MAINTENANCE

MANUAL
(HANDEX)
Pillarhouse International
Chelmsford
ENGLAND
Fax: +44 (0)1245 491331
Tel: +44 (0)1245 491333
Email: [email protected]
Email: [email protected]
Website: www.pillarhouse.co.uk
 NOTICE

2010-12 Pillarhouse International Ltd.

Rodney Way, Widford,
Chelmsford, Essex CM1 3BY
ENGLAND UK

+44 (0) 1245 491333

All rights reserved

Proprietary Information
The Information and descriptions described herein are the property of Pillarhouse
International Ltd. Such descriptions and information may not be copied or reproduced
(duplicated) by any means (in any form), or disseminated or distributed without the express
prior written permission (consent) of Pillarhouse International Ltd.
The information contained in this document is subject to change without notice and should
not be construed as a commitment by Pillarhouse International Ltd. Pillarhouse International
Ltd assumes no responsibility for any errors that may appear in this document. The software
described in this document is furnished under a license and may be used (not copied) only in
accordance with the terms of such license. Unlawful tampering with any portion of the
software or hardware contained in the Pillarhouse equipment automatically voids the
expressed and/or implied warranty and will be construed as copyright infringement.
No responsibility is assumed for the use or reliability of hardware or software on equipment
that is not supplied by Pillarhouse International Ltd.

Page 3
Limited Warranty
Pillarhouse International Ltd, with respect to the equipment described in this document, gives
the limited warranty set forth below.
Pillarhouse warrants each item of its own manufacture delivered there under shall, at the time
of delivery and for a period of twelve (12) months thereafter, be free from defects in material
and workmanship; and if any such item shall prove to be defective in material or
workmanship under normal intended usage and maintenance during the warranty period,
upon examination by Pillarhouse International Ltd or its authorised representative, then
Pillarhouse International Ltd shall repair or replace, at its sole option, such defective item at
its own expense; provided however, that the Buyer shall be prepared to ship each defective
item freight prepaid to the Pillarhouse plant in Chelmsford, Essex, England. UK.
The warranty on components not manufactured by Pillarhouse International Ltd, but part of
the Pillarhouse system, is linked to the warranty provided by the original manufacturer of
said components, and only to the extent, that such original manufacturer actually honours
such warranty (Pillarhouse International Ltd having no independent obligation as to such
warranty).

Warranty Disclaimer
All warranties are expressly limited to the repair or replacement of defective items as set
forth herein above, and in no event shall seller be liable for loss of profits, personal injury or
property damage (unless caused by Pillarhouse's negligence, expense or inconvenience) or
any other special incidental or consequential damages by reason of any breach of warranty or
defect in material or workmanship.

Copyright Notice
This document contains propriety information, which is protected by copyright. All rights are
reserved. No part of this document may be photocopied, reproduced by any means, or
translated into another language without the prior written consent of Pillarhouse International
Ltd.

Page 4
Amendment Record

AMENDMENT DATE SECTION DESCRIPTION

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Page 5
1. Handex Technical Specification ................................................................................................. 11
2. Health & Safety .......................................................................................................................... 13
Safety .............................................................................................................................................. 13
Solder and Dross ............................................................................................................................ 13
Flux ................................................................................................................................................. 13
Fumes ............................................................................................................................................. 14
Machine Safety ............................................................................................................................... 14
Safety Precautions .......................................................................................................................... 15
Soldering in a Nitrogen Atmosphere .......................................................................................... 15
Safety Precautions ...................................................................................................................... 15
General ........................................................................................................................................ 15
Asphyxiation Hazard - Oxygen Deficiency ................................................................................ 15
Working Near an Inerted Soldering System ............................................................................... 15
Liquid Nitrogen Hazards ............................................................................................................ 16
Precautionary Labels .................................................................................................................. 16
Personal Protective Equipment ...................................................................................................... 16
Hand Protection .......................................................................................................................... 16
Respiratory Protection ................................................................................................................ 16
Protective Clothing ..................................................................................................................... 16
Eye Protection ............................................................................................................................. 16
3. Installation & Commissioning .................................................................................................... 17
Unpacking ...................................................................................................................................... 17
Arrival Check.............................................................................................................................. 17
Unpacking ................................................................................................................................... 17
Packaging/Restraints................................................................................................................... 17
Fastener Check............................................................................................................................ 17
Removing Transit Restraints ...................................................................................................... 17
Cleaning & Re-Lubricating X-Y Rails ....................................................................................... 17
Location .......................................................................................................................................... 18
Machine Accessibility/positioning ............................................................................................. 18
Refitting Parts Removed For Transit.............................................................................................. 19
Installing & connecting Monitor & Keyboard............................................................................ 19

Page 6
 Monitor and Keyboard in final position ..................................................................................... 20
Installing & Connecting The PC................................................................................................. 20
Installing The Light Tower ......................................................................................................... 22
Installing ......................................................................................................................................... 22
Services ....................................................................................................................................... 22
Electrical Mains Supply.............................................................................................................. 22
Electrical Services Panel............................................................................................................. 23
Electrical Mains Supply.............................................................................................................. 23
Connecting The Mains Supply................................................................................................ 23
Air ............................................................................................................................................... 26
Connecting The Air Supply .................................................................................................... 27
Nitrogen ...................................................................................................................................... 27
Connecting The Nitrogen Supply ........................................................................................... 27
Filling The Flux Bottle ............................................................................................................... 28
Ventilation .................................................................................................................................. 29
Levelling ......................................................................................................................................... 30
Procedure .................................................................................................................................... 30
4. Maintenance Equipment ............................................................................................................. 32
Introduction .................................................................................................................................... 32
Tool/Accessories Kit ...................................................................................................................... 32
Lubricants & Adhesives ................................................................................................................. 33
Lubricants ................................................................................................................................... 33
Adhesives .................................................................................................................................... 33
Cleaner............................................................................................................................................ 34
5. General Maintenance .................................................................................................................. 35
Solder Top Up ................................................................................................................................ 35
Flux Top-Up ................................................................................................................................... 36
Tinning The Solder Nozzle ............................................................................................................ 36
Cleaning Dross From Solder Bath ................................................................................................. 37
Cleaning Fluxer Head ..................................................................................................................... 37
Daily Cleaning ............................................................................................................................ 37
Cleaning Heavy Flux Residue Build-Up .................................................................................... 38

Page 7
 Purging Flux System................................................................................................................... 38
Cleaning Wave Height Detector..................................................................................................... 39
Cleaning The Needle .................................................................................................................. 39
Cleaning X & Y Axis Slides .......................................................................................................... 39
Cleaning Z Axis Mechanism .......................................................................................................... 40
Solder Temperature Calibration ..................................................................................................... 40
Fans ................................................................................................................................................ 41
Exhaust Fans ............................................................................................................................... 41
Cooling Fans ............................................................................................................................... 42
6. Scheduled Maintenance .............................................................................................................. 44
Scheduled Maintenance .................................................................................................................. 44
Solder Bath De-Dross (Quick).................................................................................................... 45
Solder Bath De-Dross (Thorough).............................................................................................. 48
Solder Pump De-Dross ............................................................................................................... 53
Removing The Solder Bath ........................................................................................................ 60
Replacing The Bath .................................................................................................................... 64
Cleaning The Flux System ............................................................................................................. 65
Emptying The System................................................................................................................. 67
Cleaning The System .................................................................................................................. 69
Emptying The Cleaning Fluid .................................................................................................... 70
Filling And Priming The System ................................................................................................ 71
7. Removal & Replacement Procedures ......................................................................................... 73
Solder Nozzle ................................................................................................................................. 73
Removal ...................................................................................................................................... 73
Replacement ............................................................................................................................... 73
Nitrogen Shroud ............................................................................................................................. 74
Removal ...................................................................................................................................... 74
Replacement ............................................................................................................................... 74
XYZ Assembly ............................................................................................................................... 75
Sensors ........................................................................................................................................ 75
Removal .................................................................................................................................. 76
Replacement ............................................................................................................................ 77

Page 8
 Setting ..................................................................................................................................... 77
X Motor ...................................................................................................................................... 77
Removal .................................................................................................................................. 77
Replacement ............................................................................................................................ 79
X Belt Replacement .................................................................................................................... 80
Y Motor ...................................................................................................................................... 80
Removal .................................................................................................................................. 80
Replacement ............................................................................................................................ 83
Y Belt Replacement .................................................................................................................... 86
Z Motor ....................................................................................................................................... 86
Removal .................................................................................................................................. 86
Replacement ............................................................................................................................ 86
Z Belt Replacement .................................................................................................................... 86
Solder Bath ..................................................................................................................................... 86
Removal ...................................................................................................................................... 87
Replacement ............................................................................................................................... 88
Set-Up ......................................................................................................................................... 88
Heaters ............................................................................................................................................ 89
Removal ...................................................................................................................................... 89
Replacement ............................................................................................................................... 89
Thermal Trip Sensor ....................................................................................................................... 90
Removal ...................................................................................................................................... 90
Replacement ............................................................................................................................... 90
Level Detect Sensor........................................................................................................................ 91
Removal ...................................................................................................................................... 91
Replacement ............................................................................................................................... 91
Set-Up ......................................................................................................................................... 91
Solder Bath Level Check ................................................................................................................ 91
Solder Pump Assembly .................................................................................................................. 92
Pump Removal............................................................................................................................ 92
Pump Motor.................................................................................................................................... 94
Removal ...................................................................................................................................... 94

