as200 operation manual

AQUEOUS CLEANING SYSTEM

AQUASTORM 200™OPERATIONS MANUALManual Part #3-9317-521-00-0, Revision 1

Hwy. 5 South, Box 709 | Camdenton, MO 65020 Tel: 573-346-3341 | Fax: 573-346-6878

Speedline Technologies, Inc.

Aquastorm 200™

ii 2-9317-521-00-0 — Rev. 1 Operations Manual

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 iii

AQUEOUS CLEANING SYSTEM

AQUASTORM 200™OPERATIONS MANUAL

Text Part #2-9317-521-00-0, Revision 1Copyright© 1999 Speedline Technologies, Inc.

This manual may not be reproduced, stored in a retrieval system, or transmitted in part or in whole. Photocopying, recording, or other forms of reproduction is prohibited without written permission of Speedline ELECTROVERT.

Published July 30, 1999

Aquastorm 200™

iv 2-9317-521-00-0 — Rev. 1 Operations Manual

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 v

TO OUR CUSTOMERSThe purpose of this manual is to help obtain the greatest possible return on your investment. It is suggestedthat new operators study the applicable sections of this manual thoroughly before operating the equipment.It is further suggested that the manual be used as a reference by maintenance personnel and as a text fortraining of new maintenance personnel.

This manual includes operating instructions for this equipment available at the time this manual wasapproved for printing. Speedline ELECTROVERT reserves the right to make changes in design andspecifications and/or make improvements in the product without imposing any obligations upon itself toinstall them on previously manufactured products.

SPEEDLINE ELECTROVERT SALES AND SERVICES OFFICES

Speedline ELECTROVERT Customer Support Hot Line

Tel: 800-737-8110

Speedline Technologies, Inc. Main Offices

Product & Technology CenterSpeedline ELECTROVERTP.O. Box 709Camdenton, MO 65020Fax: 573-346-6878Tel: 972-606-1900

24 hr Technical Service Support/Repair PartsSpeedline ELECTROVERTP.O. Box 709Camdenton, MO 65020Fax: 573-346-0002 or 573-346-6878Tel: 800-737-8110 or 573-346-3341e-mail:[email protected]

Field Service Dispatch CenterU.S., Mexico, and Central AmericaSpeedline Technologies580-A Tollgate RoadElgin, IL 60123Fax: 847-289-3797Tel: 800-498-2429 or 847-695-5750

World Wide Training CenterSpeedline Technologies580-A Tollgate RoadElgin, IL 60123Fax: 847-289-3797Tel: 800-498-2429 or 847-695-5750

Regional Service Centers

North East Regional Service Center472 Amherst St. Suite 6Nashua, NH 03063Fax: 603-880-8757Tel: 603-883-2488

South East Regional Service Center200 Technology Dr.Alpharetta, GA 30005Fax: 770-442-1987Tel: 770-475-6100

North Central Regional ServiceCenter580-A Tollgate RoadElgin, IL 60123Fax: 847-289-3797Tel: 847-695-5750

North West Regional Service Center2968 Scott Blvd.Santa Clara, CA 95054Fax: 408-727-0672Tel: 408-727-4650

South West Regional Serv iceCenter1111 W. North Carrier ParkwayGrand Prairie, TX 75050Fax: 972-606-1700Tel: 972-606-1900

International Service Centers

Northern Europe & U.K.Electrovert U.K. Ltd.The Technology CentreUnit 1, Pincents Kiln Industrial ParkPincents KilnCalcot, ReadingBerkshire, U.K. RG31 7SDFax: 44 11-8-930-1401Tel: 44 11-8-930-1400

Speedline Technologies Asia150 Kampong Ampat#05-08 KA CentreSingapore 368234Fax: 65-289 9411Tel: 65-286 6635

JapanElectrovert-Seitec Co., Ltd.1538 Kanoya-choHachioji City, Tokyo 193 JAPANFax: 81-426-23-8350Tel: 81-426-23-7722

Northern EuropeSpeedline Technologies S.A.R.L.65 Avenue du General De GaulleImmeuble le Promethee77420 Champs-Sur Marne, FranceFax: 33 160-05-6129Tel: 33 160-06-8181

Central EuropeSpeedline Technologies, GmbhDaimlerstrasse 1ED-63303Dreieich, GermanyFax: 49 6103-832119Tel: 49 6103-8320Speedline Technologies ItalyVia Liguria 2/28I-20068 Peschiera Borromeo (MI)ItalyFax:39- 2 - 5530.8468Tel: 39- 2 - 5530.8339

Aquastorm 200™

vi 2-9317-521-00-0 — Rev. 1 Operations Manual

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 vii

EQUIPMENT MANUAL QUESTIONNAIREThe purpose of this questionnaire is to provide feedback from our customers regarding the effectiveness of the equipment manuals. Please complete the following questions and return to Speedline/ELECTROVERT. Your comments are appreciated.

Customer _______________________________________________________________________________________Address ________________________________________________________________________________________Contact ________________________________________________Date____________________________________Machine Type ___________________________________________Manual Part Number______________________Translated Manual Language ______________________________ Part Number_____________________________Option Manual __________________________________________Part Number_____________________________1. How often do you refer to the technical manual package?

❑ Frequently❑ Occasionally❑ Seldom❑ Never

2. In what instances do you refer to the technical manual package?❑ To verify process information❑ To reference procedures (operational, maintenance)❑ To order/identify parts❑ Other (please specify) ____________________________________________________________________

3. How do you rate the overall layout of the manual package?❑ Information easy to find❑ Information difficult to find❑ If difficult, please explain__________________________________________________________________

4. How do you rate our manuals in comparison to your other capital equipment suppliers?❑ Higher quality❑ Same general quality❑ Lower quality

If same general or lower quality, please explain _______________________________________________________________________________________________________________________________________________________

5. How do you rate the accuracy of the technical information?❑ Very accurate❑ Somewhat accurate❑ Not accurate❑ Can you provide examples, with page number indicated? ______________________________________

_______________________________________________________________________________________6. What tools would make the manuals easier to use and/or find information?

❑ Indexes❑ Glossaries❑ Improved Table of Contents❑ Other __________________________________________________________________________________

7. Who are the main users of your equipment manuals?❑ Operators❑ Maintenance personnel❑ Process Engineers❑ Other __________________________________________________________________________________

8. How do you rate the quality of the language translation (if applicable)?❑ Very accurate❑ Somewhat accurate❑ Not accurate

If somewhat or not accurate, can you elaborate?____________________________________________________________________________________________________________________________________________________________________________________________________________________________

Please add any additional comments about our manuals on the back of this page. Please return to:

Technical Publications Department at the address listed below

Hwy. 5 South, Box 709 | Camdenton, MO 65020 Tel: 573-346-3341 | Fax: 573-346-6878

Speedline Technologies, Inc.

Aquastorm 200™

viii 2-9317-521-00-0 — Rev. 1 Operations Manual

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 ix

The serial tag information is to be filled by the user for technical support purposes. Please have the followinginformation available when contacting Technical Support or when placing parts orders:

Machine NameModel Number

Mechanical and Electrical Serial NumbersItem/Kit Description

Aquastorm 200™

x 2-9317-521-00-0 — Rev. 1 Operations Manual

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 xi

COMMON SAFETY WARNING LABELSThe following warning labels are used throughout this manual:

Notes point out informationin this manual that may be ofassistance to the operation

or maintenance of the machine.

Caution notices areused in this manual toca l l a t tent ion to a

situation that could cause damage toequipment.

Warning notices areused in this manual toemphasize hazardous

vol tages, h igh temperatures, h ighcurrents, or other conditions that couldcause personal injury.

Danger notices areused in this manual towarn the operator that

DEATH may result if a procedure isomitted or improperly performed.

Aquastorm 200™

xii 2-9317-521-00-0 — Rev. 1 Operations Manual

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 xiii

Table of ContentsAquastorm 200™ Operations Manual

To our Customers ..................................................................................................................................................vSpeedline Electrovert Sales and Services Offices .............................................................................................vEquipment Manual Questionnaire ......................................................................................................................viiCommon Safety Warning Labels .........................................................................................................................xi

SECTION 1: SAFETY INFORMATIONSECTION 1.1: HAZARDS.........................................................................................................................................1

Hot Surface Hazards ............................................................................................................................................1Electrical Hazards.................................................................................................................................................1Mechanical Hazards.............................................................................................................................................1Other Hazards .......................................................................................................................................................1

SECTION 1.2: ...........................................................................................................................................................2SECTION 1.3: SAFETY PRECAUTIONS...................................................................................................................2SECTION 1.4: LOCK OUT-TAG OUT ........................................................................................................................3

Initial Preparation .................................................................................................................................................3Lock Out Main Power Switch...............................................................................................................................4

SECTION 1.5: PERFORM REQUIRED WORK........................................................................................................4SECTION 1.6: RESUME/BEGIN OPERATION ........................................................................................................4

Remove Lock Out Device .....................................................................................................................................4

SECTION 2: TECHNICAL DATASECTION 2.1: FACILITY REQUIREMENTS..............................................................................................................5

Water Requirements.............................................................................................................................................5Exhaust Requirements .........................................................................................................................................5

SECTION 2.2: ELECTRICAL REQUIREMENTS .......................................................................................................7Calculate FLA ........................................................................................................................................................8

SECTION 2.3: DIMENSIONS...................................................................................................................................9

SECTION 3: AQUASTORM 200™ SYSTEMSECTION 3.1: SYSTEM DESCRIPTION...................................................................................................................13SECTION 3.2: SYSTEM CONTROLS........................................................................................................................13SECTION 3.3: CONVEYOR.......................................................................................................................................14SECTION 3.4: NOISE SUPPRESSION....................................................................................................................14SECTION 3.5: PREWASH ........................................................................................................................................14SECTION 3.6: HEATED RECIRCULATING WASH..................................................................................................15SECTION 3.7: DRAG OUT/ENHANCED CHEMICAL ISOLATION.........................................................................16

Standard Chemical Isolation ...............................................................................................................................16Chemical Isolation Blower Option.......................................................................................................................16Level 1 Chemical Isolation ...................................................................................................................................16Level 2 Chemical Isolation ...................................................................................................................................16Level 3 Chemical Isolation ...................................................................................................................................16

SECTION 3.8: HEATED RECIRCULATING RINSE..................................................................................................17SECTION 3.9: FINAL RINSE ....................................................................................................................................18

Aquastorm 200™

xiv 2-9317-521-00-0 — Rev. 1 Operations Manual

SECTION 3.10: BLOWER DRYING ........................................................................................................................... 18Blower Enhancements......................................................................................................................................... 18Radiant Heater...................................................................................................................................................... 19Additional Drying Stations .................................................................................................................................. 19Electrosonic™ Airknife......................................................................................................................................... 19

SECTION 3.11: CONFIGURATION DIAGRAMS....................................................................................................... 20Standard configuration........................................................................................................................................ 20Optional Configuration ........................................................................................................................................ 20

SECTION 3.12: PLUMBING ...................................................................................................................................... 21SECTION 3.13: EXHAUST ......................................................................................................................................... 21SECTION 3.14: OPTIONS.......................................................................................................................................... 22

Interior Lighting .................................................................................................................................................... 22Utility Sink ............................................................................................................................................................. 22Photocells ............................................................................................................................................................. 22Flow Meters........................................................................................................................................................... 23Convenience Package.......................................................................................................................................... 23

SECTION 4: MACHINE SET UPSECTION 4.1: PRE-START CHECK......................................................................................................................... 25

Conveyor................................................................................................................................................................ 25Splash Shields and Windows.............................................................................................................................. 25Electrical Enclosures and Maintenance Panels ................................................................................................ 25Facility Connections ............................................................................................................................................. 25Temperature Set Points........................................................................................................................................ 26Optional Photocell................................................................................................................................................ 26Optional Auto detergent Inject System .............................................................................................................. 26Optional pH Monitor ............................................................................................................................................ 26

SECTION 4.2: SYSTEM CONTROL PANEL............................................................................................................. 27SECTION 4.3: MEMBRANE KEY PAD CONTROLS............................................................................................... 28SECTION 4.4: LCD INTERFACE KEY PAD ............................................................................................................. 29SECTION 4.5: LCD KEY PAD SCREENS ................................................................................................................ 29

Main Screen.......................................................................................................................................................... 29Configuration Screen........................................................................................................................................... 29Timer Screen......................................................................................................................................................... 29Alarm Process ...................................................................................................................................................... 29System Clock and Date........................................................................................................................................ 29Alarm Display ....................................................................................................................................................... 29

SECTION 4.6: SET UP SET POINT VALUES ........................................................................................................... 30SECTION 4.7: FILL TANKS ...................................................................................................................................... 30SECTION 4.8: ADJUST TEMPERATURES.............................................................................................................. 31SECTION 4.9: ADJUST CONVEYOR SPEED.......................................................................................................... 31SECTION 4.10: OPTIONAL PHOTOCELL SET UP 31SECTION 4.11: WEST 6700 TEMPERATURE CONTROL ......................................................................................... 33SECTION 4.12: CASCADE SET UP........................................................................................................................... 35

Organic Acid (O/A) Cascade ............................................................................................................................... 35Rosin Cascade...................................................................................................................................................... 36

SECTION 4.13: SOFTWARE UPGRADE................................................................................................................... 37

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 xv

SECTION 4.14: PROCESS TROUBLESHOOTING ....................................................................................................38Water Temperature ...............................................................................................................................................38Water Cleanliness .................................................................................................................................................38Process Chemistry................................................................................................................................................38Water Pressure......................................................................................................................................................38Conveyor Speed ....................................................................................................................................................38Component Temperature .....................................................................................................................................38Spray Nozzle Angle ...............................................................................................................................................38Blower Airknives ...................................................................................................................................................38Dryer Temperature ................................................................................................................................................38

SECTION 5: CONTROLS AND INDICATORSSECTION 5.1: CONTROL PANEL LAYOUT .............................................................................................................39SECTION 5.2: MEMBRANE KEYPAD CONTROLS ................................................................................................40

Power On control ..................................................................................................................................................41Power Off Control..................................................................................................................................................41Alarm Acknowledge .............................................................................................................................................41Level Indicator .......................................................................................................................................................42Temperature Indicator ..........................................................................................................................................43Auto Sequence Mode ...........................................................................................................................................43Photocell control...................................................................................................................................................44F1 and F2 Function Keys ......................................................................................................................................44Final Rinse Control ...............................................................................................................................................44Sump Pump Indicator ..........................................................................................................................................44Wash/Hurricane Pump Control ...........................................................................................................................45Wash JIC Pump Control .......................................................................................................................................45Wash Tank controls...............................................................................................................................................45Optional Chemical Isolation Controls .................................................................................................................46Rinse/Hurricane Control ......................................................................................................................................47Rinse JIC Pump Control .......................................................................................................................................47Rinse Tank Controls ..............................................................................................................................................47Blower Controls.....................................................................................................................................................48Radiant Heater Control.........................................................................................................................................48Conveyor Controls.................................................................................................................................................49Emergency Stop (E-Stop) Switches.....................................................................................................................50

SECTION 5.3: LCD INTERFACE KEY PAD..............................................................................................................51SECTION 5.4: LCD KEY PAD FUNCTIONS.............................................................................................................51

Menu......................................................................................................................................................................51Enter.......................................................................................................................................................................51Number Key Pad...................................................................................................................................................51Page Up/Page Down.............................................................................................................................................51Up/Down Arrows...................................................................................................................................................51Left/Right Arrows..................................................................................................................................................51Recipe, Print, Help, Del ........................................................................................................................................52

SECTION 5.5: LCD KEY PAD SCREENS.................................................................................................................52Main Screen ..........................................................................................................................................................52Configuration Screen ...........................................................................................................................................52System Clock and Date ........................................................................................................................................54Timer Screen .........................................................................................................................................................54Alarm Process.......................................................................................................................................................55Alarm Display........................................................................................................................................................55Watch Dog Test .....................................................................................................................................................56

SECTION 5.6: GAUGE PANEL.................................................................................................................................56Pressure Checks ...................................................................................................................................................56

Aquastorm 200™

xvi 2-9317-521-00-0 — Rev. 1 Operations Manual

SECTION 6: DAILY OPERATIONSECTION 6.1: ELECTRICAL POWER...................................................................................................................... 57

Facility Power ........................................................................................................................................................ 57System Power ....................................................................................................................................................... 57

SECTION 6.2: INITIAL START UP ........................................................................................................................... 57SECTION 6.3: ACTIVATE SUBSYSTEMS................................................................................................................ 58

Auto Start Timer ................................................................................................................................................... 58SECTION 6.4: SYSTEM SHUT DOWN.................................................................................................................... 58

Normal Shut Down............................................................................................................................................... 58Emergency Shut Down ........................................................................................................................................ 59

SECTION 6.5: OPERATION TROUBLESHOOTING................................................................................................ 60

SECTION 1: GLOSSARYSECTION 1.1: INTRODUCTION .............................................................................................................................. A 1

ABOUT SMEMA.................................................................................................................................................... A 1SECTION 1.2: ELECTRONICS CLEANING TERMS AND DEFINITIONS............................................................... A 1

SECTION 2: INDEX

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 1

SECTION 1: SAFETY INFORMATION

1.1 HAZARDSOperation of this equipment exposes personnelto potential health hazards.

HOT SURFACE HAZARDS

Figure 1: Hot Surface Warning Tag

Hot Surfaces/Burn Hazard — During normaloperation this equipment and some of itscomponents operate at temperatures up to 60–71 °C (140–160 °F). The operator must useextreme caution and wear the recommendedsafety garments prior to coming in contact withhot surfaces or components. Closely follow andadhere to the Warnings in this manual whichpertain to hot surfaces.

Use extreme caution when working around orwith hot components. Allow hot components tocool before handling whenever possible.

ELECTRICAL HAZARDS

Figure 2: Electrical Hazard Warning Tag

Risk of Electric Shock — Installation of thisequipment involves exposure to situationswhich may resul t in e lectr ica l shock i fprocedures are not properly followed. Pay closeattention to Warnings of this nature throughoutthe context of this manual.

When performing tests using ammeters, voltmeters, or ohm meters, electrical shock hazardis p resent . These p rocedures must beperformed only by an authorized electrician,electrical engineer, or service technicianfamiliar with testing live voltage.

HIGH VOLTAGE — I ns ta l l a t i on o f th i sequipment involves exposure to High Voltage.High Voltage can shock, burn, or cause death.Use extreme caution when performing voltageand amperage tests on live voltage. Theseprocedures must be performed only by anauthorized electrician, electrical engineer, orservice technician familiar with testing livevoltage.

MECHANICAL HAZARDS

Figure 3: Pinchpoint Warning Tag

Moving Parts — Al l mov ing par t s o f theAquas to rm sys tem, inc lud ing pu l leys ,sprockets, chains, and the conveyor representpotential hazards. Use caution and avoidhaving hands or fingers caught in any movingmechanism. Long hair, jewelry, and other partsof loose attire could be caught in movingmechanisms and cause injury.

S t o p a l l m o v i n g p a r t s w h e n m a k i n gadjustments or performing maintenance. Whenthe sys tem i s runn ing , avo id mov ingmechanisms. Use caution when working on ornear moving parts and wear safety gear.

OTHER HAZARDSHeavy Objects — When attempting to moveheavy equ ipment o r components , i t i simperative to use the proper rigging equipment.Do not a t tempt to move sk ids or la rgeassemblies without the use of a fork lift or otherrigging equipment. Hand lifting will causeserious personal injury.

To avoid damage to theequipment and systemdrain f ix tures located

under the machine, adjust the fork lift forksto their widest position. Use fork extensionson forks if the forks do not extend at leastseven (7) feet. Do not place fork lift forks atthe positions indicated by the CAUTIONlabels. The Aquastorm 200™ and Aquastorm100™ frame width is 153.7cm (59.9 inches).

Aquastorm 200™

2 2-9317-521-00-0 — Rev. 1 Operations Manual

Skin Irritation — W h e n u s i n g c e r t a i nchemicals such as descalers or saponifiers, it isimportant to follow the MSDS (Material SafetyData Sheet) guidelines for proper handling andusage. Wear appropriate clothing and safetyarticles when using descaler and saponifiersolutions. Skin or eye irritation will occur if nothandled properly.

1.2 SAFETY PRECAUTIONSElectrical work should only be performed by aqualified electrician.

Prior to applying power for the first time, ensurethat the system is properly grounded.

Post No Smoking signs in the work area andprovide measures for enforcement.

Exercise caution when using strong cleaningagents, solvents, and other chemicals. MSDSguidelines contain specific uses and safetyprecaut ions which must be thoroughlyunderstood and strictly followed. If in doubtabout any sa fe t y no t i ces , con tac t themanufacturer for clarification.

Avoid prolonged skin contact and inhalation ofchemicals and fumes.

