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Bravo 8105 Installation Manual

Convection reflow system
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Bravo 8105
®
CONVECTION REFLOW SYSTEM

INSTALLATION GUIDE

Technical Manual P/N 111–00–0
Installation Manual P/N 3–9317–370–00–0

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Summary of Contents for Bravo 8105

  • Page 1: Installation Guide

    Bravo 8105 ® CONVECTION REFLOW SYSTEM INSTALLATION GUIDE Technical Manual P/N 111–00–0 Installation Manual P/N 3–9317–370–00–0...
  • Page 2 Bravo™ 8105 Installation Guide...

  • Page 3: Preface

    ........Overview In this section This preface covers the following information: Topic See Page To Our Customers Customer Support Structure Before You Call viii 2-9317-370-00-0 Bravo™ 8105 Installation Guide...
  • Page 4 Set Guide Name Part Number Bravo™ 8105 Installation Guide 3-9317-370-00-0 Bravo™ 8105 General Information Guide† 3-9317-371-00-0 Bravo™ 8105 Programming and Operations Guide 3-9317-372-00-0 Bravo™ 8105 Preventive Maintenance Guide 3-9317-373-00-0 Bravo™ 8105 Repair Guide† 3-9317-374-00-0 Bravo™ 8105 Options Guide†...

  • Page 5: Customer Support Structure

    Speedline Distribution Center Parts Sales 1605 Dundee Elgin, IL 60120 Fax: 847-468-1029 Local Tel: 847-695-5750 Toll Free: 1-800-737-8110 Cookson Performance Solutions Training Center 580-A Tollgate Rd. Elgin, IL 60123 Fax: 847-289-3797 Local Tel: 847-695-5750 Toll Free: 1-800-737-8110 2-9317-370-00-0 Bravo™ 8105 Installation Guide...
  • Page 6 Phone: 847-695-5750 North West Regional Service 2968 Scott Blvd. Center Santa Clara, CA 95054 Fax:408-727-0672 Phone: 408-727-4650 South West Regional Service 1111 W. North Carrier Parkway Center Grand Prairie, TX 75050 Fax:972-606-1700 Phone: 972-606-1900 Bravo™ 8105 Installation Guide Rev. 2...
  • Page 7 Fax: 886 3357 6247 Phone: 886 3357 5990 Speedline Technologies, Mexico Carretera a Base Aerea Militar KM.5 No - 5850 Edificio #11 Zapopan, Jalixco C.P. 45100 MEX Fax: 013 818 9019 Phone: 013 818 9017 2-9317-370-00-0 Bravo™ 8105 Installation Guide...

  • Page 8: Before You Call

    • System Software Version • Serial Tag Information Machine Serial Tag The machine serial tag is located on side of the rear electrical panel. It provides important information that will be helpful in servicing your machine. viii Bravo™ 8105 Installation Guide Rev. 2...

  • Page 9: Table Of Contents

    Chapter 2. Bravo™ 8105 Machine Installation Bravo™ 8105 Installation Checklist........
  • Page 10 Nitrogen Machine Option — Verify Coolant Flow ......Appendix A: Index Bravo™ 8105 Installation Guide Rev. 2...

  • Page 11: Chapter 1. Safety Information

    Whenever there is a conflict between the information in this section and local information, the local rules and practices govern. In this chapter This chapter consists of the following: Topic Section Potential Hazards Safety Precautions Lock-Out Tag-Out 2-9317-370-00-0 Bravo™ 8105 Installation Guide...
  • Page 12 Overview Introduction This section describes various hazards the operator may encounter while operating an Bravo™ System. This section also describes warning tags installed on the system and ways to avoid the hazards encountered. In this section Refer to the following hazard descriptions...

  • Page 13: Hot Surface Hazards

    If in doubt whether something is hot or not, assume it is hot and take the necessary steps to avoid a burn hazard. Never place any foreign materials on the machine. Photograph The following Photograph shows the hot surface warning tag. Figure 1–1 2-9317-370-00-0 Bravo™ 8105 Installation Guide...

  • Page 14: Fire And Smoke Hazard

    There are two (2) inherent fire hazards present in the reflow system. Safety Use good housekeeping techniques and follow the operating instructions and the suggested maintenance schedule to avoid fires. Keep flammable materials and solvents clear of the Bravo™ System. Never stop the system with boards in the machine. Flammable Motors: Fire and Smoke Hazard.