Page 9
 Replacement ............................................................................................................................... 95
Pump Belt ....................................................................................................................................... 95
Removal ...................................................................................................................................... 95
Replacement ............................................................................................................................... 96
Impeller Assembly ......................................................................................................................... 96
Removal ...................................................................................................................................... 96
Sono-Tek Setup .............................................................................................................................. 98
Nitrogen Shroud Adjustment ...................................................................................................... 98
Camera (Programming) Assembly ............................................................................................... 100
Camera Set-Up.......................................................................................................................... 100
Pneumatics System ....................................................................................................................... 101
Air/Nitrogen Regulators ........................................................................................................... 101
Removal ................................................................................................................................ 101
Replacement ............................................................................................................................. 101
Nitrogen Dump Valve............................................................................................................... 102
Removal ................................................................................................................................ 102
Replacement .......................................................................................................................... 102
Control Box .................................................................................................................................. 102
Removal .................................................................................................................................... 102
Replacement ............................................................................................................................. 104
Post Replacement Setup ........................................................................................................... 104

Page
10
1. Handex Technical Specification

Machine Size: Height:

Width:
Depth:
Weight: Unpacked:
Packed:
Nominal Loading
Height:
Board Size: Maximum 457x508mm (18x20inch)
Minimum 102x102mm (4x4 inch)
Height Clearance: Above 95mm (3.7inch)
Below 45mm (1.7inch)
Edge Clearance: Below 3mm (0.12inch)

Extraction Fan: 276mm (10.8inch) Dia

Rating: 1000m³/hr (589CFM)

Solder Bath: Solder Type: All commonly used solder types

(including lead free)
Feeder: 3mm wire diameter
Bath Capacity: 15kg (11lb) – Standard Bath
25kg (55lb) – Large Bath
Applicators: - AP-1 style 2.5,3,4,6,8,10,12 & 14mm tip
sizes.
- Extended tips and jet tips nozzles also
available up to 14mm.
- Jet wave nozzles available up to 25mm
width
- Special dedicated nozzles available upon
request, including 150mm wave nozzle

Flux: - Low maintenance Drop-Jet system

- Ultrasonic system (options)
- Low solids, no clean flux
- Pressurised and inerted system
Flux Tank Capacity: 1 Bottle 1 litre
2 Bottle (option) 2 litres
Flux Spray (Drop Jet) Formation: 4.0-6.0mm (0.16-0.24inch)
Fluxer Speed: 50 dots/second
Flux Spray (Sono-Tek) Formation: 4.0-6.0mm (0.16-0.24inch)

Page
11
 Fluxer Speed: Constant Spray

X, Y & Z Accuracy Resolution: 0.15mm

Repeatability: ±0.05mm
Nitrogen Supply Pressure: 4 bar (58psi) via 8mm connector
Purity: At least 99.995%
Usage: 30-100lpm (1.06-3.53CFM)
Flux Bottle Pressure: (1.5-7.5psi)

Air Supply Pressure: 4bat to 8bar (56psi-116psi)

Usage: 20-30LPM (42-68CFH)

Power supply Voltage: 208-240 Volts

(no top preheat) Frequency: 50/60 Hz
Power: 3.5kVa
Type: 1 phase + PE
Power supply Voltage: 230 Volts
(Top/Bottom Preheat) Frequency: 50/60 Hz
Power: 6.5kVa
Type: 1 phase + PE

Page
12
2. Health & Safety
Safety
IMPORTANT: IT IS THE RESPONSIBILITY OF THE EMPLOYER TO INFORM
HIS EMPLOYEES AND TO PROVIDE ADEQUATE VENTILATION AND
PROTECTIVE CLOTHING. SOME ADVICE AND INFORMATION IS LISTED
BELOW.
Fumes evolved during soldering process are hazardous to health. It is therefore essential that
these fumes be removed from the working atmosphere. The extractor fan is only adequate to
extract the fumes from the working area of the machine. It is therefore necessary to provide
ducting and an additional fan to extract the fumes to atmosphere. If you require any
information or help, please contact Pillarhouse International Ltd or its agent.

Solder and Dross

WARNING: THE SOLDER BATHS CAN REACH EXTREMELY HIGH
TEMPERATURES. IT IS ESSENTIAL THAT PROTECTIVE HEAT RESISTANT
GLOVES ARE WORN WHEN WORKING ON OR NEAR A HOT SOLDER BATH.
FAILURE TO OBSERVE CORRECT SAFETY PRECAUTIONS COULD RESULT
IN SERIOUS BURN INJURIES.
SOLDER MAY CONTAIN LEAD, WHICH IS HAZARDOUS TO HEALTH. IT IS
ESSENTIAL THAT PROTECTIVE CLOTHING SUCH AS GLOVES AND A MASK
ARE WORN AT ALL TIMES WHEN HANDLING SOLDER AND LEAD OXIDE
DROSS.

When handling solder or when working on or near a machine using solder, cleanliness is
very important. All solder pots produce dross, the powder dross is pure lead oxide and should
only be removed from the solder pot when wearing protective gloves and mask. The dross
must be placed in a sealed container; these should be available from your solder supplier.
A leaflet entitled 'LEAD AND YOU' is available from the UK Health and Safety Executive.
A copy must be given to each person working on or near the Soldering Machine. The basic
precautions each employee should take are:

• Make sensible use of any control measure provided by your employer.

• Wear protective clothing and respirators when required.
• Keep medical appointments.
• Wash before eating, drinking or smoking.
• Don't eat, drink or smoke in a lead-contaminated area.
• Keep your workplace clean.
• Wash and where necessary, change before going home.

Flux
WARNING: ALWAYS CONSULT THE HEALTH & SAFETY DATA SHEET THAT
SHOULD BE SUPPLIED WITH THE FLUX BEFORE HANDLING ANY FLUX OR
THINNERS. IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT
PROPER PRECAUTIONS ARE TAKEN WHILST USING THESE MATERIALS.
The flux and thinners used in this machine may be of a hazardous nature. Because of the wide

Page
13
range of fluxes available for different applications it is not possible to cover in this document
the precautions that may be necessary when handling these materials.
When filling the machine with flux or thinners always use a funnel to ensure the flux goes
into the flux containers and not over the machine. If an accidental spillage does occur switch
the machine off and clean off the flux with a suitable cleaning agent (thinners).
CAUTION: IF A MAJOR SPILLAGE OCCURS WHERE THERE IS A
POSSIBILITY THE FLUX MAY HAVE COME INTO CONTACT WITH ANY
ELECTRICAL OR MECHANICAL COMPONENTS, IT IS ESSENTIAL THAT A
SUITABLY QUALIFIED PERSON INSPECTS THE MACHINE, TO ENSURE THAT
THE MACHINE IS SAFE TO OPERATE.

Fumes
WARNING: THE SOLDERING PROCESS GENERATES FUMES FROM THE
FLUX. THESE FUMES CAN BE HARMFUL TO AN OPERATOR’S HEALTH.
THE MACHINE IS FITTED WITH AN EXTRACTOR, WHICH DRAWS THE
FUMES AWAY FROM THE OPERATOR AND OUT OF THE CABINET. THE
EXHAUSTED FUMES MUST BE CONNECTED TO AN EXTRACTION AND
FILTRATION SYSTEM, BEFORE BEING RELEASED BACK INTO THE
ATMOSPHERE. UNDER NO CIRCUMSTANCES CAN THE MACHINE FAN BE
USED TO FORCE AIR UP INTO DUCTING, AS IT IS NOT ADEQUATE FOR THIS
PURPOSE AND WILL RESULT IN THE OPERATOR BEING EXPOSED TO THE
SOLDERING FUMES.

Machine Safety
The machine must be operated at all times with all guards in place, as these are provided for
operator safety. If, or when, it is necessary to open or remove a guard the machine should
first be turned off to avoid accidental contact with moving parts. Removal of guards is only to
be done by suitably qualified and authorised personnel.
The Soldering system is designed to work at temperatures up to 350ºC. Therefore care must
be taken whilst working within the machine guards even when the machine is turned off. The
Solder Bath & surrounding areas will take a number of hours to cool down to a temperature
at which it would be safe to come in contact with these parts.
Removal or examination of the electronic/electrical components within the machine is only to
be done by qualified personnel. Before proceeding with either of these operations the
machine should be turned off and the power disconnected.
If it is necessary to work on or examine electronic/electrical components while the power is
supplied to the machine, extreme Caution must be observed.

Page
14
Safety Precautions
Soldering in a Nitrogen Atmosphere
These instructions are intended for the use of supervisory personnel and trained, responsible
operators. Personnel not familiar with nitrogen and its use as an inert gas must read and
understand the safety instructions and safety data sheets provided by the nitrogen supplier.
This material must be brought to the attention of the operators of any equipment using
nitrogen inerted systems.

Safety Precautions
The nitrogen released from a soldering machine, being inerted with nitrogen, can create
safety hazards affecting operating and service personnel. It is essential that any person who
operates an inerted-soldering appliance should be briefed on the precautions required. Only
trained and responsible persons should install or operate an inert gas process.

General
This information is intended to supplement, not substitute the instructions provided by the
nitrogen supplier. Operators must observe their employer's and the nitrogen supplier's
instructions. Where instructions appear to conflict with instructions issued by the nitrogen
supplier it is incumbent on the user to resolve any such conflict before proceeding to operate
the equipment. Nitrogen is not flammable, nor is it toxic. Nitrogen can be hazardous when it
is used in an inerted-soldering machine; some of the potential hazards are discussed in the
following paragraphs.

Asphyxiation Hazard - Oxygen Deficiency

Nitrogen is invisible and has no odour. Personnel cannot depend on their senses to alert them
when nitrogen is present in amounts that exceed its normal concentration in the air (i.e. 79%).
Victims can be overcome suddenly and without warning.
Never enter any enclosed space connected to a source of nitrogen unless the inlet pipe has
been disconnected and the atmosphere inside has been tested with an approved oxygen
analyser and found to contain at least 19.5% oxygen.
The warning signs of asphyxia are dizziness, headache, or nausea. If any of these symptoms
occur, move the person to a well-ventilated area. If someone passes out or stops breathing in
what may be an oxygen-deficient atmosphere, move the person to a well-ventilated area,
providing it can be done without endangering the recovered, and administer artificial
respiration. Call a Doctor and an ambulance immediately.
Never enter a room known or suspected to contain oxygen-deficient air without wearing
appropriate protective equipment (such as self-contained breathing apparatus) or without
having been properly trained in the use of protective equipment.