Operating this equipment may introduce burnhazards. Avoid contact with all hot surfaces,hot water, and steam. The viewing glass canreach temperatures in excess of 71 °C (160 °F).Take extreme caution to avoid touching theglass surfaces. Water temperatures reach and/or exceed 71 °C (160 °F). Steam may escapefrom the system cabinet when windows areopened during operation or for maintenance,installation, upgrade, or repair procedures.Steam causes serious burns. Avoid contactwith steam.

Protective clothing is required for servicing hotmachine components or areas of the machinewh ich come in con tac t w i th chemica lapplications. Protective clothing includes thefollowing approval agency and items:

ANSI (American National StandardInstitute) approved:• Safety GogglesNIOSH (National Institute for OccupationalSafety and Health) ORMSHA (Mine, Safety and HealthAdministration) approved:• Respirator• Steel Toe Safety Shoes• High Temperature, Acid, and Water

Resistant Gloves• Apron• Long-Sleeved garment

Fumes can generate from certain saponifies,defoamers, descalers, cleaning solvents, orother chemicals used during operation. Takeprecaut ions to avo id accumula t ion o fflammable vapors. Whenever harmful fumesare present, a proper extraction (exhaust)sys tem must be prov ided. Refer to themanufacturer MSDS for information and safetyprecautions concerning their products andsystem exhaust specifications.

Refer to specific chemical manufacturersMSDS guidelines for disposal and/or removaland handling of waste materials resulting fromchemical operating processes.

All operators should be provided with an NIOSHor MSHA approved Respirator to provideeffective protection from airborne residueresulting from certain saponifiers, defoamers,descalers, cleaning solvents or other chemicalsused during operation.

The chemicals and cleaningagents recommended for usewith Aquastorm systems are not

products of Electrovert. Please refer to thespecific chemical manufacturer MaterialSafety Data Sheet (MSDS) for specific use,handling, and safety procedures for chemicaland cleaning agent applications.

Aquastorm 200™


1.3 LOCK OUT-TAG OUTBe sure to perform Lock Out – Tag Out stepsbefore beginning maintenance, installation, orupgrade procedures. Refer to the followingsteps when performing any maintenance,installation, or upgrade procedures on anAquastorm 200™ System:

1. Identify the types of energy sources used,potential hazards, and all control devices.

2. Notify all affected employees.

3. Turn off all operating controls.

4. Locate all energy sources.

5. Isolate all energy sources by blocking,bleeding and/or venting stored energy asfound in springs, hydraulic systems andpneumatic systems.

6. Lock out the main power switch in the OFFposition.

Figure 4: Main Power Switch Location

7. Test operating controls. Put all controls inthe On position. Be sure no one can gethurt before testing.

8. Return all operating controls to the Offposition before proceeding.

9. Perform the required task or maintenanceprocedure.

10. Remove lock out device only after theequipment is fully assembled and allaffected employees are notified.

11. The person who attaches a lock out deviceis responsible to remove the device.

INITIAL PREPARATIONBefore beginning maintenance, installation,upgrade, or repair procedures, be sure toperform Lock Out – Tag Out steps.

To prepare for system access:1. Ensure there are no Printed Circuit Boards

(PCB) or other product in the system.

2. Locate the Lower Control Panel at theentrance end of the system.

3. Power down all operating sections of themachine by pressing the Off buttons on theLower Control Panel.

Figure 5: Gauge Panel and Control Panel Location

Figure 6: Aquastorm 200™ Lower Control Panel

Main Power SwitchExit End of Machine

UL Tag

Serial Tag

Gauge Panel

Lower Control Panel

Entrance End of Machine

Aquastorm 200™


LOCK OUT MAIN POWER SWITCH

To attach a lock out-tag out device:1. Locate the main power disconnect switch

at the exit end of the system.

Electrical current usedcan kill. DO NOT TOUCHlive electrical components

inside the electrical enclosure.

2. Turn the main disconnect switch to the OFFposition.

3. Pull the tab and insert the Lock Out device.

4. Secure the Lock Out device in place.

Figure 7: Exit End of Machine

5. On systems with an optional EPS(Emergency Power Supply) battery backupinstalled, toggle the battery control to theOff position.

6. The system is ready for maintenance,installation, upgrade, or repair procedureson electrical, and plumbing devices.

1.4 PERFORM REQUIRED WORKProceed with the specif ic maintenance,installation, upgrade, or repair proceduresrequired. Follow the directions in the manualssupplied with the system.

Components in thesys tem become ho tduring normal system

operation. Heated sections of the machineproduce steam. To prevent burns, allowheated sections or hot components to cool orwear requ i red sa fe t y c lo th ing whenaccessing heated areas of the machine formaintenance, installation, upgrade, or repairprocedures.

1.5 RESUME/BEGIN OPERATIONPrior to removing the Lock Out device andresuming system operat ion, ensure thefollowing is complete:

• Perform and complete each scheduledmaintenance, installation, upgrade, orrepair operation

• Replace any worn parts, if necessary• Complete all required cleaning steps, if

necessary• Replace all enclosures removed during

maintenance, installation, upgrade, orrepair procedures

• Latch or appropriately tighten down allenclosures removed during maintenance,installation, upgrade, or repair operations

If items removed duringmaintenance, installation,upgrade , o r r epa i r

procedures are not properly replaced,damage to the equipment can occur.

REMOVE LOCK OUT DEVICEThe person who attaches a lock out device isresponsible to remove the device.

1. At the exit end of the machine unlock thelock out device.

2. Place the Main Power Disconnect in the Onposition.

3. On systems with an optional EPS(Emergency Power Supply) battery backupinstalled, toggle the battery control to theOn position.

4. Resume normal system operation.

Main Power Disconnect

Exit End of Machine

Aquastorm 200™


SECTION 2: TECHNICAL DATA

2.1 FACILITY REQUIREMENTSThese general facility requirements pertain tothe Aquastorm 200™ system and cover allpossible options available. During preliminarypreparation and system set up refer only tothose items relating to the system ordered orpurchased.

WATER REQUIREMENTSThe Fill and Final Rinse water supplies must beseparate.

The immersion heaters in the recirculatingwash and rinse tanks heats incoming tap ortreated water after an initial waiting period.Electrovert recommends supplying heatedwater 60–71 °C (140–160 °F) to the recirculatingwash, rinse, and optional chemical isolationtanks in o rde r to ma in ta in opera t ingtemperatures.

EXHAUST REQUIREMENTSThe following exhaust specifications assist indetermining an exhaust blower capable ofexhausting the system. Measure all exhaustmeasurements at the machine exhaust port.Proper exhaust ensures correct machineoperation and safety.

Electrovert recommends an independent,separate blower for this equipment due to thehigh volume requirements and condensatebuild up resulting from normal operation.

Contact your local HVAC specialist for blowerrequirements and ventilation hook-up.

Table 1: Facility Requirements

Water Requirements

Final RinseWater supply must be separate from Fill water supply.

Schedule 80, 3/4 in. NPT CPVC pipeTemperature 60–71° C (140–160° F)Flow Rate 11–19 L/Min (3–5 Gal./Min.)Nominal Pressure 2.8–3.3 kg/cm2 (35–40 PSI)

Fill Schedule 80, 3/4 in. NPT CPVC pipeTemperature 60–71° C (140–160° F)

System Drain Common 1-1/2 in. NPT, CPVC pipeConstant 38 L/Min. (10 GPM)

Exhaust Requirements

Recommended venting material 5.4 cm (10 in.) diameter minimumSeamless stainless steel or PVC air duct.

Total for standard two (2) dryer system 68 M3/min. @ 2.5 cm (2400 SCFM @ 1.0 in.) H2O static pressure

Total for optional add-on dryers #3 and #4 102 M3/min. @ 2.5 cm (3600 SCFM @ 1.0 in.) H2O static pressure Port #1 34 M3/min. @ 2.5 cm (1200 SCFM @ 1.0 in.) H2O static pressure Port #2 34 M3/min. @ 2.5 cm (1200 SCFM @ 1.0 in.) H2O static pressure Optional Port #3 and Port #4 34 M3/min. @ 2.5 cm (1200 SCFM @ 1.0 in.) H2O static pressure

Exhaust Notes:Measure all exhaust measurements at the machine exhaust port. Recommend an independent separate blower due to thehigh volume requirements and condensate build up resulting from normal operation.

Aquastorm 200™


Capacities

Recirculating Wash Tank 300 Liter (80 gallon)

Recirculating Rinse Tank 189 Liter (50 gallon)

Optional Enhanced Chemical Isolation Tank 95 Liter (25 gallon)

Optional Sump Pump 38 Liter (10 gallon)

Optional Treatment Interface Tank 66.24 Liter (17.5 gallon)

Specifications

Wash Section Standard – 5 HP @ 220 L/Min. (58 gpm)Hurricane – 10 HP @ 439 L/Min. (116 gpm)Heaters – Two (2) 16 KW Heaters – 32 KW Total

Optional Enhanced Chemical Isolation Tank Heater One (1) 16 KW TotalOptional Drag-Out Blower 7.5 HP, 3 Ph, 460 VAC, 500 CFM Turbine Blower

Rinse Section Standard – 5 HP @ 220 L/Min. (58 gpm)Hurricane – 10 HP @ 439 L/Min. (116 gpm)Heaters – Two (2) 16 KW Heaters 32 KW Total

Dryer Blower #1 Standard Turbine Blower – 7.5 HP, 3 Ph, 460 VAC, 500 CFM Option 1 Turbine Blower – 10 HP, 3 Ph, 460 VAC, 600 CFM Option 2 Turbine Blower – 15 HP, 3 Ph, 460 VAC, 875 CFM

Dryer Blower #2 Standard Turbine Blower – 7.5 HP, 3 Ph, 460 VAC, 500 CFM Option 1 Turbine Blower – 10 HP, 3 Ph, 460 VAC, 600 CFM

Optional Radiant Heater Two (2) 1800 Watt Radiant Heater panels; 3.6 KW Total

Conveyor 1/8 HP, 90 VDC Motor, 0.0–3.65 MPM (0–12 FPM) (0.0–4.57 Meters/Min.)

CheckMate™ Conveyor Two (2), 1/8 HP, 90 VDC Motors, 0–15 FPM (0.0–4.57 Meters/Min.)

Sump Pump 3/4 HP, 3 pH, 460 VAC, 50 gpm (189 L/Min.)

Table 1: Facility Requirements

Aquastorm 200™


2.2 ELECTRICAL REQUIREMENTS

For systems with 220 V electricalconfigurations, the customer isresponsible to provide a system

electrical disconnect capable of protectingthe Aquastorm 200™ at the amperagesspecified. Systems with 380 and 460 Velectrical configurations include a systemdisconnect.

Table 2: Electrical Requirements

Standard Electrical Configuration 460 VAC, 3 PH, 60 Hz (214 amps maximum) Includes system high voltage disconnect

Optional Electrical Configuration 220 VAC, 3 PH, 60 Hz (428 amps maximum) No high voltage disconnect380 VAC, 3 PH, 50 Hz (259 amps maximum) Includes system high voltage disconnect

Pump and Blower Upgrade Level 1Wash or Rinse ModuleOptional Chemical Isolation

Dryer Modules

Upgrades pumps to 10 HPAdds a 7.5 HP Enhanced Chemical Isolation blower And/OrAdds a tank immersion heaterUpgrades blowers to 10 HP And/OrAdds an IR Dryer to Dryer #2

Pump and Blower Upgrade Level 2Wash or Rinse ModuleOptional Chemical IsolationDryer Module

Upgrades pumps to 10 HPAdds a tank immersion heaterAdds an IR Dryer to Dryer #2 And/OrUpgrades Dryer #2 to 15 HP

Enclosed CLS (Closed Loop System)Standard PowerOptional Power

460 VAC, 3 phase, 60 Hz. (40 Amps)380 VAC, 3 phase, 50 Hz (48 Amps)

Aquastorm 200™


CALCULATE FLA To calculate the FLA (Full Load Amps) for aspecific system configuration, use the followingformula and the specific KVA ratings listed bymodule in Table 3 on page 8.

The normal operating power is 80-8 5 % o f t h e m a x i m u m p o w e rrequired, depending on process

parameters and operational load for theproduct being run.

Total Machine kVA x 1000Amps Required =

(1.732) x (Machine Voltage)

Table 3: Aquastorm 200™ Modules

MODULETOTAL POWER

MODULETOTAL POWER

Controls 3 kVA Add-On Single Dryer (Opt.)7.5 HP Blower (Std.)10 HP Blower (Opt.)15 HP Blower (Opt.)

7.7 kVA10 kVA

14.6 kVA

Wash ModuleHeaters (2 @ 16 kVA)5 HP Pump (Std.)10 HP Pump (Opt.)

32.kVA5 kVA

10 kVA

Add-On Dual Driver (Opt.) Dual Dryer Module #1

7.5 HP Blower (Std.)10 HP Blower (Opt.)15 HP Blower (Opt.)

7.7 kVA10 kVA

14.6 kVA

Chemical Isolation Level 1 (Opt.)7.5 HP Blower (Std.) 7.7 kVA

Dual Dryer Module #27.5 HP Blower (Std.)10 HP Blower (Opt.)IR Heaters (Opt.)

7.7 kVA10 kVA3.6 kVA

Enhanced Chemical Isolation Level 2 (Opt.)7.5 HP Blower (Std.) 7.7 kVA

Enhanced Chemical Isolation Level 3 (Opt.)7.5 HP Blower (Std.)Single 16 kVA Heater (Std.)

7.7 kVA16 kVA

Rinse ModuleHeaters (2 @ 16 kVA)5 HP Pump (Std.)10 HP Pump (Opt.)

32 kVA5 kVA

10 kVA

Dryer Module #17.5 HP Blower (Std.)10 HP Blower (Opt.)15 HP Blower (Opt.)

7.7 kVA10 kVA

14.6 kVA

Dryer Module #27.5 HP Blower (Std.)10 HP Blower (Opt.)IR Heaters (Opt.)

7.7 kVA10 kVA3.6 kVA

Aquastorm 200™


2.3 DIMENSIONSRefer to the following drawing and table foroverall system dimensions and information.Refer to SECTION 3: Aquastorm 200™ Systemon page 13 for specific module dimensions andoperation information.

Figure 8: Aquastorm 200™ Cabinet Dimensions

Table 4: Dimensions and Optional Features

Aquastorm 200™

Standard System Main Cabinet (Frame) 600 cm (236.38 in.) L x 154 cm (60.51 in.) W x 128 cm (50.24 in.) H

Standard System Overall Dimensions Main Cabinet, Control Panel, Sound Enclosure – 691 cm (272 in.)

Aquastorm 200™ Standard Features

Leveling Feet 10.16 cm (4 in.)

Exhaust Vent 5 cm (2.0 in.) from the top of the Main Cabinet

Aquastorm 200™ Options

Optional Inlet Conveyor 85.8cm (33.8 in.)

Optional Status Tower 58.9cm (23.2 in.) from top of Main Cabinet

Optional Treatment Interface System 133.6 cm (52.1 in.) L x 68.3 cm (26.7 in.) W x 81.62 cm (32.13 in.) H

Optional Sump Pump 61.6 cm (24 in.) L x 42.5 cm (16.6 in.) W x 61.8 cm (24.1 in.) H

128 cm(50.24 in.)

154 cm(60.51 in.)

600 cm(236.38 in.)

5 cm(2.0 in.)

694 cm(271 in.)58.9 cm

(23.0 in.)

10.16 cm(4.0 in.)

Aquastorm 200™


Optional Add-On Single Dryer Module #3Configured as a third drying station

Add-on or stand-alone unit – 79 cm (31 in.) WTemperature monitor via thermocouple sensorLCD readout on operator control panel.Two (2) tubular stainless steel height adjustable upper airknivesOne (1) fixed lower tubular stainless steel airknife7.5 HP high-velocity centrifugal blowerAir cooled – 14 m3/min. @ 97 cm (500 cfm @ 46 in.) of water

Blower Upgrade 110 HP high-velocity centrifugal blowerAir cooled – 18 m3/min. @ 117 cm (600 cvm @ 46 in.) of water

Blower Upgrade 215 HP high-velocity centrifugal blowerAir cooled – 25 m3/min. @ 147 cm (875 cvm @ 58 in.) of water

Airknife OptionElectrosonic™ Air Knife package

Optional Add-On Dual Dryer Module Blower #3 and Blower #4

Two (2) sections – 79 cm (31 in.) W — Total 158 cm (62 in.) WTemperature monitor via thermocouple sensorLCD readout on operator control panelTwo (2) tubular stainless steel height adjustable upper airknivesOne (1) fixed lower tubular stainless steel airknife7.5 HP high-velocity centrifugal blowerAir cooled – 14 m3/min. @ 97 cm (500 cfm @ 46 in.) of water

Blower Upgrade 1 for Blower #310 HP high-velocity centrifugal blowerAir cooled – 18 m3/min. @ 117 cm (600 cvm @ 46 in.) of water


Airknife Option for Blower #3Electrosonic™ Air Knife package



Airknife Option for Blower #4Electrosonic™ Air Knife package

Radiant Panel Drying Station for Blower #4Two (2) 1.8 kW (3.6 kW total) elements: One (1) upper and One (1) lower panel Temperature monitor and controller Thermocouple LCD readout capabilities

Table 4: Dimensions and Optional Features

Aquastorm 200™


Figure 9: Optional Add-On Dryer Module Drawing

M8

Hex

Nut

2-92

37-0

06-0

0-0

M8

Lock

Was

her

2-92

33-0

05-0

0-0

M8

Flat

Was

her

2-92

32-0

07-0

0-0

M8

x 50

Hex

Hea

d B

olt

2-92

00-0

53-0

0-0

M8

Flat

Was

her

2-92

32-0

07-0

0-0

Bol

t Thr

u D

ryer

Ent

ranc

e B

ulkh

ead

and

Cab

inet

Exi

t Bul

khea

d us

ing

M8

Har

dwar

e (1

7 S

ets)

Aquastorm 200™


This page intentionally left blank.

Aquastorm 200™


SECTION 3: AQUASTORM 200™ SYSTEM

3.1 SYSTEM DESCRIPTIONThe Aquastorm 200™ aqueous cleaning systemprovides automated, aqueous cleaning,contaminant fluid and particle removal fromPrinted Circuit Board (PCB) assemblies. Afterp r o c e s s i n g P C B a s s e m b l i e s t h r o u g hwavesolder or reflow systems, the Aquastorm200™ process zones provide efficient cleaningand drying to complete the operation.

The futuristic designed, one-piece constructedcabinet is built of ½ in. and ¼ in. customtextured polypropylene that resists scratchingand is aesthetically pleasing. Easily removablefront and rear access panels are constructed ofl ight weight, molded ABS (Acrylonitr i le-Butadiene-Styrene). Triple welded tanks andsta in less s tee l p lumbing complete theAquastorm 200™ package.

Figure 10: Aquastorm 200™ Process Zones

3.2 SYSTEM CONTROLSA single custom control panel and separategauge panel, located at the entrance end of thesystem, provide complete Aquastorm 200™operator control.

Using a membrane touch pad panel withgraphic symbols, a multi-line LCD (LiquidCrystal Display) with membrane keypad, and aninternal computer with fiber optic interfaceconnections the operator easily manages allsystem functions. Indicator lights providesystem water level, temperature level, pumpoperat ing indicat ion, blowers, f i l l /drainsolenoids, radiant heaters, and conveyor status.

The Aquastorm 200™ is configured with frontmounted stainless steel pressure gauges for allwet sect ions. The gauges mount at theentrance end of the system for easy operatorviewing and monitoring. Figure 11: Aquastorm 200™ Control Panel and

Gauge Panel

Prewash

Heated Recirculating Wash

Drag Out/Enhanced Chemical IsolationHeated Recirculating Rinse Fresh Water Final Rinse

Blower Drying Station #1

Blower Drying Station #2

Optional additional dryingstations #3 and #4 availablebut not pictured.

Aquastorm 200™


3.3 CONVEYORThe stainless steel wire belt conveyor is a 0.95cm (3/8 in.) pitch 50.8 cm (20 in.) wide speedcontrolled wire mesh belt. The conveyor belttransports PCB assemblies for cleaning anddrying in a single pass through the Aquastorm200™ system. Usable conveyor width is 46 cm(18 in.). Optionally the wire belt conveyor maybe configured with a 61 cm (24 in.) providing a56 cm (22 in.) usable width.

Figure 12: Standard Conveyor Entrance End

3.4 NOISE SUPPRESSIONThe noise suppression hood suppresses thenoise level equal to or better than 80 dBAmaximum measured 1 meter (3 ft.) above thefloor and 1 meter (3 ft.) from the Aquastorm200™ enclosure.

To facilitate PCB removal the noise suppressionhood incorporates a 46 cm (18 in.) exit conveyorextension. The extension protrudes 15.24 cm (6in.) past the exit end of the cabinet.

Figure 13: Noise Suppression Hood

3.5 PREWASHThe 36 cm (14 in.) prewash module includestwo (2) upper spray manifolds and two(2) lowerspray manifolds. Power cascade comes fromthe recirculating wash tank. Optionally directprewash to the drain or to cascade to therecirculating wash. When operating theprewash directly to drain, set the prewashoperating pressure lower than the final rinsepressure to prevent excess water consumptionin the wash module.

