE POT Note LEVELING IS CRITICAL TO PROVIDE CORRECT SOLDER FLOW Level machine on table Place the level supplied with tool kit on Pump Housing A Level machine front to back and side to side by...

Page 30: ... Carrier Arms Installation Install right and left carrier arms to the bearing block using the M4 screws supplied When installing the arms please note that the spring must be installed as shown 1 Start with a flow well installed on the solder pump 2 Place a level on the flow well and note level of the well ...

Page 31: ...s in to the carrier arms Align the site to be processed on the board over the flow well and lock in place 4 The board now will need to be leveled to match the flow well step 2 NOTE The adjustment will be in the Y axis only not the X axis 5 To adjust the board to match the flow well loosen the two front screws only on each arm two turns ...

Page 32: ...f each arm _ turn 7 Turn the adjustment screw clockwise on both arms equally an 1 8 of a turn at a time until the level is at the desired place 8 Once level is achieved bring the rear two screws to bare only Make a final adjustment as required and bring the front screws to bare Now snug up all the screws Do Not Over tighten ...

Page 33: ...ock Assembly Carrier Arm 3 3 PCBRM System 5 2 Carrier Arms Installation Loosen lock knob so compliant carrier arm lock assembly can straddle the x axis rail Place compliant arm lock assembly in place as shown Use mounting screws to mount carrier arm to bearing block Lock Knob Bearing Block Mounting Screw X Axis Rail ...

Page 34: ...bs Y Axis Stop and Scale Compliant Arm Lock Knobs Board Lock Knobs Carrier Arms Board Lock Knobs Carrier Arms 3 4 PCBRM System 5 2 X Axis Stops Set Up Function Locate PCB in carrier arms and lock arms in place using compliant arm lock knobs Locate PCB in the y axis and set stop Lock PCB in arms using board lock knobs Set x axis stop preheater once PCB has been located in the preheater ...

Page 35: ...pter 3 Set Up Installation Part No 4005 00 906 3 9 Z Axis Lock 3 5 PCBRM System 5 2 Z Axis Stop Set Up Function The z axis lock presets a repeatable stop in the Z Axis for board solder location Power Receptical Microswitch Interface Receptical ...

Page 36: ... Safety Stop 3 6 PCBRM System 5 2 Preheater Safety Stop Safety Stop is removed for shipping Install once machine is set up Slide preheater forward and install screw and washer into hole Secure with lock washer and nut Place protective tube over the end of exposed screw CAUTION FAILURE TO INSTALL THIS STOP COULD RESULT IN DAMAGE TO SYSTEM ...

Page 37: ... 906 3 11 A B B 3 7 Optional Fume Extraction Manifold Assembly Installation The Optional Fume Extraction Manifold for PCBRM15 or PCBRM System 5 2 consists of an Overhead Arm A two Exhaust Nozzles B and 2 Diameter Hoses which can be attached to an in house or separate filtration system ...

Page 38: ...stem 5 2 User s Manual Chapter 3 Set Up Installation Part No 4005 00 906 3 12 C 20 x 3 8 screws and washers included 2 hose Overhead Arm mounts to bracket C which mounts to the left side of the PCBRM hardware included ...

Page 39: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 3 Set Up Installation Part No 4005 00 906 3 13 A 2 hose B 2 hose ...

Page 40: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 3 Set Up Installation Part No 4005 00 906 3 14 Overarm Connection To Nozzles B To Fume System To Nozzles B ...

Page 41: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 3 Set Up Installation Part No 4005 00 906 3 15 2 hose 2 hose Y Branch 2 hose 2 hose ...

Page 42: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 3 Set Up Installation Part No 4005 00 906 3 16 ...

Page 43: ... Cleaning Procedure 9 4 6 Soldering Replacement Component 9 4 7 Specific Production Soldering Applications 9 4 8 Temperature Controller Watlow 10 4 9 Temperature Controller CAL 9900 11 4 10 Operator Procedures 12 4 11 Set Up and Process a PCB step by step 13 4 12 PCBRM System 5 2 Soldering Sequence Using Auto Mode for Soldering 21 4 13 PCBRM System 5 2 Soldering Sequence Using Manual Mode for Sold...