Working Near an Inerted Soldering System

The Nitrogen gas flowing out of the nozzle and in the air space directly above it is not safe to
breathe because it is deficient in oxygen. Breathing this atmosphere, even for a few seconds,
is likely to cause symptoms of asphyxiation, including fainting or mental failure. Persons
operating an inerted soldering machine must never place their faces in the space above the
machine. Pillarhouse machines are equipped with covers and extractor fans. When nitrogen is
used, exhaust gases must be ducted directly to atmosphere via a suitable filter.
Machine operators would normally be quite safe during production runs. However,
maintenance personnel are strongly advised to be equipped with oxygen meters which are set

Page
15
to give warning when the oxygen content of the air falls to 19.5% or less.

Liquid Nitrogen Hazards

Liquid nitrogen is extremely cold. Contact with the skin can cause frostbite and severe tissue
damage. DO NOT touch frosted pipes or valves that contain liquid nitrogen or cold gas,
unless your hands are protected with insulated gloves.
Do not operate the inerting system if the pipes supplying the apparatus are frosted past the
tank regulator outlet, as this indicates that the withdrawal rate exceeds the vaporiser capacity.
However, the vaporiser in the tank will normally raise the temperature of the vapour to above
freezing point (0°C) by the time it reaches the pressure regulator.

Precautionary Labels
Read and fully understand the precautionary labels associated with the inert gas control
apparatus and follow the instructions on the labels. DO NOT REMOVE OR OBSCURE
THESE LABELS. If the labels are missing or become difficult to read, replace them.

Personal Protective Equipment

It is recommended that the protective equipment detailed below is made available for use by
ALL personnel working on the machine.

Hand Protection
• For maintenance on solder baths: Mercury 400 Kevlar Gloves. Providing Heat
protection to EN388
• For handling Solder and printed circuit boards (PCBs): Lightweight cotton gloves.
• For handling Flux and Thinners: Disposable Latex gloves to EN374

Respiratory Protection
For maintenance of solder baths: Dust/Mist/Metal Fumes Respirator, to EN149 FFP3SL or
better.

Protective Clothing
For maintenance of solder baths: Cotton lab coat or overalls, Leather apron and sleeves and
fully enclosed shoes.

Eye Protection
For maintenance and normal operation: Safety Spectacles to EN166 1F

Page
16
3. Installation & Commissioning
Unpacking

Arrival Check
The machine is normally vacuum-sealed and encased within a wooden crate. Upon receipt it
must be inspected to ensure that no damage has occurred in transit.

NOTE: If the packaging shows signs of bad damage and, when the crate is opened the
machine also appears to be damaged, please contact the shipper directly.

Unpacking
When opening the crate, remove the lid from the crate first, then remove the sides.

CAUTION: THE MACHINE MUST BE LIFTED OFF THE PALLET USING A

FORKLIFT TRUCK WITH APPROPRIATE LIFTING CAPACITY

Packaging/Restraints
Remove all packaging from the machine. Do not dispose of any packaging until all machine
parts have been accounted for.
All bags of Silica Gel Desiccant should be removed from the machine and disposed of safely.
After removing the packaging, the machine should be inspected for transit restraints. Transit
restraints are fitted to the XY Carriage and any other parts liable to move during transit.

CAUTION: DO NOT REMOVE THE TRANSIT RESTRAINTS UNTIL THE

MACHINE HAS BEEN POSITIONED IN ITS DESIGNATED LOCATION AND HAS
BEEN CORRECTLY LEVELLED.

Fastener Check
Check that all fixings (screws, nuts, bolts etc.) are secure, as it may be possible for some
fixings to become loose during transit. If any fixings appear to be missing, damaged or
broken please contact Pillarhouse International or its representative immediately.

Add Photos of clamps here

Removing Transit Restraints
Once the machine has been levelled, the restraints fitted for transit must be removed:
• Remove the tape from the Sliding Top Cover.
• Remove the tape (where fitted) from the Solder Bath Cover.
• Remove the transit clamps from the X and Y Rails.

Cleaning & Re-Lubricating X-Y Rails

The X-Y Rails have been treated with corrosion inhibitor prior to shipping. Therefore the
rails must be cleaned using a suitable cleansing medium (e.g. Flux Thinners), then re-

Page
17
lubricated prior to use.

CAUTION: WHEN CLEANING THE RAILS, TAKE CARE NOT TO

CONTAMINATE THE BEARING SEALS WITH THE CLEANSING MEDIUM.
Re-lubricate the rails with PTFE Oil after cleaning, prior to use.
NOTE: A light film of PTFE Oil should be applied using a lint-free cloth.

Location

Machine Accessibility/positioning
It is imperative that the required access clearance is provided (as determined by the
appropriate regulations) around the machine.

NOTE: Whilst the majority of the production operation is made from the front of the
machine, access is periodically required to the rear of the machine, in order to re-fill the flux
bottles and perform maintenance tasks. Refer to the below machine footprint diagram for
details of the machine footprint dimensions and position machine with suitable clearance
distances. Lift the machine into its designated position, using a suitable fork-lift truck.

Page
18
Refitting Parts Removed For Transit
The following machine parts have been removed and packed with the machine for transit, to
prevent any damage that may occur during transit of the machine:
• Light stack tower
• Monitor and keyboard
• PC
These parts require refitting to the machine prior to use. Instructions for refitting the above
parts to the machine are provided in the following paragraphs:

Installing & connecting Monitor & Keyboard

Remove the Flat Screen Monitor supplied from its packaging and fit it to the mounting arm as
follows:
• Carefully fit the monitor to the mounting arm on the machine and secure in position using
the fixing screw supplied.
• Re-connect the 5off connectors to the monitor.
• Plug in all Monitor connections (including Power supply, video cable and USB). These
are already wired in position on the mounting arm and simply require plugging into the
connection sockets on the Monitor.
• Remove the Keyboard and mouse from its packaging and position it on the mounting
arm.
• Plug the green audio cable into the extension socket.

Page
19
 Monitor and Keyboard in final position

Rear View Of Monitor

Installing & Connecting The PC

Remove the PC from its packaging and install the PC in the base of the machine underneath
the rear stainless steel floor panel:

Pc Location In Base Of Machine

Page
20
• Remove either of the machines lower frame covers to allow access to the floor panel.
• Remove and retain the 4 screws securing the rear floor panel in position and remove the
rear panel.
• Position the PC so that the power button can be accessed via the hatch in the stainless
cover.

Pc Power Button Viewed Through Floor Hatch

• Make the following connections to the control PC:
1) The Video lead (gold) to the PCI capture card YC input
2) RS232 Serial communications cable (Silver) and the monitor cable (Black)
3) AC supply from MCB2 to the PC Power in Connector at the rear of the PC.
4) Plug the three USB connectors into any of the USB slots
5) The network cable (if network access is required)
CAUTION: ENSURE THAT THE VOLTAGE SELECTOR SWITCH AT THE REAR
OF THE PC IS SET TO THE CORRECT VOLTAGE (110V/230V) BEFORE
SWITCHING ON.

Connections In Place Connection Function

Page
21
Installing The Light Tower
The light tower is located on top of the machine to the right of the extraction fan (as viewed
from the front of the machine) the tower must be bolted securely to the machine and then
electrically connected to the internal wiring loom.

• Remove any packaging from the stack light and assemble if necessary
• Push connection through the opening on the top of the machine
• Line up the holes on base plate of the stack light with the hank bushes in the top plate
• Insert and tighten the four M5 cap heads securing the stack light to the top plate.
• Open the rear door and connect the light stack to the connector inside the machine.

Installing
Services
Services are connected to the machine via the connectors provided on the Services Panel
located at the rear left-hand side of the machine.

Electrical Mains Supply

It is essential that the machine is connected to a suitable earth; the heaters used in this
machine can have a high leakage current to earth. If the machine is protected by a residual
current trip or an earth leakage trip, then it may be subject to nuisance tripping.
The machine is designed to run on a single phase nominal supply of 200-240Vac (±10%),
50/60 Hz. The supply must be capable of providing 3kVa which should be routed to the machine
via an Isolator switch that is lockable in the OFF position. If the Topside Preheater option is fitted
then a nominal supply of 230Vac with a current rating of 6.5kVa is recommended.

Page
22
CAUTION: ENSURE THAT THE VOLTAGE SELECTOR SWITCH ON THE BACK
OF THE PC IS SET CORRECTLY. FAILURE TO SET THE VOLTAGE SELECTOR
SWITCH TO THE CORRECT VOLTAGE MAY RESULT IN DAMAGE TO THE
PC.

Electrical Services Panel

This panel acts as an interface point between the machine and all external electrical systems,
it also acts as the inlet for the machines main electrical supply.