Figure 14: Prewash Module

Figure 15: Prewash Rear View

Aquastorm 200™


3.6 HEATED RECIRCULATING WASHThe recirculating wash module measures 122cm (48 in.) and contains four (4) upper spraymanifolds and four (4) lower spray manifoldspowered by a 5 hp pump. It comes standardwith a 303 liter (80 gal.) tank and two (2) 16 kWi m m e r s i o n h e a t e r s . H e a t e r a n d w a t e rtemperatures display on the LCD keypad. Theinternal computer continually monitors andcontrols tank temperature with a thermocoupledevice. If temperatures exceed 82 °C (180 °F),the tank high temperature alarm indicatorilluminates, an audible alarm sounds, and thetank heaters shut off.

Figure 16: Heated Recirculating Wash Module

Figure 17: Wash Tank Rear View

Liquid level float switches monitor the tank fluidlevel. If the tank fluid level falls below the lowlevel float switch, the tank heaters shut off, thetank level alarm indicator illuminates, and anaudible alarm sounds.

Figure 18: Float Switches Inside Tank

A fill solenoid activated by the low and/oroperating liquid level float switch in the washtank prov ides automat ic wash tank f i l lcapabilities. When the tank is empty, the fillsolenoid activates to fill the system tank. Duringnormal operation, if the water level falls belownormal operating level , the f i l l solenoidactivates and fills the wash tank.

Hurricane Jet™ Option

The wash module can be enhanced with anoptional Hurricane Jet™ performance kit. TheHurricane Jet™ manifold mounts between thestandard four (4) upper spray manifolds. Theperformance kit provides a 10 hp pump toreplace the standard 5 hp pump.

Figure 19: Hurricane Jet™ Option

High Level

Operating Level

Low Level

Float SwitchSide View

Aquastorm 200™


3.7 DRAG OUT/ENHANCED CHEMICAL ISOLATIONThe drag out/enhanced chemical isolationmodule is 30.5 cm (36 in.) wide. Four (4)separate configurations are available:

• Standard chemical isolation• Level 1 chemical isolation• Level 2 chemical isolation• Level 3 chemical isolation

Figure 20: Chemical Isolation Module

Figure 21: Chemical Isolation Rear View

STANDARD CHEMICAL ISOLATIONThis configuration does not include airknives orspray manifolds. Excess water drips from PCBassemblies as it passes through this module.The dripping allows fewer contaminants tocarry over from the wash to the rinse section.

When adding saponifier to thewash module and recirculatingrinse water, standard chemical

isolation configuration does not provideadequate separation of wash and rinse water.

CHEMICAL ISOLATION BLOWER OPTIONTo enhance the chemical isolation module anoptional 7.5 hp turbine blower can be installed.Blower air enhances excess water removal fromPCB assemblies.

LEVEL 1 CHEMICAL ISOLATIONIncludes the turbine blower, and three (3)stainless steel airknives, one (1) lower and two(2) upper. Blower air removes and squeegeesexcess contaminant containing water fromPCB assemblies. Excess water removed via thefirst set of airknives is routed back to the washsection. This helps prevent saponifier loss andreduces cross contamination risk betweenwash and rinse modules.

LEVEL 2 CHEMICAL ISOLATIONInc ludes the same b lower and a i rkn i feconfigurations as Level 1 and adds three (3)more spray manifolds one (1) upper and (2)lower. The spray manifolds are positionedbetween the airknives.

The spray bar water supply comes from anexternal feed supplied by the customer. A lowvolume spray enhances removal of remainingsaponifier solutions. This configuration ofchemical isolation is routed directly to the drainto eliminate any cross contamination.

LEVEL 3 CHEMICAL ISOLATIONIncludes both Level 1 and Level 2 features andis supplied with an on-board 95 liter (25 gallon)tank in l ieu of an external water sourceplumbing configuration. A 1/8 hp internalrecirculation pump powers the spray manifolds.The tank includes one (1) 16 kW immersionheater, auto fill, tank liquid level floats, andrinse to chemical isolation cascade. Level 3provides increased isolation between wash andrinse modules and conserves water use.

Aquastorm 200™


3.8 HEATED RECIRCULATING RINSEThe recirculating rinse module measures 122cm (48 in.) and contains four (4) upper spraymanifolds and four (4) lower spray manifoldspowered by a 5 hp pump. It comes standardwith a 189 liter (50 gal.) tank and two (2) 16 kWi m m e r s i o n h e a t e r s . H e a t e r a n d w a t e rtemperatures display on the LCD keypad. Theinternal computer continually monitors andcontrols tank temperature with a thermocoupledevice. If temperatures exceed 82 °C (180 °F),the tank high temperature alarm indicatorilluminates, an audible alarm sounds, and thetank heaters shut off.

Figure 22: Heated Recirculating Rinse Module

Figure 23: Rinse Tank Rear View

Liquid level float switches monitor the tank fluidlevel. If the tank fluid level falls below the lowlevel float switch, the tank heaters shut off, thetank level alarm indicator illuminates, and anaudible alarm sounds. Figure 18 on page 15shows float switch location inside the tank.

A fill solenoid activated by the low and/oroperating liquid level float switch in the washtank prov ides automat ic wash tank f i l lcapabilities. When the tank is empty, the fillsolenoid activates to fill the system tank. Duringnormal operation, if the water level falls belownormal operating level , the f i l l solenoidactivates and fills the wash tank.

The recirculating rinse tank is configured with acascade pipe to the recirculating wash tank.Flow through the cascade pipe, from rinse towash, is controlled by a ball valve. Run O/A(Organic Acid) or water soluble applicationswith the valve in the open positions. Run rosinor saponifier applications with the valve in theclosed position, to eliminate any possiblecontamination in the cascade pipe.

Enhanced Chemical Isolation Level 3

If the system is configured with an on-boardtank in the chemical isolation section, acascade pipe from the recirculating rinse tankto the chemical isolation is also supplied. Thevalve on this cascade pipe remains closed forO/A applications. When running saponifierprocesses, slightly open the ball valve on thecascade pipe to the chemical isolation tank.This prevents an excess amount of saponifierbuild up in the chemical isolation tank. Adjustthe valve opening depending upon the type ofsaponifier used and the product mix or productconfiguration.

Hurricane Jet™ Option

The wash module can be enhanced with anoptional Hurricane Jet™ performance kit. TheHurricane Jet™ manifold mounts between thestandard four (4) upper spray manifolds. Theperformance kit provides a 10 hp pump toreplace the standard 5 hp pump.

Figure 24: Hurricane Jet™ Option

Aquastorm 200™


3.9 FINAL RINSEThe final rinse module is 46 cm (18 in.) long andconsists of two (2) upper and two (2) lowerstainless steel spray manifolds. A fresh waterinlet, preferably heated DI (dionized) water,facility supplied, rinses the PCB assembliesand cascades into the recirculating rinse tank.

Figure 25: Final Rinse Module

Figure 26: Final Rinse Rear View

3.10 BLOWER DRYINGEach blower module, #1 and #2, measures 76cm (30 in.) and is configured with two (2) upper,height adjustable, and one (1) lower, fixed,stainless steel airknives. A high velocity, highvolume 7.5 hp turbine blower delivers air to theairknives. Each blower module containsthermocouple sensors to provide temperaturereadout via the LCD keypad.

Figure 27: Blower Drying Module

Figure 28: Blower Rear View

BLOWER ENHANCEMENTSBlower module #1 is upgradable to a 10 or 15hp blower to ensure maximum drying efficiencyprior to PCB assemblies exiting the system. Ingeneral 15 hp blower applications work bestwith large, heavy PCB assemblies. Smaller PCBassemblies can become airborne, or lodged inthe conveyor system.

Aquastorm 200™


RADIANT HEATERBlower module #2 may be configured with anoptional radiant heater. The radiant heaterincorporates two (2) 1800 watt radiant heaterpanels, one (1) upper panel and one (1) lowerpanel for a total of 3600 watts. A thermocouplesensor provides radiant heater control andreadout. The thermocouple provides digitaltemperature readout via the LCD keypad.

Figure 29: Dryer Module with Radiant Heater

ADDITIONAL DRYING STATIONSThe Aquastorm 200™ can opt ional ly beconfigured with one (1) or two (2) additionalblower drying modules, #3 and #4. The thirddrying module is configured the same asblower dryer #1 and can include any of thesame options. The fourth drying module isconfigured the same as blower dryer #2 andcan include any of the same options.

ELECTROSONIC™ AIRKNIFETo enhance blower drying, replace the standardcylindrical airknives with Electrosonic™ariknives. The unique teardrop design of theElectrosonic™ airknife maximize air velocity asit blows through the slot and produces a sheetof air. The adjustable slot allows for optimal airdelivery depending on blower configuration. AllElectrosonic™ airknives are adjusted accordingto voltage, Hz, and blower size.

Based on res idua l we ight ga in tes t ingperformed on a variety of PCB assemblies runat 2, 4, and 6 fpm, drying performance withE l e c t r o s o n i c ™ a i r k n i v e s e n h a n c e dperformance 25–68% over traditional cylindricalairknife systems.

Figure 30: Electrosonic™ Airknife

Aquastorm 200™


3.11 CONFIGURATION DIAGRAMSStainless steel spray manifolds and airknivesdeliver water and air to the Aquastorm 200™system in the following configurations.

STANDARD CONFIGURATION

Figure 31: Standard Configuration Diagram

OPTIONAL CONFIGURATION

Figure 32: Optional Configuration Diagram

Table 5: Standard Configuration

Prewash Two (2) upper and two (2) lower manifolds

Recirculating Wash Four (4) upper and four (4) lower manifolds

Drag Out/Chemical Isolation No airknives

Recirculating Rinse Four (4) upper and four (4) lower manifolds

Final Rinse Two (2) upper and two (2) lower manifolds

Blower Dryer #1 Two (2) upper and one (1) lower manifolds

Blower Dryer #2 Two (2) upper and one (1) lower manifolds

Table 6: Optional Configuration

Prewash Two (2) upper and two (2) lower manifolds

Recirculating Wash Four (4) upper and four (4) lower manifolds and one (1) Hurricane™ Jet

Drag Out/Chemical Isolation Two (2) upper airknives and one (1) lower airknifeOne (1) upper and one (1) lower chemical isolation spray manifold

Recirculating Rinse Four (4) upper and four (4) lower manifolds and one (1) Hurricane™ Jet

Final Rinse Two (2) upper and two (2) lower manifolds

Blower Dryer #1 Two (2) upper and one (1) lower Electrosonic™ Airknives

Blower Dryer #2 Two (2) upper and one (1) lower Electrosonic™ Airknives and IR Dryer

Prewash36 cm (14 in.)

Recirculating Wash122 cm (48 in.)

Drag-Out91.44 cm (35 in.)

Recirculating Rinse122 cm (48 in.)

FinalRinse

43 cm (17 in.)Blower Dryer #1

76 cm (30 in.)Blower Dryer #2

76 cm (30 in.)

Prewash36 cm (14 in.)

HurricaneRecirculating Wash

122 cm (48 in.)

Drag-Out/EnhancedChemical Isolation91.44 cm (35 in.)

HurricaneRecirculating Rinse

122 cm (48 in.)

FinalRinse

43 cm (17 in.)

ElectrosonicBlower Dryer #1

76 cm (30 in.)

Electrosonic BlowerDryer #2 with IR Dryer

76 cm (30 in.)

Aquastorm 200™


3.12 PLUMBINGAll rear system plumbing, including fill andfinal rinse inlets is comprised of 3/4 in, 1-1/2 in.and 2.0 in. orbitally welded, tubular stainlesssteel pipe with quick-release clamps. Thewelded stainless steel provides smoothtransition, minimize pressure drops, andeliminate leaks.

Figure 33: Stainless Steel Plumbing Connections

All internal upper and lower spray manifoldplumbing is stainless steel, reducing corrosionand maintenance factors.

Quick-release clamps and Teflon™ O-ringsensure quick and easy field upgrades.

Figure 34: Removing Quick-Release Clamp

All drain lines are 1-1/2 in. CPVC with brasssolenoid drain valves. Stainless steel solenoidvalves are optional.

3.13 EXHAUSTTo permit fine tuning of system exhaust,internal slide gate dampers are designed intothe one-piece construction of the internalportion of the cabinet. Completely adjustablesl ide gate dampers are included in theprewash, drag out /enhanced chemica lisolation, blower dryer #1, and blower dryer #2modules. From the front of the system, accessthe dampers through the access windows ofthe specific module. From the rear of thesystem access the dampers at the bulkheadwall.

Figure 35: Adjust Exhaust Damper

Prewash

Machine Front Machine RearExhaust Damper

Window

Front Adjustment Rear Adjustment

Aquastorm 200™


3.14 OPTIONSSeveral options enhance Aquastorm 200™system operat ion. Common opt ions arediscussed here or elsewhere in this manual.Options discussed in detail in the AquastormSeries Options Manual include:

• Air Intake Ports• Bag Filters• Blower Fail Detect• Conveyor inlet and exit extensions and

Checkmate™ hold down conveyor• Water Heating System• Detergent injection• Hurricane Jet™ Configurations• Keyswitch password protection• Light tower• pH monitors• Rear Emergency Stops (E-Stops)• Resistivity• SCAT (Side Connector Airknife Technology)• Sump Pump• Treatment Interface• UPS (Uninterruptible Power Supply)

INTERIOR LIGHTINGThe Aquas to rm 200™ sys tem may beconfigured with three (3) fluorescent lightfixtures to provide maximum interior systemviewing. These cost efficient, 40 watt, 110 VACfixtures allow the operator to observe the entirecleaning process as product passes througheach module of the system.

Figure 36: Optional Utility Sink

UTILITY SINKLocated at the exit end of the system to the rearof the sound enclosure, the utility sink connectsto the incoming fill line and drains into thesystem main drain plumbing. A single goose-neck faucet and spray wand offer easy cleanup.

PHOTOCELLSThe photocell provides an automatic stand bymode for PCB detection. The photo sensor andreflector mount on the entrance and exit endsof the conveyor system. Photocell operationsequentially starts pumps, blowers, and finalrinse water as PCB assemblies pass by and aredetected. When PCB assemblies exit thesystem, based on a fixed time and distance,photocell operation stops the pumps, blowers,and final rinse water. The conveyor remains inoperation to move new PCB assemblies into thesystem. The system may also be configured toal low the blower to remain On with theconveyor.

Figure 37: Photocell Sensor

Figure 38: Photocell Reflector

Aquastorm 200™


FLOW METERSOptional flow meters assist in maintaining aconstant full level flow balance throughout theAquastorm 200™ system. Two (2) flow metersare available. One (1) installs in the prewashmodule plumbing. The other installs in the finalrinse module plumbing.

To achieve optimum system operation ensurethe same amount or slightly more water flowsinto the final rinse as flows into the prewash.

Figure 39: Prewash Module Flow Meter

Figure 40: Final Rinse Module Flow Meter

CONVENIENCE PACKAGEA convenience package incorporating four (4)features which promote and facilitate easymaintenance is available. The conveniencepackage includes:

• Utility Sink• Slide-out blower access• Exhaust demisting filter• On-board tool kit

Utility Sink

Refer to Utility Sink on page 22 for detailedinformation.

Exhaust Demisting Filters

Two (2) strategically located wet section filtershelp reduce water consumption and chemicaluse. One (1) filter mounts just before theprewash module at the entrance end of theconveyor. The other f i l ter mounts in theenhanced chemical isolation module.

Figure 41: Prewash Demisting Filter

Slide-out Blower Access

Available for all system blowers. Each blowermounts on its own slide-out base for easymaintenance or upgrades. As soon as theblower is disconnected from the blowerhousing and the slide mount bolts are removed,the blower slides out for easy access.

Figure 42: Blower Slide-out Access

Demisting Filter

Aquastorm 200™


Took Kit

The on-board tool kit includes tools andcommon replacement parts for the Aquastorm200™ system. The following items fit into thetool box. A convenient storage cabinet for thetool kit is located at the exit end of the system infront of the sound enclosure.

Figure 43: Tool Kit Storage Compartment

• 3/32 Hex wrench• Metric set of Allen keys• 3/8 in. Drive, 3/4 in. hex socket• Set of metric sockets

Ratchet3 in. extension 7–14, 17, 19 mm sockets

• Socket adapter 3/8 in. F x 1/4 in. M• 1/4 in. Drive, 5.5 mm socket• 1/2 in. Drive, 24 mm socket• 3/8 in. Drive, 1/2 in. socket• 3/8 in. Drive, 9/16 in. socket• 3/8 in. Drive, 5/16 in. hex bit• 1-1/8 in. Max., 10 in. adjustable wrench• Stainless steel probe–Nozzle cleaning tool• 4 mm, ball tip hex key driver• 5 mm, ball tip hex key driver• 3/16 in., ball tip hex key driver• Screwdriver with reversible bits

#1 and #2 phillips3/16 and 5/16 slotted

• 3/8 F to 1/2 M socket adapter• Two (2) sets of sst. wirebelt connecting links• 3/4 in. Teflon gasket for tubular plumbing• 1-1/2 in.Teflon gasket for tubular plumbing• 2.0 in Teflon gasket for tubular plumbing• Hurricane Jet™ orifice cleaning tool• Tool box

Tool KitStorage

Aquastorm 200™


SECTION 4: MACHINE SET UP

4.1 PRE-START CHECKPrior to initial start up or daily Aquastorm 200™operation, perform the following systemchecks.

CONVEYOR1. Inspect the conveyor to ensure there are no

obstructions or anything that could hinderfree movement.

2. Inspect conveyor wire belt tension andensure the belt does not extend more than38.1 mm (1.5 in.) from its relaxed state.

• Check the tension at the entrance endof the conveyor. Place the index fingerof your hand behind the belt at a pointmid-way in the vertical travel of the belt.

3. For systems configured with the optionalinlet conveyor ensure the wire belt tensionis acceptable and angle adjust is correct.

4. For systems configured with the optionalphotocell, ensure the photocell is clean andfree of debris. Verify the photocell emitterand reflector are properly aligned.

SPLASH SHIELDS AND WINDOWS1. Clean all splash shields and windows.

2. Ensure splash shields are in place.

3. Place all tempered glass windows down inthe closed position.

ELECTRICAL ENCLOSURES AND MAINTENANCE PANELS1. Verify that the high voltage electrical panel,

located behind the fourth and fifth frontaccess panels near the exit end of thesystem are closed and latched.

2. Verify that the system low voltage electricalpanel, located behind the first and secondfront access panels near the entrance endof the system are closed and latched.

3. Ensure all front and rear access panels arelocked in place prior to machine operation.

FACILITY CONNECTIONS1. Ensure the Aquastorm 200™ system drain

is connected to the facility drain.

2. Ensure the facility water supply to the filland final rinse connections are turned On.

3. Check and ensure the facility exhaust isactivated.

4. On 380V or 460V systems, turn On thesystem disconnect at the exit end of thesystem to activate facility power.

5. On 220V systems turn On or connect thecustomer supplied facility power source.

When facility power to the system is On, thefollowing system functions activate or areenabled:

• Liquid Crystal Display (LCD) illuminatesand displays the system status

• Main Power Off indicator illuminates red• Fill and drain solenoids• The following level indicators illuminate

green when the tank is at operating level:Wash tank Rinse tankOptional chemical isolation tank

• The following temperature indicatorsilluminate green when the tank reachesoperating temperature:

Wash tankRinse tankOptional chemical isolation tank

• Conveyor Off indicator illuminates red• Optional interior lights illuminate• Internal hard drive boots up• High temperature monitors on the West

6700 in the low voltage electrical enclosureilluminate

Aquastorm 200™


TEMPERATURE SET POINTSDefine and verify the following temperature setpoints using the LCD interface key pad:

• Wash tank• Rinse tank• Optional chemical isolation tank• High and low deviation levels

OPTIONAL PHOTOCELLLocated at the entrance end of the Aquastorm200™ the ensure the photocell sensor emitterand reflector are aligned to provide properdetection of product as it enters the system.

OPTIONAL AUTO DETERGENT INJECT SYSTEMIf configured with this option, ensure thesuction line of the detergent injection system isinserted into the detergent reservoir prior tooperation. Refer to the Aquastorm SeriesOptions Manual for detailed detergent injectionset up and operation.

OPTIONAL pH MONITORIf configured with this option, ensure the buffersolution cap is removed from the end of the pHprobe prior to filling the wash tank. Refer to theAquastorm 200™ Option Manual for detailedpH monitor set up and operation.

Ensure buffer solutionmoisture is maintainedon the pH electrodes to

prevent drying. As soon as the buffer solutioncap is removed, initiate System Start Up andfill the wash tank.