Page 44: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 4 Processes Applications Part No 4005 00 906 4 2 ...

Page 45: ... INSULATED GLOVES WHEN WORKING AROUND HEATED AREA BE CERTAIN THE MODE SWITCH IS IN THE OFF POSITION NEUTRAL POSITION Remove Pot Cover A Insert Baffle Assembly B into Pump Power up system by depressing main power and reset switch on the PCBRM module When the pot reaches 500 F 260 C place solder bars into pot until solder level is reached Using gloves provided place pot cover back on pot once solder...

Page 46: ... Heater Box Spring Tabs Screw 1 2 3 4 2 Flow Well Set Up Push the Main Power and Reset Switches Process temperature is factory set at 500 F adjust as required Using insulated gloves push down on flow well and insure it is completely seated on pump If required adjust Spring Tabs of well or tighten Clampable Shank screw as required to insure flow well maintains firmly positioned on pump ...

Page 47: ... to reach and stabilize temperature typically 45 minutes After flow well has heat soaked for 15 minutes set Solder Flow Rate Control to zero Mode Switch and Cycle Machine set to Continuous Slowly increase Solder Flow Rate Control until solder fills the flow well and starts flowing over the ends Solder may solidify in flow well if not heat soaked Do not increase flow rate Allow flow well to heat so...

Page 48: ...ely 1 16 between the top of the flow well and the bottom of the pcb Molten solder needs to flow through this space contact all leads and flow freely back into the solder pot Use Z height adjustment wheel to adjust PCBRM System 5 2 Once height is set loosen and then lock the z height adjust A Once set unit is set for repetative processes CAUTION INSUFFICIENT CLEARANCE COULD FORCE THE SOLDER TO FLOW...

Page 49: ...rom reaching the entire lead pattern Cycle machine With flow rate at zero switch mode switch to continuous mode and slowly adjust Solder Flow Rate Control to produce a level flowing solder wave 4 3 Cleaning Hood Set Up option Hood must be positioned exactly over flow well with the faces of the hood and flow well parallel and square to one another ...

Page 50: ...OLTEN SOLDER FOR SOLDERING APPLICATIONS PRESSURE MAY BE SET TO ZERO OFF TO ELIMINATE NOISE Cleaning Hood is generally used for removal applications Set Ramp Down Flow Rate Control to 10 to minimize time delay of air system when solder flow has ended 4 4 Solder Temperature Pot temperature is factory set at 500 F 260 C Applications may require different temperatures The temperature controller can be...

Page 51: ... 7 Specific Production Soldering Applications In addition to component removal and replacement the PCBRM15 is commonly used for Selective Soldering in the production process Small Sub Assemblies The PCBRM12 has many advantages compared to hand soldering sub assemblies The average solder cycle is 5 10 seconds regardless of the number of component leads The heat exposure on the PCB is less since the...

Page 52: ... located at the bottom of the solder pot The actual temperature contacting the bottom of the printed circuit board is approximately 10 F less than the process temperature which is factory set at 500 F Standby Interlock Temperature SP2 The standby interlock temperatures are the same temperature The standby temperature minimizes oxidation by automatically reducing the temperature when the module is ...

Page 53: ...interlock temperature is to prevent the pump motor from operating until the solder reaches a molten condition SP2 is factory set at 70 F less than the process temperature 500 F 70 F 430 F To Change SP1 or SP2 Follow These Procedures SP1 Temperature 1 With the power and reset switches on press the key and the SP1 setting will flash 2 By holding the key down and pressing the and keys the SP1 setting...

Page 54: ...ing Fresh air must be provided A venting system or fume extraction system is recommended Slowly increase flow rate to reach proper flow for the flow well Do not increase flow rate if solder solidifies Allow flow well to heat soak slowly Do not allow solder to flow outside the confines of the solder pot Do not cool flow well with liquid water Use only ambient air environment to cool flow well Durin...