Electrical Services Panel

Electrical Mains Supply

WARNING! IT IS ESSENTIAL THAT THE MACHINE IS CONNECTED TO A
SUITABLE EARTH.
The heaters used in this machine can have a high leakage current to earth. If the machine is
protected by a residual current trip or an earth leakage trip, then it may be subject to nuisance
tripping.
The machine is designed to run on a single phase nominal supply of 200-230Vac (±10%),
50/60 Hz. The supply must be capable of providing 6.5kVA. If the Topside Preheater option
is fitted then a nominal supply of 230Vac is recommended.
CAUTION: ENSURE THAT THE VOLTAGE SELECTOR SWITCH ON THE BACK
OF THE PC IS SET CORRECTLY. FAILURE TO SET THE VOLTAGE SELECTOR
SWITCH TO THE CORRECT VOLTAGE MAY RESULT IN DAMAGE TO THE
PC.
The supply to the PC is provided via MCB1 inside the rear services enclosure.
Connecting The Mains Supply
Before installing the mains check that the supply and cable is adequately rated for the
machine. If the machine if fitted with top/bottom side preheaters then the power requirements

Page
23
will exceed that of a standard machine.
• Locate and remove the services panel at the centre rear of the machine (this sits between
the electrical and pneumatic inlets that are located on the left and right respectively).
• From here the mains inlet block can be located (pictured below)

• Insert the mains cable through the bulkhead connection on the electrical service panel (be
sure to place the cable gland onto the cable before threading into the machine, this cannot
be done afterwards)

• The electrical service panel can be removed to allow for more work space during this
procedure.

Page
24
• The live and neutral phase of the incoming mains wire should ideally be terminated with
crimps or ferrules and the earth with an appropriately size ring crimp. The phases should
be installed into the relevant terminal block as pictured below.

The primary Mains Supply enters the cabinet, via the power in Cable Gland located on the
Services Panel at the rear left-hand side of the machine
The rear Power Enclosure contains the Incoming power supply connections to the Isolator,
MCBs, PSU and the Back Board PCB.

Page
25
The incoming supply Isolator Switch is shown above. The output from the isolator switch is
connected via the Main Circuit Breaker MCB1 to provide the internal supplies for the
electronics enclosure and the rest of the machine.
The Incoming supply is wired via the Isolator switch to MCB1 to provide an isolated supply
to the Back Board PCB and PSU and is wired via MCB2 to provide a non-isolated supply to
the PC.

CAUTION: THE SUPPLY TO THE PC AND MONITOR ARE NOT ISOLATED AND
WILL THEREFORE REMAIN LIVE AT THE INCOMING TERMINALS, EVEN
WHEN THE MACHINE POWER SUPPLIES ARE ISOLATED.

Air
CAUTION! THE MAXIMUM INCOMING AIR SUPPLY PRESSURE
RECOMMENDED IS 8 BAR. DO NOT EXCEED THE RECOMMENDED
INCOMING SUPPLY PRESSURE. EXCEEDING THE RECOMMENDED
PRESSURE MAY CAUSE DAMAGE TO THE PNEUMATICS SYSTEM ON THE
MACHINE.
All air piping used in the machine is green.

An Air supply with a minimum pressure of 5bar (72psi) is required. The air supplied to this
machine must be Clean, Dry, Filtered and Non-Lubricated.
Air is connected to the machine via an 8mm push fit pipe connector, located on the services
panel, on the right-hand/rear of the machine.

NOTE: The air supply should be connected via a lockable exhaust type shut off valve.

Page
26
Connecting The Air Supply
Ensure that the air supply is shut off. Then, using an 8mm pipe, connect to the correct inlet on
the pneumatic services panel. Slowly apply pressure to the system until equalised, applying
the pressure to quickly can damage the pneumatic system.
1) A clean, dry, filtered and non-lubricated air supply is required.
2) An air supply with a minimum pressure of 5bar (70psi) is recommended.
3) Maximum incoming air supply pressure recommended is 8bar.

Nitrogen
CAUTION! THE MAXIMUM INCOMING NITROGEN SUPPLY PRESSURE
RECOMMENDED IS 8 BAR. DO NOT EXCEED THE RECOMMENDED
INCOMING SUPPLY PRESSURE. EXCEEDING THE RECOMMENDED
PRESSURE MAY CAUSE DAMAGE TO THE PNEUMATICS SYSTEM ON THE
MACHINE.
All nitrogen piping in the machine is blue.

A Nitrogen supply with a minimum pressure of 4bar (56psi) is required. Nitrogen is

connected via an 8mm push fit pipe connector, located on the services panel, on the left-
hand/rear of the machine.
A high purity nitrogen supply is required, a minimum of 99.995% purity is recommended.
Consumption is variable depending on the size of the shroud in relation to the nozzle.
NOTE: The nitrogen supply should be connected via a lockable exhaust type shut off valve.

Connecting The Nitrogen Supply

Ensure that the nitrogen supply is shut off. Then, using an 8mm pipe, connect to the correct

Page
27
inlet on the pneumatic services panel. Slowly apply pressure to the system until equalised,
applying the pressure to quickly can damage the pneumatic system.
1) A high purity nitrogen supply is required, a minimum of 99.995% purity is
recommended.
2) A nitrogen supply with a minimum pressure of 4bar (56psi) is required.
3) Maximum incoming Nitrogen supply Pressure recommended is 8bar.

NITROGEN CONSUMPTION: Nitrogen consumption is variable depending on the size of

the shroud in relation to the nozzle. Typically the nitrogen usage for a machine using AP
style nozzles can be between 5 litres per minute up to 40 litres per minute (approximately).

Filling The Flux Bottle

The system consists of two bottles the reservoir and the drain, for the initial fill of flux only
the reservoir bottle is needed.

• Press the E-stop button to remove pressure from the flux system then remove the
reservoir bottle as illustrated in the picture below.

Page
28
• Fill about 75% with the selected flux.
• Reattach the flux bottle and allow the system to pressurise.

Ventilation
THE SOLDERING PROCESS GENERATES FUMES. THESE FUMES CAN BE
HARMFUL TO AN OPERATOR’S HEALTH.
THE MACHINE IS FITTED WITH AN EXTRACTOR FAN (LOCATED ON THE
TOP OF THE MACHINE). THE FAN DRAWS THE FUMES AWAY FROM THE
OPERATOR AND OUT OF THE CABINET. THE EXHAUSTED FUMES MUST BE
CONNECTED TO AN EXTRACTION AND FILTRATION SYSTEM, BEFORE
BEING RELEASED BACK INTO THE ATMOSPHERE.
UNDER NO CIRCUMSTANCES MUST THE MACHINE FAN BE USED TO FORCE
AIR UP INTO DUCTING, AS IT IS NOT ADEQUATE FOR THIS PURPOSE AND
WILL RESULT IN THE OPERATOR BEING EXPOSED TO SOLDERING FUMES.

NOTE: The fan rating is 1000m³/hr (589CFM). The rating of the extraction system must
exceed the rating of the fans.

Page
29
CAUTION: UNDER NO CIRCUMSTANCES ARE THE MACHINE FANS TO BE
USED TO FORCE FUMES UP DUCTING. THE FAN IS NOT ADEQUATELY
RATED FOR THIS PURPOSE AND SUCH USE MAY RESULT IN OPERATORS
BEING EXPOSED TO SOLDERING FUMES.

Levelling
Once positioned in its designated location, the machine must be set-up to be level and steady,
to ensure accurate, consistent results during normal operation.
The machine is fitted with four adjustable feet, two at the front, and two at the back. The feet
can be wound up for moving and positioning the machine and wound down to raise the
castors off the ground once the machine is in position.

CAUTION: THE MACHINE FEET SHOULD NEVER BE ADJUSTED WHILE

UNDER LOAD, AS DAMAGE TO THE SCREW THREADS MAY OCCUR. WHILE
ADJUSTING THE HEIGHT AND LEVEL, THE MACHINE MUST BE SUPPORTED
BY A PALLET TRUCK.

Procedure
An accurate engineer’s Spirit Level is required for levelling the machine, all reading are
taken from either of the board guides.
Level the machine as follows:
1) With the weight of the machine supported by a pallet truck, adjust the four feet until
they are all firmly on the ground.
2) Adjust the two front feet to the required height.
3) Check that the turret is securely held in position then place an engineer’s spirit level on
the board guide of the machine aligned with the Y axis, carefully adjust the height of
the two rear feet until the machine is level.

Page
30
4) Orientate the spirit level along the X axis of the machine using the movable board
guides if necessary. Carefully adjust the feet on one side until the machine is level.

5) Repeat steps 2 to 4 until the machine is level in both axes, to better than 0.1mm in
300mm at the required height.
6) Check that the machine is stable.

Page
31
4. Maintenance Equipment
Introduction
The Selective Soldering System requires both scheduled and unscheduled maintenance. A
number of basic tools are required to complete these functions. Pillarhouse provide a basic set
of tools and parts, as detailed below.
WARNING
WHEN IMPLEMENTING ANY MAINTENANCE ON THE MACHINE, ENSURE
THAT ALL RELEVANT HEALTH AND SAFETY PRECAUTIONS ARE
OBSERVED. FAILURE TO OBSERVE THE NECESSARY SAFETY PRECAUTIONS
COULD RESULT IN SERIOUS INJURY. REFER TO CHAPTER 1 - ‘HEALTH &
SAFETY” FOR DETAILS OF HAZARDS AND RECOMMENDED PRECAUTIONS.

Tool/Accessories Kit
The Jade machine is supplied with a basic Maintenance Kit (EA7357). Some tools are
machine specific whilst others are general proprietary items. All tools provided are intended to
be used for maintenance tasks.
Part No. Description Use
Ensure these gloves are used when
handling solder and when having to
GLA0012 Mercury Kevlar 400 glove
touch any part of the machine that may
be hot.
Allows the user to apply tinning agent to
HNT0039 Suds brushes
the solder nozzle.
Allows the user to apply cleaning agent
HNT0294 Cotton buds
to the flux head.
30ml Special Flux, for use in
conjunction with Item HNT0039 to
AD0850 Warton Activ8 flux
apply flux when Solder Nozzles require
tinning.
30ml IPA Thinners, for use in
AA1439 Flux thinners, IPA-based conjunction with Item HNT0294 to
clean the fluxer head.
AA9945
Allows the user to remove dross (lead
and Dross scrapers
oxide) from the top of the solder bath.
EA7196
A proprietary set of Metric Allen Keys
HNT0514 Metric hexagon key set
(Hex Wrenches).
Allows the user to loosen the bath
AD2291 10mm nut runner
retaining fixings.
Allows the user to loosen and move the
AD3312 6mm nut runner
nuts on the Board Placement Frame.
Special 3mm T-handle Allen Key (for
AD3313 3.0mm T-handle hex wrench
use with Board Placement Frame).