Aquastorm 200™


4.2 SYSTEM CONTROL PANELThe Aquastorm 200™ basic controls andIndicators are integrated into a Membrane KeyPad Unit. The Key Pad Unit includes thefollowing controls:

• Liquid Crystal Display (LCD) Interface KeyPad

• Membrane Key Pad Controls• Audible Alarm Speaker• Emergency Stop Switch

Figure 44: System Control Panel Layout

Aquastorm 200™


4.3 MEMBRANE KEY PAD CONTROLSThe main group of controls form the customMembrane Key Pad and consist of l ightemitting diode indicators and touch sensitivecontrols that produce an audible tone whenpressed. The purpose of each control is shownwith a distinct symbol.

The level indicator and temperature indicatorilluminate the center green bar when theoperating level or set point is reached. Colorbars above and below indicate high or lowconditions and directly affect the operation ofthe specific module.

See SECTION 5:Controls and Indicators onpage 39 for specific control and indicator useand operation.

Figure 45: Membrane Key Pad

Aquastorm 200™


4.4 LCD INTERFACE KEY PADThe LCD (Liquid Crystal Display) interface keypad prov ides d ig i ta l d isp lay o f sys teminformation, allows the operator to controlsys tem func t ions , and per fo rm se t upprocedures for the following functions. Anasterisk next to an item indicates an optionalfeature.

• Wash Temperature• Chemical Isolation Temperature*• Rinse Temperature• Dryer Section Temperatures• Radiant Heater Temperatures• Conveyor Speed• System Configuration• Auto Start Timer • Alarm Process• System Date and Clock• pH Levels*• Resistivity Levels*

Figure 46: LCD Interface Key Pad

4.5 LCD KEY PAD SCREENSThe fo l lowing inter face screens conveyoperation information or provide operatorinterface for system set up.

• Main Screen• Configuration• Timer• Alarm Process• System Clock and Date• Alarm Display

MAIN SCREENThe main screen displays standard and optionalmodule system information, module set points,and actual module temperatures. Dependingon system modules and options the mainscreen can continue to a second page.

CONFIGURATION SCREENUse the three conf igurat ion screens toconfigure, add, or remove system options.

TIMER SCREENThe timer screen allows the operator to setspecific times on selected days for automaticstart up and shut down of the Aquastorm 200™system.

ALARM PROCESSUse the alarm process screen to configurespecific software alarms and their relatedpriority. Depending on the specific processapplication alarms are configured as Ignore,Warning, or Shutdown.

SYSTEM CLOCK AND DATEThe clock and date screen displays the currentdate and time as configured in the internalcomputer. In the event of a power loss, or whenchanging to or from daylight savings time, thisfeature permits date and time computeradjustments.

ALARM DISPLAYThis screen provides a readout of configuredalarms as they occur.

Aquastorm 200™


4.6 SET UP SET POINT VALUESA flashing square cursor displays on the LCDkey pad screen next to a component. Use theup and down arrows to move the cursor to thedesired component.

Figure 47: LCD Key Pad Screen with Square Flashing Cursor

Use the number keys on the LCD interface keypad to enter the desired number or press the upand down arrow keys on the key pad to increaseor decrease the set point number. Press Enterto complete the set point process.

When entering a value the flashing squarecursor disappears and an underscore appearsbelow the value. The underscore remains belowthe value until the operator presses the Enterkey to accept the value.

Figure 48: LCD Key Pad Screen with Underscore Cursor

4.7 FILL TANKSThe operator must manually fill the tanks whenstarting the Aquastorm 200™ the first time orwhen a tank has been drained for maintenancepurposes.

To fill tanks:1. Ensure facility water supply to the

Aquastorm 200™ is properly connected andturned On.

2. Press the System Main Power On Control toenable the following circuits:

• Wash, rinse, and optional chemicalisolation tank fill solenoids

• Optional enhanced chemical isolationblower

• Immersion heater• Optional status tower• All other sub-systems

3. The Main Power Off control indicator turnsOff.

4. Manually press the Fill control on thesystem control panel for the wash, rinse, oroptional chemical isolation tank.

5. The fill control activates the fill solenoidand begins the fill process.

Tank liquid level must reach theoperating level f loat switchbe fo re immers ion hea te rs

ac t i va te . When hea te rs ac t i va te theImmersion Heater On indicator illuminatesgreen.

6. When the wash, rinse, and optionalchemical isolation tank water level reachesthe high make-up level float switch, the fillsolenoid turns Off.

7. Water is only added to tank(s) when thewater level drops below the operating levelswitch in the wash, rinse, or optionalchemical isolation tank.

MODULE SETP ACTUAL

CONVEYOR 7.7 F/min 0.0 WASH 145F 103 CHEM_ISO 145F 116 RINSE 150F 119 DRYER_1 F 74 DRYER_2 F 72

AQUASTORM 200

MODULE SETP ACTUAL

CONVEYOR 7.7 F/min 0.0 WASH 145F 103 CHEM_ISO 145F 116 RINSE 150F 119 DRYER_1 F 74 DRYER_2 F 72

AQUASTORM 200

Aquastorm 200™


4.8 ADJUST TEMPERATURESEnter the wash, rinse, and optional chemicalisolation tank temperature set points.

To enter temperature set points:1. Ensure system power is On.

2. Press the up or down arrow on the key padto move the flashing square cursor next towash on the LCD interface key pad MainScreen.

3. Enter the temperature set point using thenumber keys on the LCD interface key pad.

4. Acceptable temperature set point valuesrange from 60–70 °C (140–158 °F).

5. When the correct temperature set pointdisplays, press the Enter key on the key padto accept the new value.

6. Repeat Step 2. through Step 5. to entertemperature set points for the rinse tank,optional chemical isolation tank, andoptional radiant heater.

4.9 ADJUST CONVEYOR SPEEDAdjust conveyor speed to move productefficiently through the cleaning modules.

To adjust conveyor speed:1. Ensure system power is On.

2. Press the up or down arrow on the key padto move the flashing square cursor next toconveyor on the LCD interface key padMain Screen.

3. Enter the speed set point value using thenumber keys on the LCD interface key pad.Acceptable speed set point values rangefrom 0–3.66 MPM (0–12 fpm).

4. When the correct conveyor speed set pointdisplays, press the Enter key on the key padto accept the new value.

4.10 OPTIONAL PHOTOCELL SET UPThe photocell sensors mount on the optionalinlet conveyor extension. Perform the alignmentand sensitivity adjustments to efficientlyidentify product.

To align photocell:1. Ensure system power is On.

2. Remove any objects obstructing the emitterpath.

3. Check the green LED on the photocellemitter.

Figure 49: Photocell Emitter

4. Adjust the photocell emitter and reflectorso the green indicator on the emitterilluminates with normal movement at theentrance end of the conveyor.

Figure 50: Photocell Reflector

5. Place product with the lowest componentsfor processing in the path of the photocellemitter and reflector.

Aquastorm 200™


6. Loosen the screws securing the photocellemitter mounting bracket and photocellreflector mounting bracket enough to allowslight vertical movement of both.

Figure 51: Photocell Height Adjust

7. Slowly lower or raise the emitter andreflector until the LED on the photocellemitter does not illumine.

8. Secure the mounting hardware on thephotocell emitter and photocell reflectormounting brackets.

9. Ensure the photocell components remainin the set position.

10. After securing the mounting hardware,verify the green LED still operates byremoving sample product from thephotocell path.

11. If the green LED on the photocell emitterdoes not illumine when product isremoved, repeat Step 6. through Step 10.until the photocell is properly mounted.

To adjust photocell sensitivity:1. Ensure system power is On.

2. Remove any objects obstructing the emitterpath.

3. Verify photocell alignment.

4. Place product with the lowest componentsfor processing in the path of the photocellemitter and reflector.

Figure 52: Photocell Sensitivity Adjust

5. Turn the sensitivity adjustment screw onthe photocell emitter clockwise in ¼ turnincrements until the green LED remainsilluminated.

6. To determine the point of sensitivity, turnthe sensitivity adjustment screw on thephotocell emitter counterclockwise in ¼turn increments until the LED flashesbetween red and green.

7. To complete the sensitivity adjustment, turnthe sensitivity adjustment screw clockwise¼ turn.

Mounting Bracket

Height Adjust Bolts

Photocell Emitter

Sensitivity AdjustScrew

Green/RedLED Indicator

Aquastorm 200™


4.11 WEST 6700 TEMPERATURE CONTROLThe West 6700 control provides a safety circuitfor the Aquastorm 200™ system. The controlunit ships preset from the factory.

Figure 53: West 6700 Temperature Control Panel

Use the following to configure a replacementunit or to change operation from degreesFahrenheit to degrees celsius.

Improper WEST 6700control adjustment coulddamage the equipment.

The operator may review configuration valuesand not make changes. Any change made andsaved in the Configuration Mode affects allSetup Mode values. When exiting configurationmode, the four (4) decimal points on the upperdigital display illuminate to indicated changeswere made and saved. The operator mustchange setup mode values when changes aremade and saved.

Figure 54: Configuration Mode Menu

WEST 6700

OUT EXCEED ALM

F

Function KeyRaise KeyLower KeyReset Key

Upper Display

Lower Display

Alarm Indicator(NOT USED)

S

RESET

High or Low LimitExceed Indicator

Values

(F)

(C)

Aquastorm 200™


To enter configuration mode:1. Ensure power to the temperature controller

is turned OFF.

2. Turn power to controller back ON.

3. Within 30 seconds of activating power tothe controller, simultaneously press andhold the Function Key and Raise Arrow keysfor approximately five (5) seconds until thelower display reads inPt.

4. The operator may step through theconfiguration mode parameters using theFunction Key. The lower display shows amnemonic parameter identifier. The upperdisplay shows the current value or settingof the parameter.

5. If necessary, press the Raise or Lowerarrow keys to adjust the value or setting.When the value or setting changes, theupper display flashes indicating the newvalue or setting is not confirmed or saved.

6. Press the Reset Key to confirm or save thenew value or setting.

7. Repeat Step 5. and Step 6. for theremaining configuration mode values orsettings.

8. To exit Configuration Mode, simultaneouslypress and hold the Function Key and RaiseArrow keys. The Operator Mode displays.

I f no ac t i v i t y occurs inconfiguration mode for two (2)minutes , the West 6700

automatically exits to Operator Mode.

Figure 55: Set Up Mode Menu

To enter setup mode:1. After completing all configuration mode

settings, ensure the controller remains inOperator Mode for more than 30 seconds.

2. Simultaneously press and hold theFunction Key and Raise Arrow keys untilthe lower display reads ULoc.

3. Press the Raise Arrow key until the upperdigital display reads 10.

4. Press the Function Key until FiLt displays.

5. Use the Raise and Lower Arrow keys andenter the values listed in Figure 55 on page34.

6. Press the Reset Key to confirm or save thenew values.

7. Repeat Step 5. and Step 6. for theremaining setup mode values.

DO NOT change the value in theLoc field.

8. To exit Configuration Mode, simultaneouslypress and hold the Function Key and RaiseArrow keys.

Value

230

2.0

1

21. (F)

100 (C)

212 (F)

100 (C)

10

Aquastorm 200™


4.12 CASCADE SET UPThe Aquastorm 200™ operates either Rosin Fluxo r Organ ic Ac id F lux (O /A ) c l ean ingconfigurations. Open or close specif iedcascade valves to run one or the other.

Ensure power to the system is turned off andlocked out. Refer to 1.3 Lock Out-Tag Out onpage 3 for detailed instructions. Drain allsystem tanks prior to performing cascade setup.

Hot Surfaces – BurnHazard . A l l ow ho tplumbing to cool prior to

performing cascade set up. Plumbingcomponents operate at temperatures up to60–71 °C (140–160 °F). If it is necessary towork on hot components, use extremecaut ion and wear appropr ia te sa fe tygarments. Refer to 1.2 Safety Precautions onpage 2 for detailed information.

ORGANIC ACID (O/A) CASCADEWhen c lean ing Organ ic Ac id (O /A )applications, ensure cascade between modulesoperates. Adjust the cascade pipe ball valve asdescribed.

See Rosin Cascade on page 36when using a saponi f ier incombination with an Organic

Acid (O/A) flux.

To set up for O/A flux cascade:1. Ensure system power is Off.

2. Perform Lock Out/Tag Out steps.

3. Drain system tanks.

4. Remove the rear panels.

5. Access the rear prewash section.

6. Locate the two (2) valves exiting theprewash module.

• The prewash drain contains a ball valvecontrol

• The prewash cascade contains a ballvalve and permits prewash effluent tocascade back to the recirculating washtank

7. Turn the ball valve on the prewash drain tothe Open position to allow prewash effluentto drain directly out of the system.

Figure 56: Rear Prewash Section

8. Turn the ball valve on the prewash cascadeto the Closed position to prevent cascadingof prewash to the recirculating washmodule.

9. Access the rear recirculating rinse section.

10. Locate the cascade pipe from therecirculating rinse tank to the recirculatingwash tank.

11. Turn the ball valve located on this cascadepipe to the Open position to permitcascading to occur.

Figure 57: Rear Recirculating Rinse Section

12. For systems configured with the optionalenhanced chemical isolation tank, locatethe cascade pipe from the recirculatingrinse tank to the chemical isolation tank.

PrewashDrain

Prewash CascadeClosed Position

OpenPosition

Recirculating Rinseto Recirculating WashOpen Position

Chemical IsolationClosed Position

Aquastorm 200™


13. Turn the ball valve to a Completely Closedposition to ensure chemicals in this sectionremain isolated and prevent cross-contamination between the wash and rinsemodules.

14. Remove Lock Out/Tag Out tags.

15. Turn system power On.

16. Fill system tanks and resume operation.

ROSIN CASCADEWhen cleaning rosin flux applications usingsaponi f iers , ensure chemicals are keptsegregated. Adjust the cascade pipe ball valveas described.

To set up for rosin flux cascade:1. Ensure system power is Off.

2. Perform Lock Out/Tag Out steps.

3. Drain system tanks.

4. Remove the rear panels.

5. Access the rear prewash section.

6. Locate the two (2) valves exiting theprewash module.

• The prewash drain contains a ball valvecontrol

• The prewash cascade contains a ballvalve and permits prewash effluent tocascade back to the recirculating washtank

Figure 58: Rear Prewash Section

7. Turn the ball valve on the prewash drain tothe Closed position to prevent prewasheffluent from draining directly out.

8. Turn the ball valve on the prewash cascadeto the Open position. This allows cascadingof prewash to the recirculating washmodule.

9. Access the rear recirculating rinse section.

10. Locate the cascade pipe from therecirculating rinse tank to the recirculatingwash tank.

11. Turn the ball valve located on this cascadepipe to the Closed position. This preventscascading from occurring and keepssaponifier solutions separate.

Figure 59: Rear Recirculating Rinse Section

12. For systems configured with the optionalenhanced chemical isolation tank, locatethe cascade pipe from the recirculatingrinse tank to the chemical isolation tank.

13. Turn the ball valve to approximately a 45°angle to Slightly Open the position.

14. Remove Lock Out/Tag Out tags.

15. Turn system power On.

16. Fill system tanks and resume operation.PrewashDrain

PrewashCascadeOpen Position

ClosedPosition

Recirculating Rinseto Recirculating Wash

Chemical Isolation45 ° Slightly OpenPosition

Closed Position

Aquastorm 200™


4.13 SOFTWARE UPGRADEIn an effort to enhance Aquastorm 200™control, the operating software is sometimesupgraded in the field. Install software when anupgrade floppy arrives, or in the unlikely eventof a computer component failure.

Figure 60: Front Entrance End – Panels Removed

To install software:1. Starting from the exit entrance end of the

cabinet, remove the front access panels.

2. Insert the 3.5 in. software upgrade disketteinto the 3.5 in. floppy drive located on theleft side of the low voltage control boxtoward the entrance end of the machine.

Figure 61: Floppy Drive and Reset Button

3. Press the black Reset button just below thefloppy drive.

4. The floppy drive green LED indicatorilluminates while the computer reads fromthe disk and the computer re-boots.

5. Wait until the LED goes off. Press the floppyeject button to remove the floppy diskette.

6. Press the black Reset button again toreboot the system using the new software.

7. Replace front access panels, starting withthe front entrance end.

8. Resume normal system operation.

Panel for Low Voltage Control Boxwith Computer Processor UnitComputer

Floppy Drive

3.5 in. Floppy Drive

Floppy Drive LED

Reset Button

Floppy Eject Button

Low Voltage Control Box

Aquastorm 200™


4.14 PROCESS TROUBLESHOOTINGThis section lists possible problem scenariosthe operator may encounter during Aquastorm200™ operation. It also recommends action toasses and/or correct the problem.

WATER TEMPERATUREThe most important factor for obtaining clean,dry product under most conditions is watertemperature. Ensure water temperature ismaintained between 60–71 °C (140–160 °F) toassure the cleanest PCB assemblies possible.

WATER CLEANLINESSThe cleaner the water introduced into a PCBassembly within any aqueous cleaning process,t h e l o w e r t h e c o n t a m i n a n t l e v e l . I t i srecommended that the operator or qualityinspector verify water quality at predeterminedintervals.

PROCESS CHEMISTRYDepending on the chemicals and materialsapplied during the PCB assembly processing,such as f lux and so lder paste , vary ingconcentrations of saponifier or neutralizers maybe required in the Wash section. The optionalautomatic detergent injection system mayrequire adjustment for maintaining properconcentration levels. Too high or too low of aconcentration will directly affect cleanlinesslevels. For more details on detergent injection,refer to the Aquastorm 200™ Options Manual.

WATER PRESSUREThe amount of water pressure applied to PCBassemblies being cleaned determines theamount of flux residue and other contaminantremoval accomplished. Adequate pressurehelps ensure contaminants entrapped undercomponents are removed without damage tothe PCB assembly.

CONVEYOR SPEEDConveyor speed affects almost all other aspectsof the aqueous cleaning process. Slowerspeeds provide longer dwell times in the Washand Rinse sections, assuring a cleaner product.Slower speeds also allow a longer dryingperiod.

COMPONENT TEMPERATUREThe temperature of the PCB assembly and itscomponents as it enters the Aquastorm 200™system is important to the cleaning process. Itis best to clean PCB assemblies while they arestill hot from the wave or reflow solderingsystem.

SPRAY NOZZLE ANGLEThe angle of the spray nozzle in relation to thehorizontal conveyor is pertinent to the cleaningof various types of components on any PCBassembly. High velocity spray at sharper anglesflushes and cleans on, under, and arounddifferent configurations. Different productconfigurations may require an angle change toachieve optimum cleaning.

BLOWER AIRKNIVESThe upper blower airknife height is adjustable.These adjustment are critical for the removal ofany moisture on the board prior to entering thedryer sections.

DRYER TEMPERATUREPrecise control of optional radiant heatertemperature in the second dryer moduleenhances the ability to dry surface mountedc o m p o n e n t s o f m o s t P C B a s s e m b l yconfigurations.

Aquastorm 200™


SECTION 5: CONTROLS AND INDICATORS

5.1 CONTROL PANEL LAYOUTThe Aquastorm 200™ basic controls andIndicators are integrated into a MembraneKeypad Unit. The Keypad Unit includes thefollowing controls:

• LCD Interface Keypad• Membrane Keypad Controls• Audible Alarm Speaker• Emergency Stop Switch

Figure 62: System Control Panel Layout

Aquastorm 200™


5.2 MEMBRANE KEYPAD CONTROLSThe main group of controls form the customMembrane Keypad and consist of light emittingdiode indicators and touch sensitive controlsthat produce an audible tone when pressed.The purpose of each control is shown with adistinct symbol.

The level indicator and temperature indicatorilluminate the center green bar when theoperating level or set point is reached. Colorbars above and below indicate high or lowconditions and directly affect the operation ofthe specific module.

• Ensure the system disconnect at the exitend is turned On for 380V or 460V systems.

• Ensure the customer supplied facilitypower source is turned On or connected for220V systems.

Figure 63: Membrane Keypad

Aquastorm 200™


POWER ON CONTROLPress this key pad control to enablepower to a l l modu les o f theAquastorm 200™.

• The Power On green indicator illuminates• When power is On, tank heaters activate if

tanks are at operating levels• The Power Off indicator turns Off

POWER OFF CONTROLPress this key pad control todisable power to all modules of theAquastorm 200™.

• The Power Off red indicator illuminates• Any operating subsystems immediately

shut Off• The Power On indicator turns Off• The Conveyor Off indicator illuminates• Tank temperature indicators remain

illuminated

Risk of Electric Shock –Turning power Off usingthe power Off control

DOES NOT disable power to the system. Todisable system power turn Off power at themain disconnect or facility power safetydisconnect.

ALARM ACKNOWLEDGEConfigure process alarms withWarning, Shutdown, or Ignoreactions. Process alarms configuredas Ignore do not activate an alarm.Process alarms configured as

Warning or Shutdown initiate an audible alarm.

Figure 64: Audible Alarm Speaker

Hardware alarms are fixed within the systemand always initiate an audible alarm. In thealarm list, items marked with an asterisk arehardware related and not user programmable.