  • Page 15: Electrical Hazards

    These procedures must be performed only by an authorized electrician, electrical engineer, or service technician familiar with testing live voltage. Photograph The following Photograph shows the electrical hazard warning tag: Figure 1–2 2-9317-370-00-0 Bravo™ 8105 Installation Guide...

  • Page 16: Mechanical Hazards

    To ensure personal safety and avoid equipment damage, observe the following: Entanglement Hazard All moving parts of the Bravo™ System represent potential hazards. Use caution and avoid having hands or fingers caught in any moving mechanism. Long hair, jewelry, and other parts of loose attire could be caught in moving mechanisms and cause injury.

  • Page 17: Breathing Hazards

    Noxious fumes are created during the normal heating process of reflow soldering. The gases and vapors emitted from the solder and flux are contained in the reflow chamber and should be avoided. Inhaling noxious vapors may cause headaches, eye redness, stomach aches and breathing problems. 2-9317-370-00-0 Bravo™ 8105 Installation Guide...

  • Page 18: Inerting Hazards

    Compressed gas can cause projectiles, gas burns to exposed areas of the body, and asphyxiation. It is recommended that nitrogen is delivered at a regulated pressure, at least 103 kPa (15 psi) less than the supply line pressure. Bravo™ 8105 Installation Guide Rev. 2...

  • Page 19: Other Hazards

    Skin or eye irritation can occur if not handled properly. CAUTION Exposure to lead in any form may cause serious heath hazards. Breathing lead dust, which is nearly invisible, can cause lead poisoning. 2-9317-370-00-0 Bravo™ 8105 Installation Guide...
  • Page 20 Flammables Never store flammable material on or around the Bravo™ machine. Exposing flammables to heating elements or hot surfaces presents a fire hazard due to the operating temperature of the machine.
  • Page 21 Ensure an adequate exhaust system is installed that filters and monitors the system. Clean and monitor the exhaust ventilation system on a regular basis. Document Reference Retain copies of this Guide for reference and new personnel training. 2-9317-370-00-0 Bravo™ 8105 Installation Guide 1-11...
  • Page 22 Never use flammable cleaning solvents. The following supplies are used for cleaning and maintenance. It is recommended these items be maintained on hand. • Lint-Free Cloths • Ammonia Based Cleaner • Scale Stripper • Defoamer 1-12 Bravo™ 8105 Installation Guide Rev. 2...

  • Page 23: Lock-Out Tag-Out

    Refer to the following lock-out tag-out procedures: Topic See Page Attach Facility Lock-Out Tag-Out Device 1 – 14 Attach Machine Lock-Out Tag-Out Device 1 – 15 Perform Required Task 1 – 16 Remove Lock-Out Tag Out Devices 1 – 17 2-9317-370-00-0 Bravo™ 8105 Installation Guide 1-13...

  • Page 24: Attach Facility Lock-Out Tag-Out Device

    Procedure Refer to the following steps to lock-out and tag-out facility power to the Bravo™: 1. Ensure there are no boards or other product in the system. 2. Notify all affected employees.

  • Page 25: Attach Machine Lock-Out Tag-Out Device

    3. Pull the tab and insert the lock-out device. 4. Secure the lock-out device in place. 5. Disconnect and bleed the compressed air connections. 6. The system is ready for maintenance, installation, upgrade, or repair proce- dures. 2-9317-370-00-0 Bravo™ 8105 Installation Guide 1-15...

  • Page 26: Perform Required Task

    If procedures must continue past the shift of the person who applied the lockout device, ensure that an employee who is working the next shift applies their lockout device and the previous person removes the initial lockout device. 1-16 Bravo™ 8105 Installation Guide Rev. 2...

  • Page 27: Remove Lock-Out Tag Out Devices

    ATTENTION The person who attaches a lock-out device is responsible to remove the device. Procedure Use the following steps to remove facility and Bravo™ machine lock-out and tag- out devices: 1. Notify all affected employees. 2. Locate and remove the lock-out device from the facility main power source.
  • Page 28 S A F E T Y I N F O R M A T I O N Remove Lock-Out Tag Out Devices 1-18 Bravo™ 8105 Installation Guide Rev. 2...

  • Page 29: Chapter 2. Bravo™ 8105 Machine Installation

    Remove Bravo™ System from crate Verify that all parts of the machine are present Perform height and leveling adjustment Install computer and monitor Make utility connections from facility to Bravo™ system if applicable. Verify that the electrical components and wiring is secure...
  • Page 30 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Bravo™ 8105 Installation Checklist Table 1: Standard System Installation Checklist Verify continuous seal around heating chamber...