Page 55: ...t up NOTE BE CERTAIN THAT THE PUMP BAFFLE IS INSTALLED INTO THE PUMP ADJUST Z AXIS TO ITS HIGHEST POSITION INSTALL FLOW WELL AND CLEANING HOOD IF SO EQUIPPED 1 Move X Axis carrier all the way to the left 2 Move the carrier arms to an approximate position on the X Axis to hold the board 3 Lock the left arm to the X Axis rail 4 Hold PCB in left arm while moving the right arm to the board Lock right ...

Page 56: ...h 5 Move X Axis carrier to the right Be certain there is enough travel to locate PCB to the flow well Adjust arms as required 5A For System 5 2 be certain there is enough travel to locate the PCB in the preheater Adjust arms left or right as required 5B Move the left X Axis lock to the right to hard stop the center bracket and micro switch ...

Page 57: ...al Chapter 4 Processes Applications Part No 4005 00 906 4 15 Flow Well Lock Knob PCB NOTE FOR SYSTEM 5 2 BE CERTAIN THAT THE PREHEATER IS IN ITS FORWARD POSITION AND LOCKED IN POSITION 6 Move carrier to bring PCB to the flow well location ...

Page 58: ... PCBRM System 5 2 User s Manual Chapter 4 Processes Applications Part No 4005 00 906 4 16 Flow Well parallel PCB 7 Lower Z Axis to bring the PCB to contact the side of the flow well and square flow well to PCB ...

Page 59: ...Part No 4005 00 906 4 17 Z Axis Positioning Knob 8 Raise Z Axis using Z Axis height adjustment wheel and adjust PCB to a height of 1 16 above the flow well For System 5 2 loosen Z Axis lock knob and then tighten The Z Axis height is now set for repetitive applications 1 16 ...

Page 60: ...n over the flow well Use the APS over arm and cleaning hood to locate if so equipped Lock the X Axis carrier lock 10 Adjust the Y Axis stop to set position of PCB in the carrier arms For System 5 2 move the right X Axis lock to the left until hand stop against center bracket APS Overarm Cleaning Hood Flow Well Y Axis PCB Stop Center Bracket X Axis Lock ...

Page 61: ...e stabilize Adjust temperature as required For System 5 2 turn on preheater Adjust temperature as required Note ALWAYS HEAT SOAK FLOW WELLS FOR A MINIMUM OF 15 MINUTES BEFORE FLOWING SOLDER 13 Set solder flow rate Starting at zero set mode switch to continuous 14 Slowly increase flow rate until solder flows off the edge s of the flow well Flow rate is now set for that flow well Different flow rate...

Page 62: ... the preheater When alarm sounds temperature has been met 17 Move PCB to flow well location Mode Switch Duration Footswitch NOTE UNTIL DURATION TIME OF SOLDER FLOW HAS BEEN ESTABLISHED SET THE DURATION TO THE MAXIMUM SETTING AND START AND STOP THE FLOW BY USING THE FOOTSWITCH MANUAL MODE BY USING A STOP WATCH THE DURATION CAN BE DETERMINED THE DURATION SETTING IS A RELATIVE SCALE AND THEREFORE SET...

Page 63: ...r handle until x axis lock preheat is reached Be sure carrier is in the top position to avoid hitting the flow well Adjust z axis adjustment if necessary Carrier may be lowered to enhance preheating Allow board to preheat to desired topside temperature IR temperature sensor will monitor and display board temperature 4 When board has reached desired temperature alarm will occur Slide board using th...

Page 64: ...er is in the top position to avoid hitting flow well Carrier may be lowered to enhance preheating Allow board to preheat to desired topside temperature IR sensor will monitor and display board temperature 4 When board has reached desired temperature alarm will occur press footswitch to activate solder flow Skim off dross if necessary 5 Slide board over solder wave using the carrier handle until ca...

Page 65: ... Allow sufficient temperature to a be achieved to activate flux Board must be level to solder wave Fixturing may be required The vertical position of the board is critical for proper soldering results Allow solder to contact all leads but sufficient clearance for solder to flow Bridging may be reduced by raising carrier position and allowing solder to wick up the leads Using tacky flux may allow m...