Page
32
 Allows the user to remove solder
AF0642 Nozzle cleaning tool deposits and dross (lead oxide) from the
solder nozzle.
Ensure that this Face Mask is used when
cleaning dross (lead oxide) from the
GLA0005 Face mask
solder bath, pump housing and solder
thimbles.
AD0455 8mm polyurethane tube green For use when connecting the Air supply.
For use when connecting the Nitrogen
AD0465 8mm polyurethane tube blue
supply.
PB2766
Allows calibration of the machine
and Calibration board
offsets.
PB2763
Ensure that Safety Glasses are used
AD3305 Protective glasses
when purging the Flux System.
For use when removing AP1 nozzles
BA7300 AP1 nozzle tool
from the solder bath.
Replacement pressure relief cap for use
AD3601 Moss cap
with Flux Bottle.
AA1150 Heat conducting paste See Lubricants below.
AA9137 Super lube grease See Lubricants below.
AD3744 Pronatur lubricant + PTFE See Lubricants below.

Lubricants & Adhesives

Lubricants
Most moving machinery requires a lubricant to prevent seizure. See below for recommended
lubricants.
LUBRICANT. Type Part No
Oil Light Machine Oil
PTFE Lubricant 400ml LUB0015
(Aerosol)
PTFE Lubricant 500ml AD3744
(Trigger Operated)
Grease SUPER LUBE (Silicon AA9137
Grease)
Release Paste (for use with Heater WATLOW WTP-1120N AA1150
Assembly) (Heat Conducting Paste)

Adhesives
Pillarhouse recommend that in the event of a part being removed and subsequently replaced,
an engineering adhesive is used on the fasteners, i.e. screws etc.

ADHESIVE PART No.

Screws Loctite - Screwlock ADH0015/01
(Unilock-110-050)

Page
33
 Bearings Loctite - Bearing Fit ADH0013/01
(Unibearing Compound
310-050)

Cleaner
The machine uses various items that require occasional specialist cleaning e.g. sensors and
camera lens. Pillarhouse recommend that a proprietary “LENS CLEANER” is always used for
this purpose in conjunction with a LINT FREE CLOTH.

Page
34
5. General Maintenance
Solder Top Up
IMPORTANT! WASH YOUR HANDS AFTER HANDLING SOLDER.
A solder feed aperture is provided in the top of the solder bath, to allow the solder level to be
topped up manually. The level must be kept topped up by feeding in solder as required. Select
suitable sizes of solder to top up the level. Do not attempt to force the solder into the tube.

The Solder Bath is fitted with a Float mechanism to provide an indication of the Solder Level
in the Bath. The Solder Level in the Bath is Factory set to 8mm below the underside of the
Pump Plate. Ensure that the washer at the base of the Float Pin is floating above the Float
Chamber and not resting on the top of the chamber
The top face of the Float sits at between 14-16mm above the top face of the float enclosure,
when the solder level in the bath is at the correct level.

Note: Some systems may be fitted with a Solder Level Detect system, which incorporates a
float and sensor to detect the level and provide a low level indication on the PC screen when
the level drops below a pre-set value.
An Optional Solder Wire Feeder can be provided for the machine. This option incorporates an
automatic solder filling system that feeds in solder from a wire reel when activated by an

Page
35
associated sensor detecting that the solder level has dropped below a set level.

Flux Top-Up
The Flux Bottle is mounted on the Services panel, located at the rear left-hand side of the
machine. Periodically the Flux bottle will require refilling, when the flux level becomes low.
The top-up interval is dependent on the flux usage, which varies according to application. If
flux usage is high, the bottle level should be visually checked frequently.
Note: Some machines may be fitted with a Flux Level detect sensor, which initiates a Flux
Bottle Low message on the PC Screen.
CAUTION: ONLY USE ALCOHOL-BASED FLUX WITH THE DROP-JET FLUX
HEAD.
If the flux bottle is low, refill it as follows:
• Unscrew and remove the bottle. The bottle is slightly pressurized.
• Refill the bottle with flux. Do not overfill the bottle.
• Re-fit bottle.
After refilling wait for a few moments, to allow the system pressure to stabilise at the set level.

Tinning The Solder Nozzle

IMPORTANT! ALWAYS WEAR APPROPRIATE PROTECTIVE EQUIPMENT
WHEN WORKING NEAR A HOT SOLDER BATH (I.E. SAFETY GLASSES,
GLOVES, OVERALLS).
The nozzle needs tinning if the solder does not flow evenly down the surfaces of the nozzle.
If the flow is just slightly uneven run the solder pump and apply Activ8 Flux (AD0850)
around the tip using a small brush.

If the nozzle flow is very uneven, remove the nozzle, allow cooling and when cool cleaning
the tinned area with emery paper. Flux the tinned area with Activ8 flux and then dip it in the
solder pot to tin the end. Refit the nozzle. Run the solder pump and continue to apply Activ8

Page
36
with a brush until the nozzle flows correctly.
CAUTION: DO NOT TIN STAINLESS STEEL NOZZLES. THESE MUST ONLY
BECLEANED USING A SUITABLE NOZZLE CLEANING TOOL.

Cleaning Dross From Solder Bath

WARNING: THE SOLDER BATHS CAN REACH EXTREMELY HIGH
TEMPERATURES. IT IS ESSENTIAL THAT PROTECTIVE HEAT RESISTANT
GLOVES ARE WORN WHEN WORKING ON OR NEAR A HOT SOLDER BATH.
FAILURE TO OBSERVE CORRECT SAFETY PRECAUTIONS COULD RESULT IN
SERIOUS BURN INJURIES.
TO AVOID INHALATION OF SOLDER FUMES, IT IS RECOMMENDED THAT A
FACE MASK IS WORN.

Note: Solder oxidizes at the temperatures required for soldering components, the higher the
temperature the greater the oxidation. This oxidation forms on the surface of the solder bath
and is known as dross. The speed of the solder pump will also affect the amount of dross
formed, the higher the speed the more dross is formed. This dross is not detrimental to the
soldering process as clean solder is pumped from below the surface through the solder
applicator. However if it is allowed to build up it can affect the running of the pump.

The solder bath requires cleaning daily, to avoid excessive dross build up. Move the Head
Assembly towards the front of the machine and raise the solder bath (if required) for ease of
access. Remove the Nitrogen Shroud from the bath. Using a dross scraper, carefully extract as
much dross from the top of the molten solder and around the sides of the bath as possible.
Place the dross into an approved sealed container so it can be stored prior to re-cycling.
Once the bath is clean, replace the Nitrogen Shroud.
The solder level of the solder bath should be maintained to the Float Level marker by topping
up with solder via the solder to p-up aperture, as required. If the level is allowed to fall too
low, the soldering height may be affected. Any unnecessary turbulence of the solder flow,
which may produce abnormally large quantities of solder dross, should also be avoided by
maintaining sufficiently high solder bath level.
Note: The bath should always be topped up with the Solder Pump switched OFF to avoid over
filling of the solder pot. This is usually done after removing the solder dross from the surface
of the solder bath and should only be done by suitably trained personnel, using appropriate
safety equipment.

Cleaning Fluxer Head

If air is allowed to enter the flux system for any reason, the flux system will require purging to
remove the air.

Daily Cleaning
It is recommended that any flux residue around the flux aperture in the head is carefully
removed on a daily basis. Clean off any flux residue using a small brush or lint-free cloth
together with the appropriate flux cleansing medium (i.e. alcohol for alcohol-based flux or
water for water-based flux), then purge the flux system.
CAUTION: DO NOT UNDER ANY CIRCUMSTANCES ATTEMPT TO USE AN
AIRLINE OR ANY PRESSURISED GAS SYSTEM TO CLEAN THE FLUX HEAD,
AS THIS COULD CAUSE DAMAGE TO THE BEAD FITTED TO THE HEAD

Page
37
APERTURE.

Cleaning Heavy Flux Residue Build-Up

If the flux head aperture becomes blocked, the following action is recommended to clean the
aperture:
• Carefully remove and retain the four screws fixing the flux head cover plate in position
and carefully remove the cover plate from the top of the flux head assembly.
• Clean the top plate using the appropriate flux cleansing medium (i.e. alcohol for
alcohol-based flux or water for water-based flux). Or where residue build-up is very
heavy, the cover plate can be cleaned in an ultrasonic bath - using the appropriate
cleansing medium.
• Using a microscope to view the aperture in the bead, very carefully - using the correct
gauge of wire for the aperture size (a set of 100 microns diameter needles are provided
as part of the Maintenance Accessories/Tool Kit) - push the wire through the hole in
the bead.
• While the cover plate is removed the chamber beneath the cover plate can be cleaned,
if necessary, using a suitable lint-free cleaning swab.
• Refit the flux head cover plate to the fluxer assembly and secure in position, using the
screws removed earlier.
• Purge the flux system.
WARNING: WHEN PURGING THE FLUX SYSTEM, FLUX IS SPRAYED FROM
THE FLUX HEAD. TAKE CARE TO ENSURE THAT THE FACE IS KEPT AWAY
FROM THE VICINITY OF THE FLUX HEAD AND ENSURE THAT SAFETY
GLASSES ARE WORN TO PROVIDE EYE PROTECTION.

Purging Flux System

It is recommended that purging the flux head is done with the head in the Upright position.
To purge the flux system:
• Set the Selective Soldering Machine to override mode.
• At the PillarCOMM PC, select Diagnostics, Manual.