  • Page 31: Before Uncrating

    Keep all cartons, packing materials and paperwork. The carrier furnishes an inspection report and the necessary forms to filing concealed damage claims, as the damage is the responsibility of the carrier. 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-21...

  • Page 32: Crate And System Handling

    Crate and System Handling Crate and System Handling Introduction Keep the Bravo™ crated until installation preparation is complete. To minimize potential damage, move the Bravo™ to the installation site before uncrating. CAUTION HEAVY OBJECT — Do not attempt to move large assemblies without the use of a fork lift or appropriate rigging equipment.
  • Page 33 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Crate and System Handling Photograph Figure 2–1 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-23...
  • Page 34 Carefully remove any additional bracing from the inside of the top of the crate. Using pry bars and claw hammers, remove the ends of the crate, then remove the sides of the crate. 2-24 Bravo™ 8105 Installation Guide Rev. 2...

  • Page 35: Packing Removal

    • Verify that all parts of the machine are present. In addition to this manual, a bill of materials (BOM), mechanical drawings and electrical schematics are included. Sales drawings with facility requirements are included in the docu- mentation package to aid installation. Photograph Figure 2–3 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-25...

  • Page 36: Skid Removal

    Refer to Figure 2–6. Note that the center of gravity of the Bravo™ 8105 is slightly toward the Load End of the system. CAUTION Extend the forks to the maximum width to minimize the risk of tilting the system off the end of the forklift.
  • Page 37 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Skid Removal Photograph Figure 2–4 depicts the shipping plate attached to the leg of the machine. Figure 2–4 Photograph Figure 2–5 depicts the removal of the nuts securing the shipping plates. Figure 2–5 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-27...
  • Page 38 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Skid Removal Photograph Figure 2–6 depicts the Bravo™ 8105 being lifted from the pallet. Figure 2–6 2-28 Bravo™...

  • Page 39: Installing Leveling Feet

    Be consistent with each leveling foot. Once the leveling feet are installed, carefully position the system into place for installation. Slowly lower the system onto the pads at the site of installation, then remove the forklift. 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-29...

  • Page 40: Location Terms

    Front. The Load End is the end that the product is placed onto the conveyor for process, and the Unload End is where the product exits the conveyor. Refer to Figure 2–7. Illustration REAR LOAD UNLOAD FRONT Figure 2–7 2-30 Bravo™ 8105 Installation Guide Rev. 2...

  • Page 41: Inspection At Installation

    Report any loss or damage to a Speedline Electrovert® representative immediately. Photograph A depicts the Shock Meter installed at the Unload End of the system. If the Shock Meter is fractured, contact a Speedline Electrovert® representative. Figure 2–8 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-31...

  • Page 42: Height And Leveling Adjustment

    Height and Leveling Adjustment Introduction The Bravo™ 8105 is configured with leveling legs used for height adjustment and leveling. The leveling must be performed on both the Front to Rear direction and the Unload to Load direction. Refer to Figure 2–9.
  • Page 43 Front to Rear leveling. When the four (4) legs are properly positioned, secure them by tightening the locking nut on each leg. Refer to A. 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-33...
  • Page 44 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Height and Leveling Adjustment Photograph Adjust here with a crescent wrench to change height When adjusted to proper height, tighten this nut upward to maintain level position Figure 2–10 2-34 Bravo™ 8105 Installation Guide Rev. 2...

  • Page 45: Install Computer And Monitor

    Install Computer and Monitor Introduction The Computer and Monitor are shipped separately with the Bravo™ 8105. Some of the cables are secured in the machine during shipment. Other cables, such as the keyboard, need routed. Refer to the following description.
  • Page 46 Some of the cables may be routed and secured to the machine. If the cables are packed with the equipment, then they need to be routed upon installation. Refer to Figure 2–13 and Figure 2–14. 2-36 Bravo™ 8105 Installation Guide Rev. 2...
  • Page 47 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Install Computer and Monitor Photograph Figure 2–13 Photograph Figure 2–14 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-37...

  • Page 48: Facility Utility Connections

    Facility Utility Connections Introduction Bravo™ 8105 Nitrogen version machine requires chilled water and nitrogen connections provided from the facility. If chilled water is not available, a separate water chiller must be used. The Coolant In and Coolant Out connections are located at the Unload End of the machine on the upper portion of the frame.