Wash Section

High TemperatureLow TemperatureHigh Temperature Shutdown *High Level *Low Level *

Optional Chemical Isolation Section


Rinse Section


Dryer Section #1

High Temperature Shutdown *

Dryer Section #2


Dryer Section #2 with Optional Radiant Oven

High TemperatureLow TemperatureHigh Temperature Shutdown *

Dryer Section #3


Dryer Section #4


Dryer Section #4 with Optional Radiant Oven

High TemperatureLow TemperatureHigh Temperature Shutdown *

Other Alarms

Emergency Stop *Saponifier Low LevelOptional Treatment Interface Tank LowLevelOptional Treatment Interface Tank HighLevel *Optional Sump Pump High Level *Optional Checkmate™ Conveyor Jam *

Aquastorm 200™


Alarm Process

The audible alarm sounds on the originaloccurrence of an alarm unti l the AlarmAcknowledge control is pressed.

Figure 65: Sample Alarm Message

When an alarm occurs:• Alarm message displays on the LCD• Audible alarm sounds• Red LED on Alarm Acknowledge Control

flashes • If alarm is configured as Shutdown, the

system goes into Power Off state

Responding to an alarm:• Operator press the Alarm Acknowledge

control• Alarm message clears from the LCD and

the Main Menu displays• Audible alarm stops• If the alarm condition remains active, the

red LED on the Alarm Acknowledge Controlcontinues to flash

• If the alarm condition is cleared, the LEDstops flashing

When restarting the system after clearing aShutdown alarm condition, the system PowerOff control remains illuminated. Press thePower On control to bring the system back intooperation. If Power On is pressed and the alarmcondition remains active, the alarm re-occurs.

LEVEL INDICATORThe wash, r inse, and optional chemicalisolation modules of the membrane key padinclude a high/low liquid level indicator. Thetank level indicator provides the followinginformation to the operator.

These instruct ions assumeprocess alarms are configuredwi th Warning or Shutdown

action.

Figure 66: Level Indicator

Tank level indicators:1. If the tank liquid level reaches the high level

the following occurs:

• Audible alarm sounds• Alarm acknowledge indicator flashes

red• Tank high level red indicator

illuminates• LCD displays the specific high level

alarm• Fill solenoid for the tank disables

2. When liquid in the tank is at operating levelthe green indicator illuminates.

3. If the tank liquid level drops below theoperating level float switch, but is not at lowlevel the following occurs:

• Tank low level amber indicatorilluminates

• If the tank fill solenoid is activated, thetank fill indicator flashes and the tankfills with liquid

4. If the tank liquid level reaches the low levelthe following occurs:


red• Tank low level indicator illuminates red• LCD displays the specific low level

alarm• Tank heaters disable• Tank pump or external feed solenoid

disables

5. If a float switch hardware problem exists ina tank all tank level indicators illuminate.

WASH HIGH LEVEL ALARM

High Level

Operating Level

ApproachingLow Level

Low Level

Aquastorm 200™


TEMPERATURE INDICATORThe wash, r inse, and optional chemicalisolation modules of the membrane key padinclude a high/low temperature indicator. Thetank temperature indicator provides thefollowing information to the operator.

These instruct ions assumeprocess alarms are configuredwi th Warning or Shutdown

action.

Figure 67: Temperature Indicator

Tank temperature indicators:1. If the tank temperature exceed 82 °C (180

°F) the following occurs:


red• Tank high temperature red indicator

illuminates• Optional status tower flashes red• LCD displays the specific high

temperature alarm• Tank heater disables• System shuts down

2. When tank temperature exceeds set pointtemperature by the value set for alarmingthe following occurs:

• Audible alarms sounds• Alarm acknowledge indicator flashes

red• Tank high temperature red indicator

illuminates• Optional status tower flashes red• LCD displays the specific high

temperature alarm• Tank heaters disable• System shuts down

3. When temperature is at operating set pointthe green indicator illuminates.

4. If the tank temperature falls below set pointtemperature by the value set for alarmingthe following occurs:

• Audible alarms sounds• Alarm acknowledge indicator flashes

red• Tank low temperature indicator illuminates

red• Optional status tower flashes red• LCD displays the specific high

temperature alarm

AUTO SEQUENCE MODEThe Auto Sequence Mode controlsequentially starts each module ofthe system eliminating the need foran operator to manually press eachcontrol for system start up.

To initiate Auto Sequence Mode:1. Ensure the Power On control is turned On.

2. Verify the wash, rinse, and optionalchemical isolation tanks are full and theoperating level, and immersion heater Onindicators illuminate green.

3. If the tanks are empty or below operatinglevel, the fill indicators flash greenindicating the tanks are filling. Theoperating level and immersion heaterindicators do not illuminate.

4. Check the LCD Main Screen to ensure anasterisk displays to the left of each module.

5. When pressed, the Auto Sequence Modeinitiates the following actions.

• Conveyor activates and begins tooperate at the preset set point

• Fill solenoids activate• Float switch begins operation• Optional radiant heaters begin heating

to their preset set point

High Temperature

Operating Temperature

ApproachingLow Temperature

Low Temperature

Aquastorm 200™


6. When the tanks reach operating level, thesystem activates the following subsystemsin the order listed at two (2) secondintervals:

• Wash pump• Optional chemical isolation blower• Optional chemical isolation pump• Rinse pump• Final rinse solenoid• Blower #1• Blower #2• Optional blower #3• Optional blower #4

7. The following LCD control interfacefunctions are now in operating condition:

• Conveyor speed• Wash temperature• Optional pH readout• Optional chemical isolation temperature• Rinse temperature• Optional final rinse resistivity• Dryer #1 temperature• Dryer #2 temperature• Optional radiant heater #2 temperature• Optional dryer #3 temperature• Optional dryer #4 temperature• Optional radiant heater #4 temperature

PHOTOCELL CONTROLThe photoce l l contro l on themembrane key pad turns theoptional photocell control On orOff. When activated, the green LEDindicator illuminates.

As long as product passed by the optionalphotocell sensor at the entrance end of theconveyor, each module of the system remainsoperational. When the last product exits thesystem, and no additional product is detectedat the entrance, all modules of the system shutdown at the same time, except the conveyor.When the photocell detects new productentering the system, all modules previouslyoperating, resume operation in the followingorder:

• Wash pump• Optional chemical isolation blower• Optional chemical isolation pump• Rinse pump• Final rinse solenoid

• Blower #1• Blower #2• Optional blower #3• Optional blower #4

F1 AND F2 FUNCTION KEYSThe F1 and F2 con f igurab lefunc t ion keys rema in indevelopment. Future applicationsof the Aquastorm series aqueouscleaning system wi l l inc ludespecific actions for these keys.

FINAL RINSE CONTROLThe final rinse control activates thefinal rinse solenoid. When active,the green final rinse indicatorilluminates green. To deactivate thefinal rinse solenoid, press the

control again. The green indicator no longerilluminates indicating the final rinse solenoid isno longer active.

The final rinse control also activates anddeactivates the CLS (Closed Loop System)pump on Aquastorm 200™ systems configuredwith the optional Resys CLS Treatment InterfaceSystem. Whenever the final rinse remainsactive the CLS is also active.

SUMP PUMP INDICATORT h e s u m p p u m p i n d i c a t o rilluminates red when a high levelcondit ion occurs in the sumppump reservoir. If the condition isdetected the following occurs:

• Pump indicator illuminates red• Alarm message displays on the LCD• Audible alarm sounds• Red LED on Alarm Acknowledge

Control flashes • All drain solenoids disable

Correct the high level condition and clear thealarm prior to resuming operation.

Aquastorm 200™


WASH/HURRICANE PUMP CONTROL

Press this control to activate ordeactivate the wash and optionalhurricane pump. This control alsoac t i va tes the p rewash spraymanifolds. When turned On, the

indicator illuminates green.

WASH JIC PUMP CONTROLThe JIC pump control remains indevelopment. Future applicationsof the Aquastorm series aqueouscleaning systems will include thiscontrol.

WASH TANK CONTROLSWash Tank Fill Control

The wash tank fill control activatesthe wash tank fill solenoid.

To fill the wash tank:1. Ensure the Power On control is turned On.

2. Press the wash tank fill control.

• The green indicator flashes to signifythe tank is filling

• When full, the green indicator stopsflashing and remains illuminated

• The green indicator illuminates if thewater level in the tank is at operatinglevel

3. When starting the system using the AutoStart Timer function the following occurs:

• The fill solenoid automatically initiatesto fill the wash tank if the water isbelow operating level and tank fillcontrol green indicator flashes

• If the tank is at operating level, thegreen indicator illuminates

4. During normal operation, if the water levelfalls below the operating level float, thefollowing occurs:

• The fill indicator begins flashing• The fill solenoid activates and initiates

filling the tank to operating level.• To stop the automatic fill sequence,

press the wash tank fill control whilethe tank is filling.

Wash Tank Drain Control

The wash tank dra in cont ro lactivates the wash tank drainsolenoid. Press the wash tank draincontrol to empty the wash tank. Thedrain control indicator illuminates

green to indicate the tank is draining. The drainsolenoid remains open until the wash tankdrain control is pressed and the indicator nolonger illuminates.

Wash Tank Level Indicator

This indictor displays the status of the waterlevel in the wash tank. For detailed informationon the indicator refer to Level Indicator on page42.

Wash Tank Immersion Heaters Control

The operator cannot enable ordisable the immersion heatersusing this control. It is an indicatoronly.

The control illuminates green to indicate whenthe wash tank immersion heaters are turnedOn. The indicator turns Off when the heatersare off due to a high temperature condition orwash tank low water level.

The LCD key pad displays an asterisk next toWASH when the tank heaters are turned On. Noasterisk displays when the heaters are turnedOff.

Press the control to increase the wash tanktemperature set point. When pressed once andreleased, the temperature set point increasesone (1) degree. When pressed and held, thewash tank temperature set point increases untilthe control is released. The actual temperatureand temperature set point display on the LCD.

Wash Tank Decrease Temperature Control

Only use the decrease temperaturecontrol to decrease the wash tanktemperature set point.

Press the control to decrease the wash tanktemperature set point. When pressed once andreleased, the temperature set point decreasesone (1) degree. When pressed and held, thewash tank temperature set point decreasesunti l the control is released. The actualtemperature and temperature set point displayon the LCD.

Aquastorm 200™


Wash Tank Temperature Indicator

This indictor displays the temperature of thewash tank. For detailed information on theindicator refer to Temperature Indicator onpage 43.

OPTIONAL CHEMICAL ISOLATION CONTROLSChemical Isolation Control

Press the chemical isolation On/Offcontrol to activate the internalpump or external feed solenoid.

The control illuminates green to indicate thechemical isolation option is turned On. Theindicator turns Off when the chemical isolationcontrol is pressed again. When turned Off, theinternal pump or external feed solenoiddeactivate.

I f the enhanced chemica lisolation module is configuredwith the optional blower, the

blower must be turned On before enablingthe internal pump or external feed solenoid.This ensures no liquid is allowed to enter thelower airknife orifice.

Chemical Isolation Blower Control

Press the chemical isolation blowerOn/Off control to activate theoptional turbine blower.

The control illuminates green to indicate theturbine blower is activated. When pressedagain, the control indicator turns Off and powerto the blower deactivates.

Chemical Isolation Tank Fill Control

The optional chemical isolationtank f i l l control act ivates thec h e m i c a l i s o l a t i o n t a n k f i l lsolenoid.

To fill the chemical isolation tank:1. Ensure the Power On control is turned On.

2. Press the optional chemical isolation tankfill control.



• The green indicator illuminates if theliquid level in the tank is at operatinglevel


• The fill solenoid automatically initiatesto fill the chemical isolation tank if theliquid is below operating level and tankfill control green indicator flashes


4. During normal operation, if the liquid levelfalls below the operating level float, thefollowing occurs:



press the chemical isolation tank fillcontrol while the tank is filling

Chemical Isolation Tank Drain Control

The chemical isolation tank draincontrol activates the chemicalisolation tank drain solenoid.

Press the chemical isolation tank drain controlto empty the chemical isolation tank. The draincontrol indicator illuminates green to indicatethe tank is draining. The drain solenoid remainsopen until the chemical isolation tank draincontrol is pressed and the indicator no longerilluminates.

Chemical Isolation Tank Level Indicator

This indictor displays the status of the liquidlevel in the chemical isolation tank. For detailedinformation on the indicator refer to LevelIndicator on page 42.

Chemical Isolation Tank Immersion Heaters Control


The control illuminates green to indicate whenthe chemical isolation tank immersion heatersare turned On. The indicator turns Off when theheaters are off due to a high temperaturecondition or chemical isolation tank low liquidlevel.

Aquastorm 200™


The LCD key pad displays an asterisk next toCHEM ISO when the tank heaters are turnedOn. No asterisk displays when the heaters areturned Off.

Press the control to increase the chemicalisolation tank temperature set point. Whenpressed once and released, the temperature setpoint increases one (1) degree. When pressedand he ld , the chemica l i so la t i on tanktemperature set point increases until thecontrol is released. The actual temperature andtemperature set point display on the LCD.

Chemical Isolation Tank Decrease Temperature Control

Only use the decrease temperaturecontrol to decrease the chemicalisolation tank temperature setpoint.

Press the control to decrease the chemicalisolation tank temperature set point. Whenpressed once and released, the temperature setpoint decreases one (1) degree. When pressedand he ld , the chemica l i so la t i on tanktemperature set point decreases until thecontrol is released. The actual temperature andtemperature set point display on the LCD.

Chemical Isolation Tank Temperature Indicator

This indictor displays the temperature of thechemica l i so la t ion tank . Fo r de ta i l edi n f o r m a t i o n o n t h e i n d i c a t o r r e f e r t oTemperature Indicator on page 43.

RINSE/HURRICANE CONTROLPress this control to activate ordeactivate the rinse and optionalhurricane pump. When turned On,the indicator illuminates green.

RINSE JIC PUMP CONTROLThe JIC pump control remains indevelopment. Future applicationsof the Aquastorm series aqueouscleaning systems will include thiscontrol.

RINSE TANK CONTROLSRinse Tank Fill Control

The rinse tank fill control activatesthe rinse tank fill solenoid.

To fill the rinse tank:1. Ensure the Power On control is turned On.

2. Press the rinse tank fill control.



• The green indicator illuminates if thewater level in the tank is at operatinglevel


• The fill solenoid automatically initiatesto fill the rinse tank if the water is belowoperating level and tank fill controlgreen indicator flashes


4. During normal operation, if the water levelfalls below the operating level float, thefollowing occurs:



press the rinse tank fill control whilethe tank is filling.

Rinse Tank Drain Control

The r inse tank dra in cont ro lactivates the r inse tank drainsolenoid. Press the rinse tank draincontrol to empty the rinse tank. Thedrain control indicator illuminates

green to indicate the tank is draining. The drainsolenoid remains open until the rinse tank draincontrol is pressed and the indicator no longerilluminates.

Rinse Tank Level Indicator

This indictor displays the status of the waterlevel in the rinse tank. For detailed informationon the indicator refer to Level Indicator on page42.

Aquastorm 200™


Rinse Tank Immersion Heaters Control


The control illuminates green to indicate whenthe rinse tank immersion heaters are turnedOn. The indicator turns Off when the heatersare off due to a high temperature condition orwash tank low water level.

The LCD key pad displays an asterisk next toRINSE when the tank heaters are turned On. Noasterisk displays when the heaters are turnedOff.

Press the control to increase the rinse tanktemperature set point. When pressed once andreleased, the temperature set point increasesone (1) degree. When pressed and held, therinse tank temperature set point increases untilthe control is released. The actual temperatureand temperature set point display on the LCD.

Rinse Tank Decrease Temperature Control

Only use the decrease temperaturecontrol to decrease the rinse tanktemperature set point.

Press the control to decrease the rinse tanktemperature set point. When pressed once andreleased, the temperature set point decreasesone (1) degree. When pressed and held, therinse tank temperature set point decreasesunti l the control is released. The actualtemperature and temperature set point displayon the LCD.

Rinse Tank Temperature Indicator

This indictor displays the temperature of therinse tank. For detailed information on theindicator refer to Temperature Indicator onpage 43.

BLOWER CONTROLSPress blower control #1and #2 to activate theblowers.

Press blower control #3and/or #4 if the systemis configured with eitheror both of these optionalblowers.

The control illuminates green to indicate whenthe each blower is turned On. The indicatorturns Off when the blower is turned Off.

RADIANT HEATER CONTROLRadiant Heat On/Off Control

Press the radiant heater On/Offcontrol to activate the optionalradiant oven in Dryer #2 andoptional Dryer #4 if configured.

The control illuminates green to indicate whenthe each radiant heater is turned On. Theindicator turns Off when the radiant heaters areturned Off.

The LCD key pad displays an asterisk next toRADIANT HEATER when the radiant heaters areturned On. No asterisk displays when theradiant heaters are turned Off.

Prior to turning the radiant heater on ensure atemperature set point is defined in the LCDinterface.

Radiant Heat Increase Temperature Control

The operator cannot enable ordisable the radiant heaters usingthis control. It is an indicator only.

The control illuminates green to indicate whenthe radiant heater is turned On. The indicatorturns Off when the radiant heater is turned Off.

Press the control to increase the radiant heatertemperature set point. When pressed once andreleased, the temperature set point increasesone (1) degree. When pressed and held, therinse tank temperature set point increases untilthe control is released. The actual temperatureand temperature set point display on the LCD.

Radiant Heater Decrease Temperature Control

Only use the decrease temperaturecontrol to decrease the radiantheater temperature set point.

Press the control to decrease the radiant heatertemperature set point. When pressed once andreleased, the temperature set point decreasesone (1) degree. When pressed and held, theradiant heater temperature set point decreasesunti l the control is released. The actualtemperature and temperature set point displayon the LCD.

Aquastorm 200™


Radiant Heater Temperature Indicator

This indictor displays the temperature of theradiant heater. For detailed information on theindicator refer to Temperature Indicator onpage 43.

CONVEYOR CONTROLSConveyor On Control

Press the conveyor on control toactivate power to the conveyor. Theconveyor will not operate in anydirection without the conveyor oncontrol activated.

The control illuminates green to indicate whenthe conveyor is turned On. The indicator turnsOff when the conveyor is turned Off. Theconveyor forward control illuminates greenindicating forward movement of the conveyor.The conveyor operates at the set point speed.The speed set point displays on the LCD.

The LCD key pad displays an asterisk next toCONV when the conveyor is turned On. Noasterisk displays when the conveyor is turnedOff.

Conveyor Off Control

Press the conveyor Off control tostop conveyor movement. Theconveyor O f f r ed ind ica to rilluminates indicating power to theconveyor is disabled.

Conveyor Forward Control

The conveyor forward control is andOn/Off indicator. When the greenindicator illuminates, the conveyoris operational.

The conveyor moves forward at the set pointspeed. The speed set point displays on the LCD.

Conveyor Reverse Control

Press the conveyor reverse controlto reverse the conveyor direction.The green indicator illuminates toindicate the conveyor is operatingin the reverse direction.

The operator uses conveyor reverse when aconveyor jam occurs. Temporary operation ofthe conveyor in the reverse direction allows theoperator to remove the jam.

When operating in reverse, the conveyoroperates for a fixed time at a fixed speed, thenstops conveyor operation. When the conveyorstops, the conveyor Off indicator illuminates redto indicate the conveyor is Off.

Pressing the conveyor Off control whileoperat ing in reverse immediately stopsconveyor movement.

To abort a conveyor reverse operation andimmediately revert to forward conveyormovement, press the conveyor forward control.

Decrease Speed Control

Press the decrease speed controlto decrease conveyor speed.

Press the control to decrease the conveyorspeed set point. When pressed once andreleased, the conveyor speed set pointdecreases one (1) fpm. When pressed and held,the conveyor speed set point decreases untilthe control is released. The speed set pointdisplays on the LCD.

Increase Speed Control

Press the increase speed control toincrease conveyor speed.

Press the control to increase the conveyorspeed set point. When pressed once andreleased, the conveyor speed set pointincreases one (1) fpm. When pressed and held,the conveyor speed set point increases until thecontrol is released. The speed set point displayson the LCD.

Aquastorm 200™


EMERGENCY STOP (E-STOP) SWITCHESTwo (2) large red push-pull switches allow theoperator to halt system operation in the event ofan emergency. The E-stop switches are wired inseries. Pressing one (1) turns Off power to allsystem modules and stops process in allmodules.

Risk of Electric Shock –Turning power Off usingthe Emergency Stop (E-

Stop) control DOES NOT disable power to thesystem. To disable system power turn Offpower at the main disconnect or facilitypower safety disconnect.

One (1) emergency stop switch is located onthe operator control panel at the front entranceend of the machine. The second switch islocated on the sound enclosure at the front exitend of the machine. Two (2) addit ionalemergency stop switches are optional. Whenconfigured, they mount at the rear entranceand exit ends of the machine.