Page
38
 • Click on the PURGE FLUX button on the PillarCOMM screen to start the purge flux
action.
NOTE: The head will move to the Datum position before starting the purge action.
This action opens the Inkjet head pin-valve at a pre-set pressure and sprays a
continuous jet of flux to purge the system of air.
• Click on the PURGE FLUX button again to close the valve and stop the flux.

Cleaning Wave Height Detector

During normal use, some oxidisation of the Wave Height Detector Needle may occur. If
allowed to build up, this may cause the wave height detection system to malfunction. To
ensure that the Wave Height Detector system functions correctly it is recommended that any
oxidisation residue is removed on a Daily basis.
IMPORTANT: WHERE MORE THAN ONE SHIFT IS WORKED PER DAY, THEN
THE WAVE HEIGHT DETECTOR NEEDLE SHOULD BE CLEANED ONCE PER
SHIFT.

Cleaning The Needle

Remove any oxidisation residue as follows:
• Carefully, wipe the needle clean, using a lint-free cloth and Activate Flux.

Cleaning X & Y Axis Slides

Periodically the X and Y axis slides require cleaning and re-lubricating, to prevent the build-
up of dust and grime impairing the motion of the machine axes.
• Datum the Head.

Page
39
 • Press an Emergency Stop button, to remove the power to the motors.
• Remove the side/front panels, to gain access.
• Gently, move the Head assembly, by hand, towards the centre of the machine to gain
access to the slides.
• Using a dry/clean cloth, remove any contamination which may exist on either of the
runner-guides, X/Y drive racks, the X drive shaft and motor pinion.
• Lightly oil the runner-guides and bearings using PTFE Oil (LUB0015).
• Lightly grease the X and Y racks, X drive shaft and motor pinion using silicon grease
(AA9137).
• Slide the Head assembly up and down the length of the rails to disperse the lubricant.
• Remove any excess grease with a dry/clean cloth.
• Repeat the process for the Y axis.

Cleaning Z Axis Mechanism

Periodically the Z axis mechanism requires cleaning and re-lubricating, to prevent the build-up
of dust and grime impairing the motion of the head.
• Datum the Head.
• In Manual Mode, drive the Head assembly up.
• Press an Emergency Stop button, to remove the power to the motors.
• Remove the side/front panels, to gain access.
• Using a dry/clean cloth, remove any contamination from the vertical lead screws.
• Apply PTFE Oil (LUB0015) to the vertical lead screws.
• Close the door and reset the machine.
• Drive the head up and down a few times to disperse the lubricant.
• Press the Emergency Stop button, to remove the power to the motors.
• Open the front door.
• Remove any excess oil with a dry/clean cloth.

Solder Temperature Calibration

It is important that the temperature of the solder in the bath is calibrated correctly, to avoid
associated problems such as excessive nozzle wear, the possibility of solder solidifying within
the nozzle or pump tube and higher pump speeds being required. The calibration should be
required not more than once a month. Typical frequencies are once every six months.
To calibrate the solder temperature:
• Select Configure, System, Calibrate System, Temperature in PillarCOMM (see
below).

Page
40
 • Once the correct password is entered the Calibrate Temperature Screen is displayed.

• Click on the Show Nozzle button, this moves the head position to the front left-hand
corner of the machine.
• If the pump is not running, switch ON the pump by clicking on the Pump ON/OFF
icon.
Note: When the pump is switched ON, it will allow 30s for nitrogen purge before
solder flows at the nozzle.
• Ensure that the solder has been flowing correctly for a minimum of 10 minutes.
• Measure the temperature at the nozzle and adjust the Calibrate Temperature, using the
up/down arrows to the measured temperature value.
• Select Apply to store the Calibrate Temperature.
• Select Close to close the Calibrate Temperature window.

Fans
Periodically the Cooling and Exhaust Fans require cleaning, to prevent build-up of dust and
grime from impairing the operation of the fan s.

Exhaust Fans
It is recommended that Exhaust Fan filters are cleaned at monthly intervals. Check and clean

Page
41
fan filters as follows:
• Remove the fan filter cover from the Fan unit and lift out the filter foam pad and mesh.
• Clean the foam pad and mesh by rinsing in a solution of warm water and proprietary
cleaning agent.
• Allow to dry then refit the mesh and foam pad into the cover.
• Refit the cover to the Fan unit.
Check and ensure through flow of the exhaust fans.

Cooling Fans
It is recommended that the Cooling Fan filters are cleaned at monthly intervals. Check and
clean fan filters as follows:
• Remove the fan filter cover from the Fan unit and lift out the filter foam pad and mesh.
• Clean the foam pad and mesh by rinsing in a solution of warm water and proprietary
cleaning agent.
• Allow to dry then refit the mesh and foam pad into the cover.
• Refit the cover to the Fan unit.

Page
42
Page
43
6. Scheduled Maintenance
Scheduled Maintenance
The Recommended Maintenance Schedule for the machine is detailed below. It includes
Daily, Weekly and Monthly tasks which are simple to execute by an experienced engineer.

IMPORTANT NOTE: WHERE MORE THAN ONE SHIFT IS WORKED PER DAY,
IT IS RECOMMENDED THAT ALL DAILY SCHEDULED MAINTENANCE TASKS
ARE IMPLEMENTED ONCE PER SHIFT. ALSO DEPENDENT UPON MACHINE
USAGE AND NOZZLE SELECTION, SOME DAILY TASKS SUCH AS TINNING
THE NOZZLE MAY HAVE TO BE MONITORED PERIODICALLY DURING
PRODUCTION AND UNDERTAKEN WHEN NECESSARY.

Task Daily Weekly Monthly Instructions Estimated

Time
Solder nozzle Clean Surface and re-tin if necessary 5 minutes
X
Solder bath Clean Surface dross by removing 5 minutes
(Quick) X nitrogen shroud
Clean nozzle Remove nozzle and clean dross from 2 minutes
sleeve X sleeve
Flux head Using a cotton bud and alcohol to 1 minute
X clean the top of the fluxer
Flux purge pad Remove purge pad from holder and 2 minutes
X wash with water. Squeeze dry and
replace.
Solder bath Remove pump body from bath and 20 minutes
(Thorough) X de-dross entire bath
Camera lens Clean off flux residue with lens 1 minute
X cleaner and lint free cloth
Solder bath Calibrate Solder Temperature at 20 minutes
temperature X Nozzle (make sure the pump run for
at least 15 minutes)
X & Y axis Check for debris on racks and grease 15 minutes
X with super lube, check rails and oil
with PTFE spray.
Fluxer nozzle Remove top plate and use cleaning 10 minutes
X pin to clear aperture
Tractor conduits Check for chaffing and signs of 5 minutes
X degradation
Pipes and wires Check for twisting, chaffing and 5 minutes
X degradation
Extractor fan Check operation and clean filters 10 minutes
X
Page
44
 Cooling fans Check operation and clean filters 10 minutes
X
Drive pulleys Check pulleys are all tight and are not 20 minutes
X showing signs of wear
Fluxer pipes Empty flux bottle and replace with 30 minutes
X thinners. Purge the flux head to clean
the pipe work
Solder pump Remove pump from bath and 90 minutes
X disassemble pump. Clean dross from
pump body
Z axis Check bearings for debris and inspect 10 minutes
X lead screws

Solder Bath De-Dross (Quick)

This maintenance should be performed at the beginning of each shift and simply involves
removing the dross that forms around the front of the solder bath. This area is prone to quick
dross build up on account of the fact the solder running from the spiral returns to the main
body of solder and agitates the surface. This cause dross build up that if left unchecked can
cause large deposits of dross on all pump/bath components.

NOTE: This procedure must be undertaken whilst the bath is hot and the solder molten so
care should be taken with every aspect of the procedure. Appropriate personal protection
equipment should be worn at all times and the working area should be clean and free of
obstructions.

1) The machine must be put into MAINTENANCE MODE, this will provide the optimal
working space for undertaking the procedure. This feature is accessed by selecting
• Diagnostics
• Manual mode

The carriage will now move to the maintenance offset position and the following form will be
presented:

Page
45
2) Carefully lift off the nitrogen shroud as shown below, there will be drips of solder from
the base of the assembly. Ensure that no solder lands on any part of the X Y assembly
or the viewing camera.
NOTE: Whist the nitrogen shroud is hot and the solder molten it is prudent to remove
any excess solder from the inner and outer lip of the shroud (highlighted below). This
makes the shroud easier and faster to replace when the maintenance is complete.

Page
46
 Nitrogen Shroud Under Side View

NOTE: If selective preheat is fitted, upon replacement of the shroud the preheat tube
must be aligned with the feed tube in the bath. This can make fitting a little tight as the
two tubes must make a good seal.

3) With the shroud removed access can now be had to the front of the bath. The exposed
area should be thoroughly de-drossed both on the solder surface and the submerged
portions of the bath
NOTE: At this juncture inspect the condition of the nitrogen diffuser (highlighted
below), if it appears blocked remove and inspect before commencing production.

4) Replace the nitrogen shroud making sure that the lower portion is completely
submerged in the solder.
5) Press the CLOSE button on the maintenance form, the bath will now return to the
datum position.

Page
47
Solder Bath De-Dross (Thorough)
The through de-dross should be performed once a week (depending on usage) this involves
removing the pump mechanism from the bath in order to clean the entire bath and also the
pump itself.

1) The machine must be put into MAINTENANCE MODE, this will provide the optimal
working space for undertaking the procedure. This feature is accessed by selecting
• Diagnostics
• Manual mode

The carriage will now move to the maintenance offset position and the following form will be
presented:

Page
48
2) Carefully lift off the nitrogen shroud as shown below, there will be drips of solder from
the base of the assembly. Ensure that no solder lands on any part of the X Y assembly
or the viewing camera.
NOTE: Whist the nitrogen shroud is hot and the solder molten it is prudent to remove
any excess solder from the inner and outer lip of the shroud (highlighted below). This
makes the shroud easier and faster to replace when the maintenance is complete.