Page 66: ... cleaning operation starts immediately at the end of the component removal procedure There will be an audible signal that indicates solder has stopped flowing against the board At this time lower the Air Cleaning Hood It is important that sufficient downward pressure be applied to insure a good seal between the hood and board surface Be sure entire area is sealed Air leakage will prevent maximum e...

Page 67: ...tions In the automatic mode the end of solder flow is indicated by an audible signal Do not attempt to remove component after the signal The board must remain rigid and level during the removal process Do not pull the board upward away from the wave or push downward into the wave since this will cause flooding Fixturing may be required 4 15 Component Replacement Reference Soldering procedure 4 15 ...

Page 68: ...PCBRM15 PCBRM System 5 2 User s Manual Chapter 4 Processes Applications Part No 4005 00 906 4 26 ...

Page 69: ...arts 5 Maintenance Parts 3 5 0 Preventative Maintenance Schedule 3 5 1 Solder Removal 4 5 2 Pump Cleaning 4 5 3 Pump Disassembly Cleaning 5 5 4 Pump Leveling 8 5 5 PCBRM System 5 2 Specific Parts 11 5 6 PCBRM15 Mechanical Breakdown 12 5 7 PCBRM15 Electrical Compartment 14 5 8 PCBRM15 Fuses 15 5 9 Tooling 16 ...

Page 70: ...Pcbrm15 PCBRM System 5 2 User s Manual Chapter 5 Maintenance Parts Part No 4005 00 906 5 2 ...

Page 71: ...mpeller shaft A fine black powder will collect at the surface where the rotating impeller shaft enters the molten solder Remove with spatula tool Dispose of dross in a metal container The dross is at a very high temperature and should not contact anything that can melt or catch fire Report any problem to supervisor Fix any problems before further damage to the machine or customer assemblies occur ...

Page 72: ...n all parts except pump bearings thoroughly Use mineral spirits to remove dirt Use a wire brush for easy to get at areas Use a scraping tool for hard to reach areas 4 Inspect parts before reassembling especially pump bearings Check bearings for free smooth action no binding or rough action if so replace Assembly see Disassembly Procedure 5 Be certain when assembling the pump housing to pump bracke...

Page 73: ... R and discard 18 Clean all parts of solder and dirt using a wire brush or a tool to scrape solder from pieces 19 Re assemble pump as shown in drawing as follows Insert lower bearing into pump bracket Turn bracket upside down and insert pulley hub side into upper bearing hole Place spacer on top of pulley Insert shaft into bracket through pump sleeve bearing spacer and pulley Turn bracket over and...

Page 74: ... 1 4 Button Hd 2 60A I Washer 6 SAE 2 9A J Screw 10 32 x 5 8 2 9000 00 000 titanium K Nut 10 32 2 9000 06 002 titanium L Nut 6 32 x 4 8B M Set Screw 6 32 x 5 16 4 11A N Pump Sleeve Assembly 1 2004 01 041 titanium O Set Screw 10 32 x 3 8 1 9000 10 249 titanium P Baffle Assembly 1 2004 01 043 titanium Q Pump Mounting screws 10 32 x _ 2 23A R Pump Insert 1 12418 H I E G F E M L A H I J N Index Mark D...

Page 75: ... Spacer and Lower Bearing can be removed Remove Bearing Retainer Hex Screw and Washer allowing removal of Upper Bearing Use graphite lubricant on screws 5 3 2 Replacement of Drive Belt A Disconnect electrical power Remove Rear Cover Screws 4 Remove Flow Well B Pot Cover C Remove Belt Guard Hex Screws 2 and Belt Guard D Loosen Screws 4 holding Motor E Slide motor as high as possible Remove Drive Be...

Page 76: ...TING SCREWS NEED TO BE LOOSENED PRIOR TO MAKING ADJUSTMENTS TO ANY OF THE LEVELING SCREWS THEN SNUG BACK DOWN TO READ THE LEVEL TWO LEVELING SCREWS NEED TO BE ADJUSTED IN ANY ONE ADJUSTMENT EXAMPLE WHEN PARALLELING THE PUMP TO THE CARRIER ARMS EITHER THE RIGHT TWO SCREWS WILL BE ADJUSTED TOGETHER OR THE LEFT TWO SCREWS TOGETHER FOR EAST WEST ADJUSTMENT AND THE BOTTOM TWO SCREWS WILL BE ADJUSTED TO...