  • Page 49: Nitrogen Machine Option - Turn Nitrogen On

    6. Check the connection for leaks. ATTENTION After setting the nitrogen flow rate, it is important to ensure that the line pressure does not change from use. Verify that the pressure remains at 44 psig (305 kPa). 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-39...
  • Page 50 Read psi pressure here Set flow rate (SCFH) here Pressure here Sample Read SCFH rates here O2 ppm with O2 Analyzer here Keep the facility N2 flow to the machine On here (Main Shut Off Valve). 2-40 Bravo™ 8105 Installation Guide Rev. 2...

  • Page 51: Electrical Connectors

    To ensure that a safety hazard does not exist, torque the appropriate connections during machine installation (and also quarterly as part of the preventive maintenance of the machine — refer to the Bravo™ Maintenance Manual). Visually inspect all electrical connections first to see if any are noticeable loose or damaged as a result of transit.
  • Page 52 • Torque Wrench Torquing Procedure • The terminal block connections are located in the electrical cabinet on the front of the Bravo™. • Using a torque wrench, torque all terminal block connections to 2.0 Nm (18.00in.–lbs). • Torque the M6 terminal blocks to 0.6 Nm5 (.3 in.–lbs).
  • Page 53 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Electrical Connectors Photograph NOTE There are terminal blocks located on the rear of the chamber. Refer Figure 2–17. Ensure that these torqued appropriately. Figure 2–17 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-43...

  • Page 54: Facility Power Verification

    The three (3) voltage measurements should be approximately equal. The facility voltage (just measured) and the voltage listed on the machine serial number name plate must be approximately the same. Photograph Figure 2–18 2-44 Bravo™ 8105 Installation Guide Rev. 2...
  • Page 55 If power does not match, do not apply power. Contact Speedline Electrovert Technical Support. ATTENTION If configured with the UPS option, ensure that the UPS is electrically connected and that the output is enabled. The UPS is turned Off for shipping. 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-45...

  • Page 56: Power Connection

    Refer to C in Figure 2–19. 2. Locate the Main Power Disconnect Switch (SW01) inside the electrical cabi- net on the front of the Bravo™ 8105. Refer to B in Figure 2–19 to see the out- side of the switch.
  • Page 57 3. The Main Power Disconnect Switch, SW01, is shipped with an insulator plate installed on the bottom of the switch. Remove the tabs that slide into the bot- tom of the insulator plate. Refer to Figure 2–20. 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-47...
  • Page 58 7. Tighten the hex lug connectors with an appropriately–sized allen wrench. 8. Return the insulator tabs that were removed in Step 3 into the bottom of the switch insulator plate. 2-48 Bravo™ 8105 Installation Guide Rev. 2...
  • Page 59 (2) L connectors (i.e., L1 and L2, L2 and L3 or L1 and L3) should be approximately the same value that was measured at facility voltage. Note that it is a phase–to–phase measurement (not phase–to–ground). 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-49...
  • Page 60 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Power Connection Photograph A identifies the location of the L wires inside the power cabinet. L1, L2 and L3 Figure 2–22 2-50 Bravo™ 8105 Installation Guide Rev. 2...

  • Page 61: Verification Of Options In Software

    Powering Up the Bravo Turn the Bravo™ System On at the Main Power Disconnect Switch by placing the switch in the On (1) position. Refer to Figure 2–23.The Main Power Disconnect Switch is located on the lower Unload End of the Bravo™.
  • Page 62 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Verification of Options in Software ATTENTION Security Levels can only be set when the “Administrator” level is active. 2-52 Bravo™ 8105 Installation Guide Rev. 2...
  • Page 63 Set the level to Administrator by entering the default Administrator password of Software Bravo (case–sensitive) when prompted, or by pressing F11 and selecting Administrator Level and entering the password. To view the parameters for the current level when operating the Bravo™ select the Security > Access Screen. Software Representation Figure 2–24...
  • Page 64 Verification of Options in Software Configure > Options To verify that the correct Options are configured on the Bravo™ 8105, select Configure > Options from the Menu Bar at the top of the screen. Ensure that the applicable boxes are selected. Refer to Figure 2–25.

  • Page 65: Doors, Panels And Hood Covers

    Doors, Panels and Hood Covers Doors, Panels and Hood Covers Ease of Operation The moveable parts to the Bravo™ 8105 are secured and/or latched for shipping. After the packing material is removed, verify that the hood, doors and panels open with ease.
  • Page 66 The end panels at the Front and Rear of the Conveyor are secured by latches that require a 15° Angle Wrench to open. The wrench is included with the system. Attach the wrench to the hex head bolt and rotate it 1/4 turn to open the panel. 2-56 Bravo™ 8105 Installation Guide Rev. 2...