3) Using a 10MM nut spinner or spanner, loosen the two indicated hex pillars. This will
release the pump body from the bath so the unit can now be lifted directly upwards

Page
49
 NOTE: Inserts prevent the pillars from being fully removed from the pump body, this
feature is to aid re-assembly.

4) Carefully lift the pump body directly upwards so all the electrical and pneumatic
connections are disengaged.

5) Lift the pump body out of the solder bath tilting it back slightly as shown in the picture
below. This will allow the solder that is inside the pump casting to drain back into the
solder bath, so should be left a few moments until the solder flow stops.
Make sure that there is a suitable place to put the pump body once it has been removed,
such as a metal try or the service tray provided. Even with the best heat proof gloves on
the heat will eventually transfer to the user’s hands, this is why it is vital that the area is
clear and free from hazards and obstructions.

Once the pump has been removed clean the entire body using a brush or gloves, repaint

Page
50
 the body with high temperature paint if required.

6) Clean all dross from the bath using the dross scraper provided in the machine accessory
kit. The following picture shows a bath with no solder so as to highlight submerged
obstructions. It is particularly important to clean dross from the back of the bath as this
is where the solder is drawn into the pump.

Page
51
7) When cleaning is complete place the pump body back into the solder bath, check that
the location dowels line up with the holes on the underside of the pump body. Also
verify that all motor and pneumatic connections are firmly made.

8) Apply anti seize heat transfer paste to the thread of the hex pillars and tighten.
NOTE: The application of heat transfer past to all fixings is critical to the serviceability
of the machine.

9) Replace the nitrogen shroud making sure that the lower portion is completely
submerged in the solder.
10) Press the CLOSE button on the maintenance form, the bath will now return to the
datum position.

11) Check the solder bath offset.

Page
52
Solder Pump De-Dross
Each month the pump body must be separated from the pump body so as to remove dross
from the impellor and pump base, this is vital to the longevity and reliability of the pump
unit. As this is involves stripping the pump completely apart it is also useful for observing
any worn/damaged parts of the pump unit, this allows components to be changed in a
preventive fashion hence avoiding unforeseen pump failures.

1) The machine must be put into MAINTENANCE MODE, this will provide the optimal
working space for undertaking the procedure. This feature is accessed by selecting
• Diagnostics
• Manual mode

The carriage will now move to the maintenance offset position and the following form will be
presented:

2) Carefully lift off the nitrogen shroud as shown below, there will be drips of solder from
the base of the assembly. Ensure that no solder lands on any part of the X Y assembly
or the viewing camera.
NOTE: Whist the nitrogen shroud is hot and the solder molten it is prudent to remove
any excess solder from the inner and outer lip of the shroud (highlighted below). This

Page
53
 makes the shroud easier and faster to replace when the maintenance is complete.

3) Using a 10MM nut spinner or spanner, loosen the two indicated hex pillars. This will
release the pump body from the bath so the unit can now be lifted directly upwards

4) Carefully lift the pump body directly upwards so all the electrical and pneumatic
connections are disengaged.

Page
54
5) Lift the pump body out of the solder bath tilting it back slightly as shown in the picture
below. This will allow the solder that is inside the pump casting to drain back into the
solder bath, so should be left a few moments until the solder flow stops.
Make sure that there is a suitable place to put the pump body once it has been removed,
such as a metal try or the service tray provided. Even with the best heat proof gloves on
the heat will eventually transfer to the user’s hands, this is why it is vital that the area is
clear and free from hazards and obstructions.

Once the pump has been removed clean the entire body using a brush or gloves, repaint
the body with high temperature paint if required.

Page
55
6) Clean all dross from the bath using the dross scraper provided in the machine accessory
kit. The following picture shows a bath with no solder so as to highlight submerged
obstructions. It is particularly important to clean dross from the back of the bath as this
is where the solder is drawn into the pump.

7) The pump casting needs to be removed from the pump body to gain access to the

Page
56
 impellor, this should only be attempted when the assembly is at full bath temperature.

8) Remove the two remaining hex pillars using a 10mm nut spinner or spanner. This will
free the pump casting from the main body.
NOTE: Inserts prevent the pillars from being fully removed from the pump body, this
feature is to aid re-assembly.

9) The pump body can now be separated from the pump casting, if this maintenance has
not been undertaken for some time then the two halves can be hard to separate (if this is
the case please refer to point 10 below).

Page
57
10) If the pump is difficult to separate simply use two M8 bolts in the positions indicated in
the picture below.

These bolts can then be tightened forcing the two halves of the pump to separate. Be
sure to tighten the screws equally so as to lift the pump casting off squarely.

11) With the pump separated thoroughly de-dross the impeller recess and the impeller its
self. If any solder has solidified by this point place the pump component carefully back
into the bath to return to temperature.

Page
58
12) Re-assemble the pump lining up the dowels on the pump casting with the holes on the
pump body. Apply heat transfer compound to the thread of the hex pillar and tighten,
the pillars should be firmly tightened but not excessively so.
13) When cleaning is complete place the pump body back into the solder bath, check that
the location dowels line up with the holes on the underside of the pump body. Also
verify that all motor and pneumatic connections are firmly made.

Page
59
14) Apply a small amount of anti-seize heat transfer paste to the thread of the hex pillar and
tighten.
15) Replace the nitrogen shroud making sure that the lower portion is completely
submerged in the solder.
16) Press the CLOSE button on the maintenance form. The carriage will now return to the
datum position.

17) Check the solder bath offset.

Removing The Solder Bath

The bath on the machine can be changed very rapidly using only a 10mm spanner/nut spinner

Page
60
and the bath lift cradle and can be done with the bath hot or cold. It is preferable to undertake
to procedure with the bath cold and the solder to be in a solid state as this presents fewer
safety issues.

NOTE: The solder bath is heavy and should only be removed with TWO people present.

1) Ensure the drives are ON and the override switch is set to OVERRIDE.
2) From the drop down menu select DIAGNOSTICS > MAINTENANCE.

3) The offset form will now be presented and the carriage will drive to the maintenance
position at the rear of the machine.

NOTE: If the bath does not move to the desired maintenance position, re-teach the
Maintenance offset to the desired position

4) Use a 10mm spanner to release the two pump clamp bolts on either side of the bath.
These are captive within the bath so cannot be physically removed, only loosened.

Page
61
5) Position the lift cradle (pictured below) over the bath so the four hooks line up with the
lift pegs located on each corner of the pot.

Page
62
6) The bath can now be lifted from the carriage. If the bath is hot, extreme caution must be
exercised, the bath must be lifted up squarely to prevent a solder spillage. Once the bath
has been lifted enough for the pump motor to disconnect, the stainless steel flap will
drop over the connections to protect them from any accidental solder spillage.
NOTE: As the bath is lifted away from the carriage, a hiss of escaping gas will become
audible. This is only the compressed air that is used for the pump cooling and is nothing
to cause concern.

NOTE: The bath has four location legs that must be clear of the top plate before the
assembly can be moved away from the carriage

Page
63
Replacing The Bath
Re-fitting the bath is simply the reversal of the removal procedure:

1) Hold the pump motor cover flap open.

2) Place the bath onto the top plate, confirm that the location legs are lined up with the
appropriate holes Press the assembly firmly down onto the plate to ensure all
connections are firmly made.
3) Tighten the two pump clamp bolts using a 10mm spanner as before. Be sure to tighten
the bolts evenly else the bath will not sit flat on the plate.
4) When the operation is complete press the CLOSE button on the maintenance form to
finish the replacement procedure

Page
64
5) Check the nozzle offset before running a program.

Cleaning The Flux System

Over time the flux lines can become congested with crystallised flux reducing the overall
flow of liquid through the system, the symptoms of this are poor flux coverage and
inconsistent spray formation. The recommended interval for this maintenance is once a
month, some fluxes will require this to be procedure to be undertaken with increases
frequency as they will restrict the lines more rapidly.

In order to clean out the system thinners must be flushed through the flux lines, this will
break down any unwanted deposits and suspend them in the thinners. This solution can then
be flushed into the drain bottle and disposed of.

NOTE: The cleaning instructions should be followed sequentially and to the extent described,
failure to do so can result in the flux head administering thinners to production boards
causing soldering defects.

Page
65
Page
66
Emptying The System
1) Press the emergency stop button to stop the nitrogen supply to the bottle.
2) Unscrew the flux reservoir bottle

3) Empty the flux from the reservoir bottle into a clean container so the flux can be reused
in the system if required.
4) Replace the empty flux reservoir bottle

Page
67
5) Release the emergency stop and press the start button to apply pressure to the bottle.
6) Verify that the drain bottle is in position and release the drain valve
NOTE: the valve is opened by turning the white knob anti clockwise, the valve has a
locking collar that can prevent the knob from turning. If this situation arises simply turn
the locking collar half a turn to free the mechanism.

7) After a few seconds a small stream of flux will emerge from the valve, over time this
will reduce to a few drops. Leave this valve open for at least 5 minutes to allow as
much flux as possible to drain from the system.
Once the majority of the flux has been drained lock the drain valve shut.

Page
68
Cleaning The System
1) Press the emergency stop button to stop the nitrogen supply to the bottle.
2) Unscrew the flux reservoir bottle and fill 75% with thinners.
3) Release the emergency stop and press the start button to apply pressure to the bottle
4) With the pressure reapplied to the bottle the thinners will now flow though the flux
pipes breaking down any residual crystallisation.
NOTE: If the drain valve is left open it will take longer for the liquid to work its way
through the pipe work. The valve should be left shut and the system left for about a
minute in order for the liquid to reach the head and then the drain valve.