Figure 68: Entrance End Emergency Stop Switch

Figure 69: Exit End Emergency Stop Switch

E-Stop conditions

The fo l lowing condi t ions const i tute anemergency situation and will completely shutdown system operation:

• Depressing any E-Stop switch• An immersion heater reaches high

temperature shut down mode• A dryer module reaches high temperature

shut down mode

Restart the machine

Prior to turning power On and resumingoperation, correct the emergency situation andensure all emergency stop switches are pulledto the Out position.

EmergencyStop Switch


Aquastorm 200™


5.3 LCD INTERFACE KEY PADThe Liquid Crystal Display (LCD) interface keypad prov ides d ig i ta l d isp lay o f sys teminformation, allows the operator to controlsys tem func t ions , and per fo rm se t upprocedures for the following functions. Anasterisk next to an item indicates an optionalfeature.

• Wash Temperature• Chemical Isolation Temperature*• Rinse Temperature• Dryer Section Temperatures• Radiant Heater Temperatures• Conveyor Speed• System Configuration• Auto Start Timer • Alarm Process• System Date and Clock• pH Levels*• Resistivity Levels*

Figure 70: LCD Interface Key Pad

5.4 LCD KEY PAD FUNCTIONSThe following key pad control descriptionsexplain the use of each control as it appears onthe LCD interface key pad.

• Menu• Enter • Number• Page Up/Page Down• Up, Down, Left, Right Arrows• Recipe• Print• Help• Del(ete)

MENUPressing the menu control displays the MainMenu, Configuration, or Timer screens. Pressthe menu control repeatedly to toggle betweenthe screens.

ENTERPress the enter key to accept changes made tomain menu set points, system configuration,timer setup, clock and date setup, and alarmprocess values.

NUMBER KEY PADUse the number keys to enter set point values,adjust time settings, set system clock and dateand enter alarm process values.

PAGE UP/PAGE DOWNThe page up and page down arrow keys allowthe operator to scroll up or down through theseparate pages of the main, configuration, andalarm process screens.

UP/DOWN ARROWSUse the up and down arrow keys to move theunderline screen cursor up or down on the LCDscreen to review or adjust values on all menuscreens.

LEFT/RIGHT ARROWSUse the left and right arrow keys to move theunderline screen cursor left or right betweenfields within the timer, system clock and date,and alarm process menu screens.

Aquastorm 200™


RECIPE, PRINT, HELP, DELThe Recipe, Print, Help, and Del(ete) controlsremain in development. Future applications ofthe Aquastorm series aqueous cleaningsystems will include these controls.

5.5 LCD KEY PAD SCREENSThe fo l lowing inter face screens conveyoperation information or provide operatorinterface for system set up.

• Main Screen• Configuration• Timer• Alarm Process• System Clock and Date• Alarm Display

MAIN SCREENThe main screen displays standard and optionalmodule system information, module set points,and actual module temperatures. Dependingon system modules the main screen cancontinue to a second page.

Figure 71: LCD Key Pad Main Screen

CONFIGURATION SCREENUse the four (4) configuration screens toconfigure, add, or remove system options.

Figure 72: LCD Key Pad Configuration Screen #1




System software may lockup i f the opera to rattempts to configure

items that do not exist on the system.

The configuration screens interface with thesystem software. When an option is added tothe system or removed from the system, theoperator adds, or removes the option(s) on theconfiguration screens.

MODULE SETP ACTUAL

CONVEYOR 7.7 F/min 0.0 WASH 145F 103 RINSE 150F 119 DRYER_1 F 74 DRYER_2 F 72 PW_FLOW 17.0 LPM

AQUASTORM 200

MODEL 200 TEMP_UNITS F SPEED_UNITS F/min CHECKMATE NO pH MONITOR NO WASH PUMP HURRICANE RINSE PUMP HURRICANE

CONFIGURATION

RESISTIVITY NONEDRYER #2 BLOWER ONLYDRYER #3 NODRYER #4 NOSUMP TANK STANDARDSUMP TANK #2 NONEC/I SPRAY PUMPC/I BLOWER YES

LIGHT TOWER YESBOARD_TRACKING YESSAPONIFIER YESUPS NOCONV PITCH 3/8KEYSWITCH DISABLEBLOWER FAIL NOSYS_CLOCK SET

ALARM_PROCESS SETWATCH_DOG TESTPRE_WASH_FLOW YESFINAL_RINSE_FLOW YESFLOW_UNITS GPMGAS_HEAT NO

Aquastorm 200™


Press the Menu key on the LDC Interface keypad to access the main configuration screen. Toscroll between the configuration screens pressthe page up or page down keys. To move theunderline screen cursor to a specific optionpress the up or down arrow keys. Press theEnter key to toggle between selection choices.The following table lists configuration options.

Press the Menu key to accept the changes. Thefollowing message briefly displays then thesystem returns to the main menu.

Figure 76: Update Message

MODEL — Ensure Aquastorm 200™ displays.

TEMP_UNITS — Use the Ce ls ius o rFahrenheit scale to display temperaturereadings.

SPEED_UNITS — Use fee t pe r minu teimperial units or meters per minute metricunits for conveyor speed display.

OPTIONS — Indicates whether any of thefollowing options is installed. For detailedinformation, refer to the Aquastorm 200™Options Manual.

Checkmate™ pH MonitorsResistivity Sump TankLight Tower UPSKeyswitch Gas HeatFlow Meters for Prewash or Final Rinse

WASH PUMP/RINSE PUMP — If installed,toggle to hurricane. For normal operationchoose standard.

IR HEATER/DRYER #2 — Indicates when anIR heater is installed and whether Dryer #2 hasa blower installed or blower and IR heater.

C/I SPRAY–C/I BLOWER — For op t iona lchemical isolation, indicate whether or not theoptional spray enhance or optional blower isinstalled.

BOARD TRACKING — Board t rack ing i sprovided via photocel ls mounted on theoptional inlet conveyor.

CONV PITCH — Standard wire mesh beltspacing is 3/8. Choose 1/4 when the optionalwire mesh belt is used.

BLOWER FAIL — When configured with thisoption, any amperage change in bloweroperation initiates an alarm situation.

Table 7: Configuration Selections

SYSTEM COMPONENT

SELECTION CHOICES

MODEL 100/200

TEMP_UNITS C/F

SPEED_UNITS F/Min. M/Min.

CHECKMATE YES/NO

pH MONITOR YES/NO

WASH PUMP STANDARD/HURRICANE

RINSE PUMP STANDARD/HURRICANE

RESISTIVITY NONE/YES

DRYER #2 BLOWER ONLY/BLOWER + IR

DRYER #3 YES/NO

DRYER #4 YES/NO

SUMP TANK RECYCLE/NONE/STANDARD

SUMP TANK #2 NONE/STANDARD

C/I SPRAY YES/NO

C/I BLOWER YES/NO

LIGHT TOWER YES/NO

BOARD_TRACKING YES/NO

SAPONIFIER YES/NO

UPS YES/NO

CONV PITCH 1/4 / 3/8

KEYSWITCH DISABLED/ENABLED

BLOWER FAIL YES/NO

SYS_CLOCK SET

ALARM_PROCESS SET

WATCH_DOG TEST

PRE_WASH_FLOW YES/NO

FINAL_RINSE_FLOW YES/NO

FLOW_UNITS L/MIN/GPN

GAS_HEAT YES/NO

UPDATING CONFIGURATION

PLEASE WAIT . . .

Aquastorm 200™


SYSTEM CLOCK AND DATEThe clock and date screen displays the currentdate and time as configured in the internalcomputer. In the event of a power loss, or whenchanging to or from daylight savings time, thisfeature permits date and time computeradjustments.

Keep in mind the in te rna lsystem clock is a 24 hour clock.

Figure 77: System Clock and Date Screen

To set system clock and date:1. Press the menu key on the LCD interface

keypad to access configuration screen #1.

2. Press the page down key twice to displayconfiguration screen #3.

3. Press the down arrow key until theunderline cursor blinks in line withSYS_CLOCK.

4. Press the enter key to access the DATE/CLOCK utility.

5. Press the arrow keys to move the underlinecursor between fields.

6. Use the number keys to enter the correctdate and time.

7. Press the enter key to accept the changes.

8. Press the menu key twice to exit the DATE/CLOCK utility and bypass the Auto Timerscreen.

9. The changes made are saved and the mainscreen displays.

TIMER SCREENThe timer screen allows the operator to setspecific times on selected days for automaticstart up and shut down of the Aquastorm 200™system.

The timer is based on the 24hour internal system clock.Ensure the correct time and date

are set on the internal clock before settingthe automatic timer.

Figure 78: LCD Key Pad Timer Screen

To configure the automatic timer:1. Press the menu key twice on the LCD

interface keypad to access the timerscreen.

2. Press the up and down arrow keys until theunderline cursor blinks in line with the dayrequiring editing.

3. Press the left and right arrow keys to movebetween the Start, Stop, and Enable fields.

4. When the underline cursor is in the startfield, press the number keys to enter therequired start time. The start time must beset to a time prior to the stop time.

5. Press the enter key to accept the start time.

6. Move the underline cursor to the stop field.Press the number keys to enter therequired stop time. The timer runs on a 24hour clock. For example to stop at 5:00 pmenter 17:00:00 in the stop time field.

7. Press the enter key to accept the stop time.

8. Move the underline cursor to the enablefield.

9. Press the enter key to toggle between Yesand No. Yes enables the timer for a specificday and No disables it.

10. Repeat Step 3. through Step 9. to set thetimer for each day of the week.

11. After entering all timer screen information,press the menu key to save the changesmade and return to the main screen.

03-08-1999 08:12:04

PRESS ENTER TO SETPRESS MENU TO EXIT

TIMER START STOP ENABLE

SUN 00:00:00 00:00:00 NO MON 00:00:00 00:00:00 YES TUE 00:00:00 00:00:00 YES WED 00:00:00 00:00:00 YES THU 00:00:00 00:00:00 YES FRI 00:00:00 00:00:00 YES SAT 00:00:00 00:00:00 NO

Aquastorm 200™


ALARM PROCESSUse the alarm process screen to configurespecific software alarms and their relatedpriority. Depending on the specific processapplication alarms are configured as Ignore,Warning, or Shutdown.

Figure 79: LCD Key Pad Alarm Process Screen

Configure process alarms for the followingprocesses:

• Wash high and low temperatures• Optional chemical isolation high and low

temperatures• Rinse high and low temperatures• Optional radian heater high and low

temperatures• Conveyor speed deviation• Resistivity level deviation• pH level deviation• Saponifier tank level

To set alarm values:1. Press the menu key on the LCD interface


2. Press the page down key three (3) times todisplay configuration screen #4.

3. Press the down arrow key until theunderline cursor blinks in line withALARM_PROCESS.

4. Press the enter key to access theALARM_PROCESS screen.

5. Refer to the following fields to completealarm process configuration.

Alarm – The module or componentLimit – The set point deviation level. Whenthe actual reading reaches the set limit inthe plus or minus direction, the designatedalarm activates.Action – Select the alarm condition level.Press the enter key to toggle between thethree options:

IGNORE – No alarm or LCD displayactivates.WARNING – An audible alarm and LCDdisplay activate. The system remains inoperation.SHUT DOWN – An audible alarm andLCD display activate. The system shutsdown operation.

Realarm – Configure this value to reinitiatean alarm if it is not corrected when it firstactivates. The realarm value set point isfrom 1–99 minutes.

6. Use the left and right arrow keys to togglebetween fields and numeric characters inthe Limit and Realarm fields.

7. Use the number keys to enter digits.

8. Use the up and down arrow keys to choosethe specific module or component foralarm adjustment.

9. After configuring all alarms, press themenu key twice to save the changes madeto the alarm values and return to the mainscreen.

ALARM DISPLAYThis screen provides a readout of configuredalarms as they occur.

Figure 80: Alarm Acknowledge

ALARM BAND ACTION REALARM

CONV 1.0 FPM WARNING 05 MIN WASH 10 F SHUTDOWN 05 MIN CHEM 10 F IGNORE 05 MIN RINSE 10 F SHUTDOWN 05 MIN BLWR 10F WARNING 05 MIN PW_FL 3.8 LPM IGNORE 05 MIN FR_FL 3.8 LPM IGNORE 05 MIN

ALARM SCREEN

NO ACTIVE ALARMS

PRESS ENTR TO ACKNOWLEDGE ALRM

Aquastorm 200™


WATCH DOG TESTThe watch dog test is an internal software utilitythat re-boots the internal computer system inthe case of a lock up.

Figure 81: LCD Key Pad Watch Dog Test

To perform the watch dog test:1. Press the menu key on the LCD interface


2. Press the page down key three (3) times todisplay configuration screen #4.

3. Press the down arrow key until theunderline cursor blinks in line withWATCH_DOG.

4. Press the enter key.

5. The system shuts down and the computerre-boots.

5.6 GAUGE PANELThe gauge panel displays the water pressure inthe Prewash, Wash, Opt ional ChemicalIsolation, Rinse, and Final Rinse modules.Actual pressure rating depends on the pumphorsepower rating. The table lists averagepressure readings for the pumps.

PRESSURE CHECKSOn 1/3 hp pumps, if the pressure increases by138 kPa (5 psi) check and clean nozzles in theoptional chemical isolation module. On 5 hp or10 hp pumps, if the pressure increases by138kPa (5 psi) check and clean the nozzles inthe module where the increase displays. In theWash and Rinse modules also check theoptional hurricane jet nozzle.

When an optional Bag Filter is installed, if thepressure drops by 69 kPa (10 psi) perform LockOut-Tag Out steps, (refer to 1.3 Lock Out-Tag Outon page 3) check, and clean or replace the bagfilter.

Ensure regu la r p revent i vemaintenance is performed on allnozzles. Refer to the Aquastorm

Series Maintenance Manual for procedures.

Figure 82: Gauge Panel Layout

ALARM_PROCESS SETWATCH_DOG TESTPRE_WASH_FLOW YESFINAL_RINSE_FLOW YESFLOW_UNITS GPMGAS_HEAT NO

Table 8: Gauge Panel Readings

PUMP RATE PRESSURE READING

1/3 hp 103.5 – 138 kPa (15 – 20 psi)

5 hp 552 – 586.6 kPa (80 – 85 psi)

10 hp 621 kPa (90 psi)

Aquastorm 200™


SECTION 6: DAILY OPERATION

Prior to turning power On to the Aquastorm200™ system complete the Pre-Start Checklistand Set Up procedures outlined in SECTION 4:Machine Set Up on page 25. Ensure theoperator is familiar with the controls andindicators on the control panel pr ior tooperating the system.

6.1 ELECTRICAL POWER

FACILITY POWERActivate power to the Aquastorm 200™ byturning On the main power disconnect locatedat the exit end of the system for 380V and 460Vsystems. On 220V systems turn On the facilitypower source.

The following indicate power to the system isOn:

• Interior lights illuminate• Computer boots up• Power is enabled to the control panel

Figure 83: Main Power Disconnect

SYSTEM POWERPress the Power On control on the membranekeypad. All Aquastorm 200™ subsystems areenabled. If tank levels are at operating level,immersion heaters activate.

6.2 INITIAL START UPWhen starting the Aquastorm 200™ for the firsttime, the system parameter settings displayfactory defaults. Prior to operating pumps,blowers, and optional radiant heaters, it isnecessary to change one (1) or more of thedefault parameter settings.

Figure 84: Factory Default Settings

Refer to previous sections in this manual toadjust temperature set points, conveyor speed,fill system tanks, and initiate operation.

CONVEYOR (No Default – Must be Set) WASH 65 °C 150 °F CHEM_ISO 65 °C 150 °F RINSE 65 °C 150 °F DRYER_1 IR_HEATER 65 °C 150 °F

Aquastorm 200™


6.3 ACTIVATE SUBSYSTEMSUse the membrane control panel to initiate thefollowing in the sequence listed.

To activate subsystems:1. Press the conveyor On control to activate

the conveyor.

2. Press the wash module hurricane pumpOn/Off control to activate the optional washHurricane™ pump. The prewash modulespray nozzles, wash module spray nozzles,and optional Hurricane™ Jet spray nozzleenergize.

3. Press the chemical isolation module blowerOn/Off control to activate the optional dragout blower. The blower air knives in theoptional chemical isolation moduleenergize.

4. Press the rinse module hurricane pumpOn/Off control to activate the optional rinseHurricane™ pump. The rinse module spraynozzles and optional Hurricane™ Jet spraynozzle energize.

5. Press the final rinse On/Off control toactivate the final rinse module solenoid andthe optional treatment interface pump. Thefinal rinse solenoid, spray nozzles, andoptional treatment interface pumpenergize.

6. Press each blower On/Off control toindividually activate the blowers.

7. Press the radiant heater On/Off control toturn the IR heater On for operation.

AUTO START TIMERIf configured, the auto start timer eliminatesproduction delays by auto enabling the systemfill solenoid and the wash and rinse tankimmersion heaters prior to system start up.Ensure power to the Aquastorm 200™ remainsturned On for the auto start timer to workproperly.

Configure daily start and stop times for eachday of the week using the timer function andthe LCD interface keypad. See Timer Screen onpage 54 for detailed timer set up.

6.4 SYSTEM SHUT DOWNShut down the Aquas torm 200™ whenperforming preventive maintenance or in anemergency situation.There are two (2) shutdown procedures for the Aquastorm 200™,normal and emergency.

NORMAL SHUT DOWNUse the membrane control panel to initiate thefollowing in the sequence listed.

To manually shut down subsystems:1. Press the radiant heater On/Off control to

stop IR heater operation.

2. Press each blower On/Off control toindividually turn each blower Off.

3. Press the final rinse On/Off control to stopthe final rinse module solenoid and theoptional treatment interface pump. Thefinal rinse solenoid, spray nozzles, andoptional treatment interface pumpoperations stop.

4. Press the rinse module hurricane pumpOn/Off control to stop the optional rinseHurricane™ pump. The rinse module spraynozzles and optional Hurricane™ Jet spraynozzle operations stop.

5. Press the chemical isolation module blowerOn/Off control to stop the optional drag outblower. The blower air knives in the optionalchemical isolation module stop.

6. Press the wash module hurricane pumpOn/Off control to stop the optional washHurricane™ pump. The prewash modulespray nozzles, wash module spray nozzles,and optional Hurricane™ Jet spray nozzleoperations stop.

7. Press the conveyor Off control to stop theconveyor.

8. Perform the post shut-down clean andcheck of the system. For detailedinformation on maintenance refer to theAquastorm 200 Maintenance Manual.

Aquastorm 200™


EMERGENCY SHUT DOWNT h e E m e r g e n c y S t o p ( E - S t o p ) c o n t r o limmediate ly s tops a l l Aquastorm 200™processing. Any PCB assemblies in processcould be damaged or adversely affected whenthe system is stopped in this manner.

Use the Emergency Stop(E-Stop) controls only inresponse to situations

that place operators or equipment in danger.DO NOT use E-Stop controls to routinely shutthe system down. This causes line surgesand could affect machine performance.

Press one (1) of the two (2) large red push-pullswitches. One (1) emergency stop switch islocated on the operator control panel at thefront entrance end of the machine. The secondswitch is located on the sound enclosure at thefront exit end of the machine. The E-stopswitches are wired in series. Pressing one (1)turns Off power to all system modules andstops process in all modules.

Risk of Electric Shock –Turning power Off usingthe Emergency Stop (E-

Stop) control DOES NOT disable power to thesystem. To disable system power turn Offpower at the main disconnect or facilitypower safety disconnect.

Two (2) additional emergency stop switches areoptional. When configured, they mount at therear entrance and exit ends of the machine.

Restart the machine

Prior to turning power On and resumingoperation, correct the emergency situation andensure all emergency stop switches are pulledto the Out position.

Figure 85: Entrance End Emergency Stop Switch

Figure 86: Exit End Emergency Stop Switch



Aquastorm 200™


6.5 OPERATION TROUBLESHOOTINGThis section lists possible problem scenariosthe operator may encounter during Aquastorm200™ operation. It also recommends action toasses and/or correct the problem.

Refer to the Aquastorm 100 and Aquastorm 200Insta l la t ion Manual , Aquastorm Ser iesMaintenance Manual, or Aquastorm SeriesOptions Manual for detailed information asrequired.

Table 9: Operation Troubleshooting Chart

SYMPTOM PROBABLE CAUSE RECOVERY

No heat in wash, rinse, or optional chemical isolation tanks.

Immersion heater burned out Replace immersion heater.

Temperature set point set too low Adjust temperature to correct setting.

Thermocouple is defective Replace thermocouple.

Fuse is blown Replace fuse.

Immersion heater contactor defective Replace immersion heater contactor.

Low level float switch deactivates immersion heaters

Contact Technical Support.

Scale buildup on heaters and reducing heat output

Perform descaling procedure.

Low level alarms

Make up level float switch sticks Clean or replace float switch.

Low level float switch sticks Clean or replace float switch.

Scale build up on or around float switches

Perform descaling procedure.