  • Page 67: Exhaust Setup And Balancing

    Exhaust Setup and Balancing Exhaust Setup and Balancing Introduction It is important that the exhaust to the Bravo™ 8105 is properly connected and balanced. Use a manometer or similar measuring device to ensure adequate exhaust when making the facility connections.
  • Page 68 Velocity Pressure (inches of H2O) Flow Rate Equivalent Load End 0.08 Unload End 0.50 Center (per stack) 0.18 Water gauge static pressure drop is 33 mm (1.3 in.)for the152 mm (6 in.) stack on the machine 2-58 Bravo™ 8105 Installation Guide Rev. 2...
  • Page 69 Velocity Pressure (inches of H2O) Flow Rate Equivalent Load End 0.18 Unload End 0.18 Center (per stack) 0.18 Water gauge static pressure drop is 33 mm (1.3 in.)for the152 mm (6 in.) stack on the machine 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-59...
  • Page 70 Load End blast gate and continuing until all of the gates are re–adjusted. Refer to Figure 2–30 for location of the measure- ment points and blast gates. It may require further repetition until all measure- ments are accurate. 2-60 Bravo™ 8105 Installation Guide Rev. 2...
  • Page 71 The depiction of the blast gates is enlarged for the purpose of identifying the location on the actual machine. Air Flow Air Flow Measurement Measurement Points Points Air Flow Air Flow Blast Gates Blast Gates Figure 2–30 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-61...

  • Page 72: Conveyor Operation And Speed Accuracy

    • Tape Measure Procedure Speed Verification • At the Load End of the Bravo™ 8105, mark a reference point with a pencil in a Procedure location similar to the position shown in Figure 2–31. • Using a standard tape measure, connect the tape measure so that it is secured to the mesh belt of the Bravo™...
  • Page 73 • Use the following formula to calculate speed: Speed = Length/Time ATTENTION When a conveyor is the Combination type that has both a Pin Chain Conveyor and a Mesh Belt Conveyor, the Pin Chain is the determining component for speed calibration. 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-63...

  • Page 74: Photocell Verification

    Figure 2–32. If the Conveyor is On, the Boards In Machine value under the PCBs Data increments by one (1). To clear the PCBs in Machine, select Maintenance > Clear All PCBs from the Menu Bar at the top of the display. 2-64 Bravo™ 8105 Installation Guide Rev. 2...
  • Page 75 B R A V O ™ 8 1 0 5 M A C H I N E I N S T A L L A T I O N Photocell Verification Software Representation Photocell Icon Figure 2–33 2-9317-370-00-0 Bravo™ 8105 Installation Guide 2-65...

  • Page 76: Blower Operation Verification

    Inspect the blower housing to verify operation. The upper blowers are observed by raising the hood. The lower blowers are observed by removing the lower access panels on the rear of the Bravo™ 8105 system. Refer to Figure 2–34. Photograph\ Bottom Blower Access Figure 2–34...

  • Page 77: Test Machine Operation

    Machine Mode, or press Function Key F2. Auto Stop Stop the Bravo™ 8105 in Auto Stop Mode and verify that the blowers stay On until the temperature drops below 95° C (203° C). To Auto Stop the Bravo™ 8105 System, click on the Stop button or press Function Key F3.

  • Page 78: Nitrogen Machine Option - Verify Coolant Flow

    This, however, only affects deviation alarms — those that are set with minimum and/or maximum values. It does not affect the Low Coolant Flow alarm. Software Representation Figure 2–35 2-68 Bravo™ 8105 Installation Guide Rev. 2...
  • Page 79 Installing Leveling Feet Electrical Connectors End Panels Opening Exhaust Nitrogen Setup Leveling Adjustment Standard Air Setup Leveling Feet Installation Procedure Ventilation Leveling Legs Exhaust Distribution Drawing Photograph of Adjusting Legs Exhaust Setup and Balancing Location Terms 2-9317-370-00-0 Bravo™ 8105 Installation Guide...
  • Page 80 Receiving and Placement Instructions Description 10, 13 Before Uncrating Machine Main Power Switch Removing Packing Material Remove Facility Device Removing the Bravo from the Skid Remove Machine Device Shift Change Steps 13, 14, 16 Logging Onto Bravo™ Software Safety Access Clearance...
  • Page 81 Machine Mode Software Options Verification Speed Verification Procedure Speedline International Service Centers Main Offices Regional Service Centers Torque Connectors Torque Settings Table Torquing Procedure Tools and Materials Needed UL Approval Tag Water, Chilled - Requirements 2-9317-370-00-0 Bravo™ 8105 Installation Guide...

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