Page 77: ...nd by how much Note THE PUMP HOUSING STACK MUST BE PARALLEL TO THE CARRIER ARMS THEY DO NOT NEED TO BE LEVEL LEVELING THE MACHINE IS THE NEXT STEP Re check the level of the pump and lock down the 4 lock nuts DO NOT OVER TIGHTEN Machine Level Next level the machine place level on the solder pump and level the machine on a workbench Bring the bubble dead center in both x and y positions by using the...

Page 78: ... and tighten motor screws Attach pulley guard 2 1 4 hex head screws Install pot heat shield Install rear door Turn machine on and let it heat up Note Do not run pump without solder Damage to the pump sleeve will occur Once machine comes up to temperature load lead free solder approx 35 lbs _ from top of pot Once pot is filled with solder place pot cover on pot Motor belt Pulley guard ...

Page 79: ...5 5 PCBRM System 5 2 Specific Parts Note SEE PCBRM15 FOR A LIST OF COMMON PARTS Item Part Description 1 Temperature Controller 2 PH161 Circuit Breaker 3 Proj DRS SCS 73 Handle 4 4005 01 111 Handle Extension 5 ST350 Flow Well Heater Box option 6 PH154 Panel Heater PH157 Panel Heater Thermocouple not shown ...

Page 80: ... 26 25 29 4 5 6 7 8 2 3 16 1 17 18 14 15 44 45 47 49 49 48 50 51 52 53 54 57 56 55 20 58 21 59 19 46 43 42 41 40 39 37 38 12 13 36 35 10 33 34 10 9 30 Lock Rod 12318 Bracket 12324 Screw 5A 6 32 x 1 2 6B 6 32 x 3 4 10A 6 32 x 3 16 37B 5 16 x 5 8 Screw 36B Washer Idler Gear SM 12354 Idler Gear LG 12323 3 Phomalic Washer 12370 Idler Screw 12369 ...

Page 81: ...t Shield 1 12322 24 Screw 6 32 x 1 4 Heat Shield 3 1A 25 Bracket 1 12316 26 Spring 1 12374 27 Knob 1 12319 1 28 Washer 10 1 53A 29 Y Stop Knob 1 0100 03 046 30 Y Stop 1 12326 31 Carrier Arm Lock Knob 2 12306 32 Arm Attach Screw 4 29B 33 E Stop 1 12837 34 Carrier Lock Shaft 1 12320 35 Carrier Lock Knob 1 12356 36 Z Crank Assembly 1 12CK 37 Leveling Legs 4 12151 38 Hex Nut 5 16 1 36A 39 Height Adjus...

Page 82: ...r duration 25K 2 9002 05 018 Potentiometer flow 50K 3 9002 11 051 Temperature controller Watlow 4 12862 Cycle control board 5 12420 Motor assembly 6 12865 Pot relay 7 12864 Transformer 220 110v 8 12879 Latching relay 24v 9 12883 Emergency off relay 24v 10 12882 Transformer 220 24v 11 9001 12 006 Air regulator 12 12750 Solenoid 1 3 4 2 10 9 8 7 6 5 11 12 ...

Page 83: ...RM15 PCBRM System 5 2 User s Manual Chapter 5 Maintenance Parts Part No 4005 00 906 5 15 5 8 PCBRM15 Fuses NOTE Refer to the schematic 2004 00 902 1 2 AMP Slow Blow 3 10 AMP 1 4 AMP Slow Blow 15 AMP 2 AMP ...

Page 84: ...r multiple soldering of components 5 9 Tooling 5 9 1 Special Soldering Desoldering Applications Special Flow Wells and Cleaning Hoods can be manufactured for specific applications where issues of clearance adjacent components and mixed technology boards are concerns Consult Air Vac for details concerning your specific requirements and the optimum solution A detailed dimensioned customer print and ...