Unbalanced water flow gpm in/gpm out The volume of water entering Final Rinse should be equal to the volume of water exiting Prewash. Adjust flow as required.

Drain solenoid stuck in open position Perform Lock Out-Tag Out steps (See 1.3 Lock Out-Tag Out on page 3) and clean or replace the solenoid.

Photocell does not activate wash, rinse, and final rinse modules

Photocell sensitivity adjusted too low Follow photocell set up steps (See 4.10 Optional Photocell Set Up on page 31).

Condensation on photocell emitter or reflector

Clean photocell emitter and reflector with a clean soft cloth

Misaligned photocell Realign photocell (See 4.10 Optional Photocell Set Up on page 31).

Dirty photocell emitter or reflector Clean photocell emitter and reflector with a clean soft cloth

Aquastorm 200™


High level alarms

Drain solenoid defective Perform Lock Out-Tag Out steps (See 1.3 Lock Out-Tag Out on page 3) and clean or replace the solenoid.

Clogged drain Perform maintenance procedure on tank where drain is located.

High level float switch stuck Clean or replace float switches as required.

Unbalanced water flow gpm in/gpm out The volume of water entering Final Rinse should be equal to the volume of water exiting Prewash. Adjust flow as required.

Jerky conveyor belt

Nylon sprocket not aligned with wire belt

Loosen the set screw on the sprocket, reposition the sprocket on the shaft, and retighten the set screw.

Wire belt tension too loose Refer to the wire belt tensioning information in the Installation or Maintenance manual and adjust.

Conveyor speed control out of calibration

Refer to the calibration section in the Maintenance Manual.

Excess steam escapes entrance or exit end of system

Clogged spray nozzles Check nozzles and clean or replace as required.

Scale buildup Perform descaling procedure.

Clogged recirculation filter Check and clean or replace filter

Final rinse water does not activate

Defective final rinse solenoid Replace the final rinse solenoid.

Broken or loose wire connection. Perform Lock Out-Tag Out steps (See 1.3 Lock Out-Tag Out on page 3) and repair the wire.

Facility water supply diminished or not activated

Replenish or activate facility heated water supply.

Immersion heater over-temperature sensor does not reset

Immersion heater and over-temperature sensor need replacement

Contact Technical Support for assistance in the replacement process.

Table 9: Operation Troubleshooting Chart

SYMPTOM PROBABLE CAUSE RECOVERY

Aquastorm 200™


This page intentionally left blank.

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 A – 1

APPENDIX A: GLOSSARY

A.1 INTRODUCTIONThe following guide lists industry terms as theyrelate to printed circuit assembly cleaning.Many of the definit ions are from the IPC(Institute For Interconnecting And PackagingElectronic Circuits) web site (www.ipc.org).

ABOUT SMEMAThe Surface Mount Equipment ManufacturersA s s o c i a t i o n ( S M E M A ) i s a n o n - p r o f i torganization of companies manufacturingequipment or producing software for surfacemount board production.

Its objectives are to:

• Promote standards for the interface andoperation of equipment

• Provide users with the ability to selectequipment with the assurance that theequipment will interface easily

• Advance SMT and promote its use• Investigate areas where the association

can act to the benefit of all membercompanies

A.2 ELECTRONICS CLEANING TERMS AND DEFINITIONSABSORPTION — The penetrat ion of onesubstance into the inner structure of anothertermed the absorbent.

ACID — A substance that ionizes in solution torelease the positive ion of the solute. Thestrength of tile acid is proportionate to theamount of ions released in solution. Thestrongest acids have the lowest pH readings,i.e. closest to I.O.

ACIDITY — The quantitative capacity of awater or water solution to neutralize an alkali orbase. It is usually measured by titration with astandard solution of sodium hydroxide andexpressed in terms of its calcium carbonateequivalent.

ADSORBED CONTAMINANT — Acontaminant which is attracted to the PWBsurfaces and held captive in the form of a gasor liquid.

ADSORBENT — A material, usually solid,capable of holding gasses, liquids and/orsuspended matter at its surface and in exposedp o r e s . A c t i v a t e d c a r b o n i s a c o m m o nadsorbent used in water.

ADSORPTION — T h e p r o c e s s i n w h i c hmatter adheres to the surface of an adsorbent.

AERATION — The process in which air isbrought into intimate contact with water, oftenby spraying water through air or by bubbling airthrough water. Aeration may be used to addoxygen to the water for the oxidation of mattersuch as i ron, or to cause the re lease ofdissolved gasses such as carbon dioxide orhydrogen sulfide from the water.

AIRKNIFE — A means, usually a slotted tube,by which air can be directed into a focused flowtoward a surface. Airknife shapes and orificescan vary. The term airknife can also refer to thecurtain or “knife” of air itself. Typically airknivesare fed by high velocity or high volume blowers.

ALKALINITY — The quantitative capacity of awater or water solution to neutralize an acid. Itis usually measured by titration with a standardacid solution of sulfuric acid and expressed interms of its calcium carbonate equivalent.

ANHYDROUS — Free of water.

ANION — A negat ive ly charged ion thatmigrates to an anode, as in electrolysis.

ANION EXCHANGE — A n i o n e x c h a n g eprocess in which anions in solut ion areexchanged for other anions from an ionexchanger.

AZEOTROPE — A solvent blend that has thesame composition and characteristics in thevapor phase as it does in the liquid phase, Thisproperty enables all azeotropic solvent to gofrom the l iquid state to the boil ing state(evaporation) and be cooled (condensed) backto the liquid state for recovery or distillation.DuPont's Vertret™ III SMT is an example of anazeotrope.

BASE — A substance that ionizes in solutionwith water to release negatively chargedhydroxyl (OH,) ions. The strength of the base isproportionate to the amount of hydroxyl ionsreleased in solution. The strongest bases havethe highest pH readings, i.e. closest to 14.0.(Base is also referred to as alkali or alkaline).

Aquastorm 200™

A – 2 2-9317-521-00-0 — Rev. 1 Operations Manual

BED — The ion exchanger or filter media in acolumn or other tank or operational vessel.

BIODEGRADABILITY — The propensity of asubstance to decompose by microorganismsnormally found in the environment.

B.O.D/C.O.D. — Biological oxygen demand/chemical oxygen demand. A relative measureof impact, in terms of oxygen demand, ofdissolved and colloidal organic matter oil thebiological units (bacteria) required to maintaina properly functioning waste treatment facility.Chemical addit ives to aqueous cleaningsystems will often raise BOD/COD over theacceptable limits of the POIV.

BRACKISH WATER — W a t e r c o n t a i n i n gdissolved solids in the range of 1,000 to 10,000mg/l.

BRINE — A strong solution of salt(s), such ast h e s o d i u m c h l o r i d e b r i n e u s e d i n t h eregeneration of ion exchange water softeners,but also applies to the mixed sodium, calcium,and magnesium chloride waste solution fromregeneration.

CFC — Abbreviation for Chlorofluorocarbon.

CFC-113 — A common name for the mostcommon CFC solvent–1,1,2-trichloro-1,2,2-tr i f luoroethai ie . CFC-113 has an ODP ofapproximately O.8.

CALORIE — The amount of heat necessary toraise one gram of water one degree centigrade(at 1 atmosphere pressure). A Calorie (with acapital C) is the amount of heat needed to raiseone kilogram of water one degree centigrade.

CAPACITY — An expression of the quantity ofan undesirable material which can be removedby a water conditioner between servicing of themed ia , i . e . , c l ean ing , regenera t ion , o rreplacement, as determined under standardtest conditions.

CAPILLARY ACTION — T h e i n t e r a c t i o nbetween a liquid and a small diameter openingin a solid. Because of surface tension, theliquid is drawn into tile opening by this action.The Young-Laplace equation of differentialpressure can demonstrate this phenomenon.

CASCADE SYSTEM — A c o n f i g u r a t i o nwhereby cleansed water is used in one tank, orsection, and overflows to the previous tank orsection relative to board movement. A typicalexample would be deionized water entering thefinal rinse section of a cleaner, flowing to arecirculating rinse section, then to a wash, thento a prewash, and then to drain. Thus, the board

assembly is exposed to progressively cleanerwater as it moves through tile system. This flowconfiguration is typically used when cleaningwithout wash additives, such as with watersoluble fluxes.

CATION — A posi t ive ly charged ion thatmigrates to a cathode during electrolysis.

CATION EXCHANGE — I o n e x c h a n g eprocess in which cations in solution areexchanged for other cations from an ionexchanger.

CHEMICAL ISOIATION — Term developedby Hollis Automation referring to an enhanceddrag-out section in an in-line cleaner. Instead ofa simple airknife/blower combination, chemicalisolation uses a low-flow water spray in betweentwo sets of airknives to flush residual washw a t e r f r o m c o n n e c t o r b o d i e s , u n d e rcomponents, etc. The water from this sectionmay be supplied from the rinse section, from itsown tank, or from an external source.

CHEMICAL COMPATIBILITY — T h i s t e r mrefers to the acceptability of use of a chemicalrelative to the machine in which it's used, andtile product it cleans. Some chemistries willhave degradable effects on equipment and/orboards. Chemical compatibility should beverified prior to implementing a cleaningprocess.

CHLORINE — A gas Cl2, widely used in thedisinfection of water and an oxidizing agent fororganic matter, iron, etc.

CHLORINATOR — A m e c h a n i c a l d e v i c especifically designed to feed chlorine gas ors o l u t i o n s o f i t s c o m p o u n d s , s u c h a shypochlorites, into a water supply in proportionto the flow of water.

CHLORINATED POLYVINYL (CPVC) — Aplastic often used in cleaner plumbing which issimilar to commercially available PVC found indomestic plumbing, however, it can handlegreater temperatures and pressures. It isavailable in Schedule 40 or Schedule 80 grades,w i th 80 be ing the most durab le . CPVCplumbing is easy to work with because it doesnot require threading or welding, it is glued.CPVC also works well with Deionized water.

CHLOROFLUOROCARBON (CFC) — Acompound consisting of carbon, hydrogen,chlorine, and fluorine to have a negative impactoil the earth's protective ozonosphere. Thesecompounds are being phased out of productionby edict of the Montreal Protocol.

Aquastorm 200™


CLEANLINESS TESTING — Any of a familyof tests used to verify a required cleanlinessspecification. Testing may include residualionic evaluation (conductivity testing), surfacei n s u l a t i o n r e s i s t a n c e t e s t i n g ( S I R ) ,chromatography evaluation.

COAGULATION — The process in which verysmall, finely divided solid particles, oftencolloidal in nature, are agglomerated into largerparticles.

CONCENTRATE — Waste water which issent to the drain from a reverse osmosis (RO)machine.

CONORMAL COATING — A p r o t e c t i v ematerial applied in a thin, uniform layer to aprinted wiring assembly.

CONDENSATION — The change o f s ta tefrom a gas to a liquid.

CONDUCTIVITY — The quality or power tocarry electrical current. In water, conductivity isrelated to the concentration of ions capable ofcarrying electrical current.

CONDUCTIVITY TESTING — Also knownas residual ionic evaluation, solvent extractresistivity testing and Omegameter/Ionographtesting. A quantitative evaluation of residualconductive (ionic) material left on a board inwhich th is mater ia l i s expressed as anequivalent of micrograms of salt (NACI) persquare inch. This test involves immersing theboard in a known volume of so lut ion ofisopropyl alcohol and deionized water at aknown initial conductivity. In some machinesthis solution is heated and agitated during thetest period. During the typical 10 minute test,residual ionics go into solution, thus increasingthe conductivity of the solution. By analyzingthis change in conductivity relative to thesurface area of t i le board, an equivalentmeasurement o f contaminat ion ca l l bedetermined. There are many specificationscovering this test, but the most quoted is Mil-P-28809.

CONTAMINANT — An impurity that may ormay not affect the performance of a circuitassembly. Typically, contaminants are classifiedas polar, non-polar or particulate in nature.

CONTAMINATION — The addition of foreignmatter to a substance which reduces the valueof the substance, or interferes with its intendeduse.

CORROSION — T h e d e s t r u c t i v edisintegration of metal by electrochemicalmeans.

DECANT — In semi-aqueous cleaning mosthydrocarbon-based and terpene-based solventswill separate from water and rise to tile top in atank. This enables tile solvent to be recoveredfrom water, as in when wash SA solvent iscarried or dragged out into tile water rinsesection, by separating into a weir.

DEFOAMING AGENT — An additive to washor rinse tanks in a cleaner which will reduce thetendency to produce a head of foam in the tank.

DEIONIZATION (DI) — The removal of a l lionized minerals and salts (both organic andinorganic) from a solution by a two-phase ionexchange procedure. The term is often usedinterchangeably with demineralization.

DEIONIZED WATER — Water which has hada degree of positive and negative ions removedso as to decrease i ts conductivi ty (raiseresistivity). Typically, this is done in the ionexchange process. in general, the highestdegree of deionization possible under normalconditions will result in resistivity of 18.2 meg-ohms. Tap water has resistivity as low as 1-5k i l o - o h m s . I n a d d i t i o n t o h a v i n g l o wconductivity potential, DI water is prone toabsorbing ions aggressively in the r inseprocess. Because of low dissolved mineralcontent, DI water is also less prone to leavingwater spots on a board. In the cleaning process,it is rarely necessary to deionize to the 18.2meg-ohm extent. Desired results can usually beachieved in the 500k to 3 meg-ohm range.

DEMINERALIZATION — T h e r e m o v a l o fionized inorganic minerals and salts (notorganic materials) from a solution by two-phaseion exchange process similar to deionization.

DENDRITIC GROWTH — A n i n d i c a t o r o felectro-migration. The appearance of stalk-likegrowth between conductors to which a biasvoltage has been applied indicating thatelectrolytic transfer has occurred, and, hence apotential problem for current conductivityexists. This is a visual test usually tinder 2-8Xmagnification.

DETERGENT — A cleaning agent that exertsan emulsifying action at polar/non-polarinterfaces, as in oil/water, so as to separatethem and enable them to be rinsed away.

Aquastorm 200™


DISINFECTION — A p r o c e s s i n w h i c hpathogenic (disease-producing) bacteria arekilled; may involve disinfecting agents such aschlorine or physical process such as heating.

DISSOLVED SOLIDS — The weight of matterin true solution in a stated volume of water;includes both inorganic and organic matter;usually determined by weighing the residueafter evaporation of the water at (105° or 180°C)(221° or 356°F).

DISTILIATION — A p r o c e s s o f b o i l i n g ,evaporation, and condensation of a substancefor purification by separating out contaminants.This process was typically used for recovery ofsolvents in CFC cleaning. Multiple distillationsare required for extreme purity.

DRAG-OUT — The carryover of water, washchemistry, and/or contaminants in solutionfrom one functional section of a cleaner toanother.

EFFLUENT — The stream emerging from aunit, system, or process, such as the softenedwater from an ion exchange softener or run-offto a drain.

ELUTION — The stripping of ions from an ionexchange mater ia l by other ions, e i therbecause of greater affinity or because of muchhigher concentration.

ELECTRICAL LEAKAGE — A phenomenonassociated with the degradation of surfaceinsulation resistance on a circuit board leadingto partial conduction of current electrical traceand on to the substrate.

EMULSION — A suspension of small globulesof one liquid in a second liquid with which thefirst will not mix. This can occur with somesemi-aqueous solvents in water.

EQUIVALENT PER MILLION — A u n i t o fconcentration used in chemical calculations. Tocalculate, divide the concentration in ppm ormg/L by the equivalent weight.

EVAPORATION — The process by which al i q u i d v a p o r i z e s i n t o t h e s u r r o u n d i n gatmosphere. This process can generally beaccelerated by adding heat. One cause of thel o s s o f w a t e r i n a c l e a n i n g s y s t e m i sevaporation.

FEED WATER — Any water fed into a machine.

FINAL RINSE — The last wet section of acleaner. Typically, this is where deionized wateris introduced to the machine. It may or may notcascade to preceding sections.

FILTER — A device or system for the removalof solid particles (suspended solids); includesmechanica l , adsorpt i ve , ox id i z ing , andneutralizing filters.

FILTRATION — The process of separatingsuspended solids from a liquid by forcing themixture through a porous barrier.

FLASH POINT — The temperature at which avolatile liquid mixes with air in such proportionsas to produce a flammable gaseous mixture.This mixture will flash when exposed to a flameor spark, but will not necessarily continue tosupport combustion.

FLOCCULATION — The agglomeration offinely divided suspended solids into larger,usually gelatinous particles; the development ofa floc after treatment with a coagulant by gentlestirring or mixing.

GRAIN (gr.) — A unit of weight equivalent to0.0648 gram or 1/70000 of a pound.

GRAIN PER GALLON (gpg) — A c o m m o nbasis for reporting water analyses in the UnitedStates and Canada; one grain per US gallonequals 17.12 milligrams per liter (mg/L). Onegrain per British (Imperial) gallon equals 14.3milligrams per liter or parts per million.

GREENSAND — A natural mineral, primarilycomposed of complex silicates, which possesion exchange properties.

HALIDES — A compound containing fluorine,chlorine, bromine, iodine, or astatine. Thesemater ia ls are sometimes present in theactivators of soldering fluxes. Halide residuesmust be cleaned off the circuit board.

HARDNESS — A characteristic of naturalwater due tot he presence of dissolved calciumand magnesium; water hardness is responsiblefor most scale formation in pipes and waterheaters. Hardness is usually expressed ingra ins per ga l lon , par ts per mi l l ion , ormilligrams per liter.

HARD WATER — Water containing a totalhardness of one grain per gallon or more ofcalcium carbonate or other minerals whichtend to collect on cleaner tank walls and inplumbing, forming a hard-to-remove scumlayer.

HYDRATION — The chemical combination ofwater into a substance.

Aquastorm 200™


HYDROLOGIC CYCLE — The water cyc le ,including precipitation of water from theatmosphere as rain or snow, flow of water overor through the earth, and evaporation ortranspiration to water vapor in the atmosphere.

HYDROPHILIC — Having a strong tendencyto absorb, attract, or be dissolved in water.

HYDROPHOBIC — Incapable of dissolving inwater. Water “fearing.”

HYGROSCOPIC — T h e t e n d e n c y o f amaterial to readily absorb water, usually fromthe air.

INFLUENT — The stream entering a unit,system, or process, such as the water enteringthe prewash, wash, chemical isolation, rinse, orfinal rinse sections of an aqueous cleaner orthe hard water entering an ion exchange watersoftener.

INORGANIC — A chemical compound nothaving the element carbon, with the exceptionof carbon dioxide and compounds containingthe carbonate radical.

ION — A positively or negatively chargedparticle. Ionic residues are conductive.

ION EXCHANGE — A r e v e r s i b l e p r o c e s susing coated resins called anionic and cationicin which ions are released from an insolublepermanent material in exchange for other ionsin a surrounding solution. The direction of theexchange depends upon the affinities of the ionexchange fo r the ions present and theconcentration of the ions in the solution.Typically, this process is combined with acarbon tank to remove organic contaminantsand a bag or cartridge filter to remove largeparticulates. This process is used to deionizewater.

IONIC CONTAMINATION — R e s i d u a lmaterial left on a board that is ionic in nature,and, therefore, is potentially conductive.

IRON BACTERIA — Organisms which arecapable of using ferrous iron, either from thewater or from steel pipe, in their metabolismand precipitating ferric hydroxide in theirsheaths and gelatinous deposits.

ISOLATING CURTAINS — Flexible curtains,usually silicone rubber or BUNA-N, mountedbetween cleaner stages to help limit oversprayand drag-out.

MANGANESE GREENSAND — G r e e n s a n dwhich has been processed to incorporate in itspores and on its surface the higher oxides ofmanganese.

MEDIA — The selected materials in a filter thatform the barrier to the passage of certainsuspended solids or dissolved molecules.

MICRON — A linear measure equal to onemillionth of a meter, or 0.00003937 inch. Thesymbol for the micron is the Greek letter µ.

NO-CLEAN FLUX — A low residue flux thatcan be left on the substrate. As componentsbecome more complex, very weak flux thatleaves a small residue becomes a problem.

NON-POLAR — A substance that wil l notbreakdown electr ical ly into posit ive andnegative components in solution. A non-polarcontaminant can only be removed by a non-polar solvent. Rosin is a non-polar contaminant.

ODP — Ozone-depleting potential.

ORGANIC — Containing carbon.

ORGANIC ACID FLUX (O/A) — Act ive f luxeasily removed with water. Provides excellentPrinted Circuit Board (PCB) solderability.

OSMOSIS — A process of d i f fus ion of as o l v e n t s u c h a s w a t e r t h r o u g h asemipermeable membrane which will transmitthe so lvent but impede most d isso lvedsubstances.

OZONE — An unstable form of oxygen (O3),which can be generated by an electr icaldischarge through air or regular oxygen or theaction of ultraviolet light or a strong electricfield. It has the property of blocking the passageof dangerous wavelengths of ultraviolet light.A l t h o u g h i t i s a d e s i r a b l e g a s i n t h eatmosphere, it is toxic to living organisms atground level. It is a strong oxidizing agent andhas been used in water condit ions as adisinfectant.