Page 85: ...5 9 2 Application Specific Tooling Provides the Most Efficient Process Solution Send your board to Air Vac for quick assistance to enhance your process and improve productivity A three dimensional tooling model can be forwarded to you for viewing Fixtures allow multiple boards or areas to be soldered in one cycle using the y axis stop All boards are preheated at the same time Fixtures can also be ...

Page 86: ...HOODS CAN BE MODIFIED TO MORE CLOSELY CONFORM TO LEAD PATTERNS Dimension Flow Well Dimension Flow Well W x L Part Number W x L Part Number 1 4 x 1 1 4 FW8 40 7 8 x 1 5 8 FW28 52 3 8 x 1 3 8 FW12 44 1 x 1 7 16 FW32 46 3 8 x 2 3 16 FW12 70 1 1 8 x 1 1 8 FW36 36 3 8 x 2 3 4 FW12 88 1 1 4 x 1 1 4 FW40 40 3 8 x 3 1 4 FW12 104 1 3 8 x 1 3 8 FW44 44 _ x 29 32 FW16 29 1 _ x 1 _ FW48 48 _ x 1 FW16 32 1 3 4...

Page 87: ... 2 User s Manual Chapter 6 Troubleshooting Part No 4005 00 906 6 1 6 Troubleshooting 6 Troubleshooting 3 6 0 Air Vac Technical Service 3 6 1 Common Problems Solutions 3 6 2 Temperature Controller Installation CAL 9900 only 5 ...

Page 88: ...Pcbrm15 PCBRM System 5 2 User s Manual Chapter 6 Troubleshooting Part No 4005 00 906 6 2 ...

Page 89: ...ng com 6 1 Common Problems Solutions NOTE ALL PCBRM UNITS ARE TESTED PRIOR TO SHIPPING TEMPERATURE CONTROLLERS ARE PROGRAMMED AND TESTED AT 500 F 260 C 6 1 1 Machine will not turn on or turns on for a short period and shuts off 1 Defective latching relay 12879 2 Consult Air Vac for further help 6 1 2 Pump Motor will not run 1 Motor fuse blown WARNING DO NOT REPLACE MOTOR FUSE WITH ANY OTHER FUSE B...

Page 90: ...further help 6 1 5 Fault Indication CAL9900 only Temperature display on a fault indication is replaced by EE flashing followed by a digit This indicates that an error has been detected in the system Action should be taken as follows EE1 SENSOR BURNOUT CHECK SENSOR AND OR CONNECTIONS THEN KEY EE2 TEMPORARY SYSTEM ERROR SELF CLEANING EE8 LOSS OF CALIBRATION EE9 NVM DATA FAULT NON VOLATILE MEMORY Not...

Page 91: ...Installation CAL 9900 only 1 Remove the socket by pressing in the lock buttons 2 Slide the controller into the cut out 3 Fit the mounting clip by pressing it firmly against the panel jacking screws optional 4 Plug on the socket 6 2 1 Setting Parameters of the CAL 9900 Temp Controller also refer to Cal control booklet ...

Page 92: ...Pcbrm15 PCBRM System 5 2 User s Manual Chapter 6 Troubleshooting Part No 4005 00 906 6 6 ...

Page 93: ...Pcbrm15 PCBRM System 5 2 User s Manual Chapter 7 Schematics Part No 4005 00 906 7 1 7 Schematics ...

Page 94: ...Pcbrm15 PCBRM System 5 2 User s Manual Chapter 7 Schematics Part No 4005 00 906 7 2 ...

Page 95: ... 8 7 4 4 11 12 0 F4 0 3A M M1 SOLDER PUMP TS4 TS10 TS8 TS9 45 46 51 50 53 45 51 50 1 2 3 4 5 6 J5 13 10 ACCEL 100K DECCEL 500K T2 30VA EMO 89 88 240V AC 24V AC 1 5 7 9 LT1 POWER R LT2 CYCLE G 17 70 33 34 69 18 5 4 6 7 59 CR1 CR2 RESET CR2 35 56 15 14 26 69 4 7 LIMIT CONTROLLER OTC OTC CONT TEMPERATURE CONTROLLER HEATER CONTROL CR2 6 8 57 55 CYCLE CONTROL CARD CONNECTORS SW1 3 4 SW2 SW3 58 71 72 73...