OZONE DEPLETING POTENTIAL — Arelative index indicating the extent to which achemical product may cause ozone depletion.The reference level of 1.0 is the potential of CFC-11 and CFC-12 to cause ozone depletion. If aproduct has an ozone depletion potential of 0.5,a given weight of the product in the atmospherewill, in time, deplete half the ozone that thesame weight of CFC-11 will deplete.

Aquastorm 200™


pH — The measure of acidity or alkalinity of asolution or the reciprocal of the logarithm of thehydrogen ion concentration. The pH scale isfrom zero to 14, with 7.0 considered neutral;greater than 7.0 is alkaline (basic) and less than7.0 is acidic. The greater the deviation from 7.0,the stronger the acid or base. There are manytests to determine pH, the most common beinglitmus paper.

PARTICULATE CONTAMINATION — General classification of residues left on aboard that are not attributed to flux. This may berouter dust, room dust, metal shavings, etc.

PERMEATE — Descr ibes wa te r tha t haspassed through a reverse osmosis membrane.

POLAR — A term describing a substance atthe atomic level which will breakdown insolution into positive and negative electricalcomponents. A polar contaminant can only bedissolved by a polar solvent. Water is a polarsolvent.

POLYPROPYLENE — A polymer of propylenethat is a thermoplastic resin. It is often used inthe manufacture of cleaning systems becauseo f i t s e a s e o f a s s e m b l y , r e s i s t a n c e t ochemicals, and cost-effectiveness.

POTABLE WATER — Water which is suitablefor human consumption.

POTW — Publicly Owned Treatment Works.Refers to a community 's publ ic sewagetreatment facility.

ppm — The abbreviation for parts per million.

PRECIPITATE — To cause a d i sso l vedsubstance to form a solid particle which can beremoved by settling or filtering, such as in theremoval o f d isso lved i ron by ox idat ion ,precipitation, and filtration.

PREWASH — The first stage in a cleaner. Thefunction of this section is to remove grosscontamination to drain, without carrying overinto the recirculating wash station. In straightaqueous (non-saponified) systems, this stageshould always go to drain or in a closed looprecycle system. In saponified systems, thisstage should not be plain water, but should bean extension of the wash section, sprayingsaponified water on to the board.

PRESSURE EQUALIZATION AND BALANCING — Refers to a setup process in acleaner whereby the upper spray manifolds andairknives are biased to a sl ight ly higherpressure than the lowers so as to avoid atendency for the board to lift up off the conveyorbelt from the pressures delivered by the lowermanifolds and airknives.

PROCESS WINDOW — A t e r m u s e d t odescribe the range of settings for variousprocess parameters within which success ofthe process is achieved.

PUMP PERFORMANCE CURVE — Ac u r v e d g r a p h s u p p l i e d b y a p u m p ' smanufacturer plotting flow on one axis andpressure on the other. A properly designedcleaner will have spray manifolds optimized sothat pressure and flow fall along this curve. Anincrease in pressure results in a correspondingdecrease in flow, and vice versa.

REGENERANT — A so lut ion o f chemica lcompound used to restore the capacity of anion exchange system. Sodium chloride brine isused as a regenerant for ion exchange watersofteners, and acids and bases are used asregenerants for cation and anion resins used indemineralization.

RESIDUAL — T h e a m o u n t o f a s p e c i f i cmaterial remaining in the water following awater treatment process; may refer to materialremaining as a result of incomplete removal orto material meant to remain in the treatedwater.

RESIN — A s o l i d o r s e m i - s o l i d o r g a n i c(synthetic) compound lacking a crystallinestructure. Resins are characterized by the lackof a definite melting point, and are usually notconductors of electr icity. Natural resinsoriginate in plants, such as pine sap, and arenot water soluble. The rosin used in flux is aresin. Synthetic resins may have many or all ofthe properties of natural resins.

REVERSE OSMOSIS (RO) — A mechanicalprocess that reverses, by the application ofpressure, the flow of water in a natural processof osmosis so that the water passes from themore concentrated to the more dilute solutiont h r o u g h a s e m i p e r m e a b l e m e m b r a n e .Membrane porosity determines the purity of thewater. The smaller the pores in the membrane,the more pure the resultant water, however,smaller pores allow lower flow rates.

RINSE — A stage in the cleaning process ofremoving residual soils or wash solutions left

Aquastorm 200™


from the previous stage. In a cleaning system,there may be mult ip le r inses, they maycascade, they may have fresh water inputs,and/or they may recirculate.

ROSIN — A naturally occurring resin, usuallyassociated with pine sap. It is widely used influx.

• R = Rosin, non-activated• RMA = Rosin, mildly activated• RA = Rosin activated

SALT — A compound formed by the reactionbetween an acid and a base. The hydrogen ionof the acid is replaced by the metal associatedwith the base, and tile hydroxyl ion of the baseis replaced by the negative ion from the acid.The hydrogen and hydroxyl ions combine tofo rm wate r . A common example o f theformation of a salt is table salt, NaCl, formedfrom the reaction of hydrochloric acid, HCI, andsodium hydroxide, NAOH. Salts ionize in waterand are conductive.

SAPONIFIER — A general term applied to asolution of organic or inorganic bases andvarious agents, such as wetting agents anddispersants, for promoting the removal of non-water soluble contaminants, such as rosinfluxes, greases, oils, etc. The removal of rosinflux is based on the chemical reaction betweenacids in the rosin and the alkaline saponifier,which results in a water soluble or dispersiblerosin “soap.”

SATURATED SOLUTION — A s o l u t i o n i nwhich the solvent can accept no more solute.The result of adding more solute is usuallyparticles in suspension or which precipitate tothe bottom of the containment vessel.

SEMI-AQUEOUS — As applied to cleaning,refers to a process of cleaning with a solvent int h e w a s h s t a g e , t y p i c a l l y a t e r p e n e ,hydrocarbon, or alcohol blend , followed bywater rinse (s).

SOFT WATER — Processed water in whichthe calcium and/or magnesium ions causinghardness have been replaced through a watersoftening process with sodium ions. Cautionmust be taken when using softened water, asopposed to deionized water, in rinse stagesbecause i t may increase res idual ion icreadings.

SOFTENED WATER — A n y w a t e r t h a t i streated to reduce hardness minerals to 17.1mg/L (1.0 gpg) or less, expressed as calciumcarbonate.

SOLIDS CONTENT — In rosin fluxes, refersto the percentage by-weight of rosin and othersolids in a particular formulation.

SOLUTION — A homogeneous mixture inwhich a solid, liquid or gas is dissolved in aliquid, called a solvent, and it forms a clear ortransparent mixture.

SPRAY BAR — A pipe plumbed from a feedmanifold having one or more spray nozzles onit.

SUBLIMATION — A p h y s i c a l p r o c e s swhereby a solid evaporates directly into a vaporwithout passing through a l iquid phase.Evaporation of dry ice is an example of this.

SURFACE INSULATION RESISTANCE TEST (SIR) — An accelerated aging test thatevaluates the resistance on the surface of aboard which undergoes temperature andhumidity cycling. Typically this test involves agrid test pattern on the board which has a biasvoltage applied during testing. if conductivematerial remains on the board, when exposedto temperature and humidity cycling, this willmanifest itself by decreasing the surfacei n s u l a t i o n r e s i s t a n c e , w h i c h w i l l b emeasurab le . Mi l -S td 2000 inc ludes theacceptable test measurements. SIR testingusually takes 168 hours. While this test is highlyaccurate at the area evaluated, it does notprovide an overall analysis for the entire boardsurface.

SURFACE TENSION — A property of liquidswhereby molecular forces tend to contract thevolume into a form with the least surface area.The higher the surface tension, the greater thetendency of a droplet to bead up from a flatsurface. Droplets with lower surface tensiontend to spread out, or wet the surface. Surfacetension, in and of itself, is not an accuratemeasurement of a droplets ability to penetrate atight space. Capillary action must also beevaluated. As a general rule, higher surfacetension favors penetration, but lower tensionfavors rinsability. Surfactants can reducesurface tension of a liquid.

SURFACTANT — A chemical agent that actsupon a liquid to reduce its surface tension.

Aquastorm 200™


SUSPENSION — A mixture of liquid or solidin a liquid that is not a true solution becausediscrete droplets or particles are visible, and thesolution is not clear. If the particles are smallenough to pass through a filter, or do not settleout after standing, the mixture is called acolloid.

THERMAL COEFFICIENT OF EXPANSION — The incremental factor ofchange in dimension of a material due totemperature r ise. These factors becomeimportant when mating different materials toeach other. If they expand at dissimilar rates,the method of attachment must compensatefor the differing growth rates to avoid stressfractures, leaks, etc.

TOTAL DISSOLVED SOLIDS (TDS) — T h eweight of solids per unit of volume of waterwhich are in true solution, usually determinedby the evaporation of a measured volume offiltered water and determination of the residueweight.

TURBINE BLOWER — A combination of amotor driving a rotary fan assembly, typically viabelt, at very high rpm (relative to direct drive, or“squirrel cage” blowers). The effect is toproduce a high velocity air flow which hasproven to be very effective in drying whendirected through an air knife.

ULTRASONIC CLEANING — A process inwhich ultrasonic energy is added to a liquid toimpart energy to it and enhance its cleaningability. Ultrasonic energy causes alternaterarefication and compression of the liquid tocreate small vacuum cavities which thencollapse or implode during compression. This isa rapid process, called cavitation, and it isresponsible for developing the scrubbing actionand ability to penetrate blind areas which isunique to ultrasonics. The cavity s ize isdetermined by the f requency used. Lowfrequencies generate large, but relatively few,cavit ies with high cleaning abi l i ty . Highfrequencies generate a great number of smallcavities, which have good penetrating ability.There is an optimization that must be achieved,with 40 KHz being the best “all-around.” Thecleaning chemistry's physical characteristicsalso affect cleaning ability. The solution willideally soften the soils, yet must activate andrinse easily.

V-JET NOZZLE — A general term applied tospray nozzles which project a pattern like theletter “v” with the vertex emanating from thenozzle orifice. The spray may be flat or slightlyelliptical. A round pattern is indicative of a conenozzle.

VAPOR PRESSURE — The pressure exertedby a vapor in equilibrium with its solid or liquidphase. The pressure exerted by the vapordepends on temperature. The higher the vaporpressure , the greater the vo la t i l i t y andevaporation rate.

VESICATION — A blistering defect whichmay occur on boards with conformal coatingswhen excessive residues are present.

VOLATILE ORGANIC COMPOUND (VOC) — Constituents that will evaporate attheir temperature of use and which, by ap h o t o c h e m i c a l r e a c t i o n , w i l l c a u s eatmospheric oxygen to be converted intopotent ia l smog-promot ing t ropospher ic(ground level) ozone under favorable climaticconditions.

VOIATILITY — T h e r e l a t i v e r a t e o fevaporation of a liquid.

WASH — Refers to the functional section orprocess within a cleaner in which the primaryremoval of contaminants takes place. The washmay be with straight water, straight solventchemistry, or a mixture of water and saponifieror solvent.

WATER PURIFICATION — Any process thatinvolves removing or reducing the level ofsuspended or dissolved contaminants from awater supply.

WATER SOFTENING — T h e r e m o v a l o fcalcium and magnesium, the ions which arethe principle cause of hardness, from water.

WATER SOLUBLE — C a p a b l e o f b e i n gdissolved in or by water.

WHITE RESIDUE — A general name for amilky white residue that sometimes appears onthe board after the cleaning process. There aremany possible causes for this, some of whichare funct ional ly harmful , and some not.Possible causes include incomplete f luxresidue removal, leeching of material from thelaminate, and incomplete cure of the solderresist on the board.

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 B – 1

APPENDIX B: INDEX

AAdjust Photocells 31Alarm

Audible Speaker 27, 39, 41Display Screen 29Process Screen 29, 42, 55Response 42Set Values 55

AlarmsAcknowledge 41, 55Additional 41Chemical Isolation 41, 55Conveyor 55Display 55Dryer 41Hardware 41pH Level 55Radiant Heater 55Resistivity 55Rinse 41, 55Saponifier 55Sump Pump High Level 44Tank Level 42Temperature 43Troubleshooting 60User Programmable 41Wash 41, 55

Aquastorm 200™ System 13Auto Sequence Mode 43, 58Automatic Timer

See Timer Screen.

BBlower 18

Chemical Isolation Option 16Drying 18Enhancements 18On/Off 48Radiant Heater 19

CCalculate FLA 8Cascade

Chemical Isolation 17Organic Acid (O/A) 35Prewash 14Rinse 17Rosin 36Set Up 35

Chemical Isolation 16Alarms 41, 55Blowers 16, 46

Decrease Temperature 47Drag Out/Enhanced 16Drain Tank 46Fill Tank 30, 46Gauge Panel 56Immersion Heaters 46Level 1 16Level 2 16Level 3 16, 17Level Indicator 42, 46On/Off 46Standard 16Temperature Indicator 43, 47Temperature Set Points 26, 31

CLS (Closed Loop System) 44Configuration Diagrams

Optional 20Standard 20

Configuration Screen 29, 52Display 52Selections 53Update Message 53

Control Panel 27, 39Alarm Acknowledge 41Audible Alarm Speaker 27, 39, 41Auto Sequence Mode 43Chemical Isolation 46Conveyor 49Emergency Stop 27, 39, 50Final Rinse 44Function Keys 44Initial Start Up 57Layout Diagram 27, 39LCD Key Pad 27, 29, 39, 51Level Indicator 42Membrane Key Pad 27, 28, 39, 40Photocells 44Power Off 41Power On 41Rinse 47Shut Down Sequence 58Start Up Sequence 58Sump Pump 44Temperature Indicator 43Wash 45

Conveyor 14Alarms 55Daily Inspection 25Decrease Speed 49Forward 49Increase Speed 49On/Off 49Reverse 49Troubleshooting 61

Aquastorm 200™

B – 2 2-9317-521-00-0 — Rev. 1 Operations Manual

DDaily Inspection 25, 57

Conveyor 25Detergent Injection 26Electrical 25Facility Connections 25pH Monitor 26Photocells 26Windows 25

Detergent InjectionDaily Inspection 26

Dimensions 9Drag Out/Enhanced Chemical Isolation 16Dryer

Add-On 19Alarms 41Electrosonic™ Airknife 19

EElectric Shock 1Electrical

Calculate FLA 8Daily Inspection 25Facility Power 57Hazard 1Requirements 7System Power 57

Electrosonic™ Airknife 19Emergency Stop Switch 27, 39, 50, 59

Alarms 50Location 50, 59

E-Stop. See Emergency Stop SwitchExhaust 21

Demisting Filter 23Requirements 5

FFacility Requirements 5

Daily Inspection 25Electrical 7, 57Exhaust 5Water 5

Fill Solenoid 15, 17Fill Tanks 30Final Rinse 18

Gauge Panel 56On/Off 44Troubleshooting 61

Float Switches 15, 17Flow Meters 23Function Keys 44Functions

LCD Key Pad Keys 51

GGauge Panel 56

Layout Diagram 56Pressure Checks 56Pressure Readings 56

HHardware Alarms 41Hazards

Electrical 1Heavy Objects 1Hot Surface 1Mechanical 1Skin Irritation 2

Heated Recirculating Rinse 17Heated Recirculating Wash 15High Voltage 1Hot Surface Hazard 1Hurricane Jet™ Option 15, 17

IImmersion Heaters

Chemical Isolation 46Rinse 48Troubleshooting 60Wash 45

Initial Start Up 57Interior Lighting 22

LLCD Key Pad 27, 29, 39, 51

Enter Key 51Function Keys 51Layout Diagram 29, 51Left/Right Arrows 51Menu 51Number Key Pad 51Page Up/Page Down 51Recipe, Print, Help, Del Keys 52Screens 29, 52Up/Down Arrows 51

Level Indicator 28, 40, 42Alarm 42Chemical Isolation 46Operation 42Rinse 47Wash 45

Lock Out-Tag Out 3Preparation 4Removing 4

MMain Screen 29, 52

Display 52

Aquastorm 200™

Operations Manual 2-9317-521-00-0 — Rev. 1 B – 3

Mechanical Hazard 1Membrane Key Pad 27, 28, 39, 40

Layout Diagram 28, 40Level Indicator 28, 40Temperature Indicator 28, 40

Menu Screens. See ScreensMoving Parts 1

NNoise Suppression 14

OOn/Off

Blowers 48Chemical Isolation 46Chemical Isolation Immersion Heaters 46CLS (Closed Loop System) 44Conveyor 49Final Rinse 44Photocells 44Power 41Radiant Heater 48Rinse Immersion Heaters 48Rinse/Hurricane Pump 47System Power 57Treatment Interface System 44Wash Immersion Heaters 45Wash/Hurricane Pump 45

Operation Troubleshooting 60Optional Configuration 20Options 22

Add-On Dryer Module 11Convenience Package 23Dimensions 9Electrosonic™ Airknife 19Exhaust Demisting Filter 23Flow Meters 23Hurricane Jet™ 15, 17Interior Lighting 22Photocells 22Radiant Heater 19Slide-out Blower Access 23Tool Kit 24Utility Sink 22

Organic Acid (O/A) Cascade 35

PpH Monitor

Alarms 55Daily Inspection 26

Photocells 22Adjust Height 32Adjust Sensitivity 32Alignment 31Daily Inspection 26

Operation 44Set Up 31Setup 31Troubleshooting 60

Plumbing 21Power Off Control 41Power On Control 41, 57Prewash 14

Gauge Panel 56Process Troubleshooting 38

Blower Airknives 38Chemistry 38Component Temperature 38Conveyor Speed 38Dryer Temperature 38Spray Nozzles 38Water 38

RRadiant Heater 19

Alarms 55On/Off 48Temperature Control 48Temperature Indicator 49

RinseAlarms 41, 55Decrease Temperature 48Drain Tank 47Fill Tank 30, 47Gauge Panel 56Hurricane Pump 47Immersion Heaters 48JIC Pump 47Level Indicator 42, 47On/Off 47Temperature Indicator 43Temperature Set Points 26, 31Termperature Indicator 48

Rosin Cascade 36

SSaponifier 16, 17

Alarms 55Screens

Alarm Display 29Alarm Process 29Configuration 29, 52LCD Key Pad 29, 52Main 29, 52System Clock and Date 29, 54Timer 29, 54Watch Dog Test 56

Set Point Values 30Set Points

Photocells 31

Aquastorm 200™

B – 4 2-9317-521-00-0 — Rev. 1 Operations Manual

Shut DownEmergency 59Normal 58

Slide-out Blower Access 23Software 37, 52

Configure Alarms 55Upgrade 37Watch Dog Test 56

Standard Configuration 20Start Up

Sequence 58Sump Pump Indicator 44System Capacities 6System Clock and Date Screen 29, 54

Display 54Set Clock and Date 54

System Controls 13Control Panel 27Initial Start Up 57LCD Key Pad 29LCD Key Pad Screens 29Membrane Key Pad 28

System Description 13Add-On Dryer 19Conveyor 14Drag Out/Enhanced Chemical Isolation 16Electrosonic™ Airknife 19Exhaust 21Final Rinse 18Heated Recirculating Rinse 17Heated Recirculating Wash 15Hurricane Jet™ Option 15, 17Noise Suppression 14Options 22Plumbing 21Prewash 14

System Dimensions 9System Specifications 6

TTanks

Drain Chemical Isolation 46Drain Rinse 47Drain Wash 45Fill Chemical Isolation 46Fill Process 30Fill Rinse 47Fill Wash 45Level Indicator 42Temperature Indicator 43

Technical Data 5Dimensions 9Electrical Requirements 7Facility Requirements 5Options 9Standard Features 9

Temperature 31Alarm 43Component 38Decrease Chemical Isolation 47Decrease Radiant Heater 48Decrease Rinse 48Decrease Wash 45Dryer 38Indicator 28, 43Radiant Heater 48Set Points 26Water 38West 6700 Control 33

Temperature Indicator 40Chemical Isolation 47Radiant Heater 49Rinse 48Wash 46

Timer Screen 29, 54Display 54Set Automatic Timer 54

Tool Kit 24Treatment Interface System 44Troubleshooting

Operation 60Process 38

UUser Programmable Alarms 41Utility Sink 22

WWash 15

Alarms 41, 55Decrease Temperature 45Drain Tank 45Fill Tank 30, 45Gauge Panel 56Hurricane Pump 45Immersion Heaters 45JIC Pump 45Level Indicator 42, 45On/Off 45Temperature Indicator 43, 46Temperature Set Points 26, 31

Watch Dog Test 56Display 56

Water Requirements 5West 6700 Temperature Control 33

Configuration Menu 33Set Up Menu 34

WindowsDaily Inspection 25

as200 operation manual

Documents

tollgate road

floppy eject

center green

service technician

flashing square

external feed

enhanced chemical

underline