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Page 97: ...M1 SOLDER PUMP TS4 TS10 TS8 TS9 45 46 51 50 53 45 51 50 1 2 3 4 5 6 J5 13 10 ACCEL 100K DECCEL 500K T2 30VA EMO 89 88 240V AC 24V AC 1 5 7 9 LT1 POWER R LT2 CYCLE G 17 70 33 34 69 18 5 4 6 7 59 CR1 CR2 RESET CR2 35 56 15 14 26 69 4 7 LIMIT CONTROLLER OTC OTC CONT TEMPERATURE CONTROLLER HEATER CONTROL CR2 6 8 57 55 CYCLE CONTROL CARD CONNECTORS SW1 3 4 SW2 SW3 58 71 72 73 ELEC SCHEMATIC PCBRM15 EUR...

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Page 99: ...vac eng com Right heater plug PLUG AC FEMALE LEFT heater Plug PLUG AC FEMALE Heater control box On Off SW SPST POT1 KBMC 23BV POT2 KBMC 23BV Right heater control Left heater control F1 2 A F2 2 A F3 2 A F4 2 A Brown or black Light Blue Green yellow 4004 90 909 220 VAC N 220 VAC L1 Chassis GND PE Assembly ST 350 Z 220 VAC Euro Swiss Plug attached Initial release A 10 03 02 Add machine connection no...

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Page 103: ...g Inc 30 Progress Ave Seymour CT 06483 www air vac eng com Right heater plug PLUG AC FEMALE LEFT heater Plug PLUG AC FEMALE Heater control box On Off SW SPST POT1 KBMC 23BV POT2 KBMC 23BV Right heater control Left heater control F1 2 A F2 2 A F3 2 A F4 2 A 4005 00 903 FWHTR 2 FWHTR 1 FWHTR 3 WIRE 14 awg Initial release A 4 4 05 Brown Light Blue Green yellow Brown Green yellow Brown Green yellow Br...

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Page 105: ...T T C T C UPPER HEATER CH GND HEAT HEAT T C T C LOWER HEATER GN GN BK BK NOTES 1 ALL WIRING 12 AWG EXCEPT WHERE NOTED 2 WATLOW AND SSR SIGNAL WIRES ARE 16 AWG 3 THERMOCOUPLE CABLE IS K TYPE 4 PROCESS AND OVERTEMP TC ARE INTEGRATED INTO THE SAME PROBE 5 FUSE F1 F4 TO BE MIN 5KA INTERRUPT RATING AT 240V 240V AC POWER TO PCBRM 15 FOR SYSTEMS E STOP INTERCONNECT FOR SYSTEMS BK BL THERMOCOUPLE HEATER H...

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Page 107: ...L BK GND PCBRM 15 GN GN G 94 SSR2 SSR2 SSR1 SSR1 CH GND HEAT HEAT T C T C UPPER HEATER CH GND HEAT HEAT T C T C LOWER HEATER GN GN BK BK NOTES 1 ALL WIRING 12 AWG EXCEPT WHERE NOTED 2 WATLOW AND SSR SIGNAL WIRES ARE 16 AWG 3 THERMOCOUPLE CABLE IS K TYPE 4 PROCESS AND OVERTEMP TC ARE INTEGRATED INTO THE SAME PROBE 240V AC POWER TO PCBRM 15 FOR SYSTEMS E STOP INTERCONNECT FOR SYSTEMS BK BL THERMOCOU...

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Page 109: ... 3 1 2 3 Shorting Jumper Plug 5003 03 104 Assembly CON3 1 2 3 In Preheater position switch 5003 03 101 assembly CON3 Switch located on the carrier arms 9002 13 014 1 2 JP Thermocouple conn L1 AC HOT 7 L2 AC RET 8 RCV B 9 XMT A 10 COM 11 OUT1 NO 3 OUT1 C 4 OUT2 5 OUT2 6 T C 1 T C 2 Cal 3300 rev date Description A 7 01 05 Initital build release In position SW SPST Red wire Black wire 1 2 NC 3 NO 900...

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