Open the drain valve and allow the thinners to transfer from the reservoir bottle to the drain
bottle. Let the system run until about 50% of the liquid in the reservoir bottle has been used.

5) Lock the drain valve shut

6) In order to clean the flux head spray aperture and the internal mechanics of the unit a
purge function must be performed. This can be done by selecting:
• Diagnostics
• Manual Mode

Select PURGE FLUX icon from the manual mode form, this will continually fire the fluxer
for 20 seconds breaking down any deposits in the aperture.(The time is limited to 20 seconds
to prevent the head from overheating)

Page
69
NOTE: Some tissue should be held over the fluxer to prevent any machine components
becoming fouled by the spray. This is also useful to check that liquid is actually being
sprayed as sometimes it can take several purges for the head to actually spray, this is
normally down to air trapped in the pipe work

Once it is confirmed that the head is spraying 4 – 5 purges should be run to clean the head.

The cleaning phase of the operation is now complete, this process can be repeated a number
of times by refilling the reservoir bottle with fresh thinners.

Emptying The Cleaning Fluid

Before the machine can be used in production all thinners must be removed from the system,
this step is essential to ovoid soldering defects in production PCB’s.

1) Press the emergency stop button to stop the nitrogen supply to the bottle.
2) Unscrew the flux reservoir bottle
3) Empty the bottle and properly dispose of the contaminated thinners
4) Replace the empty flux reservoir bottle
5) Release the emergency stop and press the start button to apply pressure to the bottle.

Page
70
6) Verify that the drain bottle is in position and release the drain valve
7) After a few seconds a small stream of liquid will emerge from the valve, over time this
will reduce to a few drops. Leave this valve open for at least 5 minutes to allow as much
fluid as possible to drain from the system.
Once the majority of the thinners have been drained, lock the drain valve shut.

Filling And Priming The System

Now the system is empty the head must be re-pressurised with flux, it must be observed that
flux is spraying from the head before production resumes.

1) Press the emergency stop button to stop the nitrogen supply to the bottle.
2) Unscrew the flux reservoir bottle and fill with flux. (Do not over fill 80% – 85% is
adequate)
3) Release the emergency stop and press the start button to apply pressure to the bottle
4) With the pressure reapplied to the bottle flux will now flow through the pipe work and
pressurise the head. This may take a few minutes as the filter offers
NOTE: Make sure that the drain valve is shut as this will speed up the flow of the flux
through the system.

5) A check must be performed to confirm that the head is spraying flux this is best done
by running the purge function. This can be done by selecting:
• Diagnostics
• Manual Mode

Select the PURGE FLUX button from the form and check that liquid is dispensing from the
head

NOTE: It may take a few purges for the flux to start spraying.

Once fluid is flowing from the head, run the purge a further 4 or 5 times and confirm that flux
is present, the machine is now ready to re-enter production.

Page
71
Page
72
7. Removal & Replacement Procedures
This section provides information for Maintenance Engineers and includes step-by-step
procedures on how to Remove, Replace and Set-up the most important parts and assemblies
on the machine. To aid identification of components, parts, fixings and assemblies, where
appropriate, photographs and drawing references are provided to support the procedures.

NOTE: It is recommended that maintenance is implemented by suitably qualified,

experienced personnel.
When implementing procedures that involve the removal and refitting/replacement of some
component parts of the machine, care must be taken to ensure that the refitted/replaced parts
(where possible) are fitted to the same position as the original part.
For some items it will be necessary to recalibrate and reset some values within the software.
These items are:
• Datum Sensors/Flags
• Programming Camera
• Flux Head Assembly
• Solder Bath Assembly
• Solder Pump Assembly
The majority of the replacement procedures require the machine to be powered down during
replacement of faulty/worn parts.

Solder Nozzle

Removal
This procedure should only be undertaken when the bath is hot
• Use nozzle removal tool provided in the Handex Day-to-Day Service kit
• Line up the flats on the nozzle tool with the flat sides of the nozzle and turn anti-
clockwise
• Remove nozzle taking care not to let it drop into the bath or into any part of the machine
• Place on a heat proof surface to cool

Replacement
• Replacement is the opposite of removal

Page
73
 • It should be noted that a replaced nozzle tip will need time to reach a useable
temperature, if used immediately solder will freeze in the nozzle.
WARNING: ENSURE THAT THE NOZZLE TIP IS COMPLETELY DRY AND
CONTAMINANT FREE BEFORE RE-FITTING, AS A DAMP/WET NOZZLE MAY
CAUSE SOLDER TO BE EJECTED FROM THE BATH.
CAUTION: IF CHANGING NOZZLE TO ONE OF A DIFFERENT SIZE OR TYPE
(ESPECIALLY WHERE THE SIZE DIFFERENCE IS LARGE) ADJUSTMENT OF
THE SOLDER LEVEL (I.E. REMOVING/ADDING SOLDER FROM/TO BATH)
MAY BE NECESSARY. IN ADDITION ENSURE THAT THE PUMP RUNS AT A
SAFE SPEED WITH THE NEW NOZZLE FITTED, BY CHECKING THAT THE
NEW NOZZLE TYPE IS CORRECTLY SELECTED AND ACTIVE IN THE NOZZLE
EDIT SCREEN AND ADJUSTING THE SETTINGS IF REQUIRED.

Nitrogen Shroud
A metal plate/container is required. Ensure that all necessary safety equipment is used during
removal of the Nitrogen shroud.

Removal
• Using the protective gloves; carefully lift the Nitrogen Shroud clear of the bath and out
of the machine.
• Carefully wipe around the edges of the Nitrogen Shroud, to remove any molten solder or
dross.
• Place the shroud on a metal plate away from the machine to cool.

Replacement
• Using the protective gloves; carefully lift the Nitrogen Shroud into the Solder Bath,
ensuing that it sits fully into the solder.
Note: Where a different size nozzle tip is fitted, it may be necessary to check the pump
speed settings to obtain the required solder flow at the new nozzle tip.

Page
74
XYZ Assembly

The X-Y Assembly is mounted on linear rails providing X-Y movement of the Head
assembly. The X-Y axis movement is transmitted using stepper motors, toothed gears, drive
belts and X-rack and Y-rack assemblies.
The Z Assembly uses vertical screw rods to provide Z movement of the Head assembly. The Z
movement is transmitted using a stepper motor, toothed gears and drive (timing) belts.
Each axis is governed by sensors and flags, which are provided to control the datum position
and over-travel of the Head assembly.

Sensors
The sensors are proximity type sensors and sense the presence of the metallic datum flags
NOTE: Datum Sensors and Flags are "Factory Set" and should not normally require any
adjustment. However, where the Datum sensor or flag is moved or replaced the following
resetting procedures must be implemented before returning the machine to use:
The following must be reset:
• Bath Offset
• Nozzle Offset
• Fluxer Offsets
• Camera Offset
The following Sensors are fitted to the X-Y and Z Assemblies:
The X-axis Datum position sensor is located at the rear of the machine. The Y-axis Datum
position sensor is located on left-hand side of the Head Carriage Assembly. The Z-axis Datum
position sensor is located on the left-hand side of the Head Carriage Assembly.

Page
75
 X Datum Sensor

Y Datum Sensor

Z Datum Sensor
Removal
• Power down machine.
• Locate the required sensor assembly for removal.
• Unplug electrical connectors from the sensor assembly.
• Remove the 2 off retaining lock nuts fixing the sensor assembly to the sensor mounting

Page
76
 bracket.
• Remove the sensor assembly from its mounting bracket.
Replacement
Replacement of the sensor assembly is the reverse of the removal procedure.
Once the machine has been restarted, check that the sensor is operating correctly.
Setting
If the sensors require setting DO NOT attempt to reset the position of the sensors by moving
the sensor mounting bracket. The Sensor Mounting Brackets are Factory Set to the correct
positions and should not require adjustment.
NOTE: All Offsets must be “re-learned” by the machine, after moving datum sensors.

X Motor
NOTE: The X Motor is located on the rear rail of the XYZ assembly.
Removal
• Power down machine.
• Remove the two belt cover retainers and remove the cover.

• Loosen the X motor bracket and slide the bracket forward therefore removing the belt
tension.

Page
77
• Disconnect the electrical connectors from the motor.
• Remove the four motor retainer screws.

Page
78
• Remove the belt from the pulley and remove the X Motor from the carriage.

Replacement
• Install the new motor making sure to hook the belt onto the pulley, then replace and
tighten the motor retainers.

Page
79
• Pull the motor bracket away from the drive shaft to re-apply tension to the belt. Once
the tension is sufficient, tighten the bracket retainers.

• The belt tension should not be extremely high as this will reduce the life of the belt,
also not too loose as this will result in inaccurate movement.

X Belt Replacement
Follow the instructions for the X Motor change to replace the X belt.

Y Motor
The simplest way to remove/replace the Y axis motor is to drop the entire drive hub from the
carriage assembly.
Removal
• Power down machine.
• Loosen the wiring to the datum sensor and the motor by means of cutting the cable ties
holding wiring in position. If there is not enough wiring to comfortably remove the drive
hub from the machine it may be necessary to unplug the motor/datum sensor from the
control box.
• Position of the Z axis to achieve maximum possible working space. With the machine
powered down the Z axis can be moved manually by carefully pulling the timing belt
left or right to raise or lower the lift plate (removing the bath makes this easier)

Page
80
• Four fixings on the carriage base plate hold the Y-axis drive hub to the carriage.
Remove the fixings and drop the hub to a position that exposes the motor.

Page
81
• With the hub removed, loosen the four motor retaining bolts and the two slide clamp
bolts, then slide the motor towards the drive gear to remove the tension to the belt.

NOTE: Some machines may have some grub screws that are used to keep tension on
the side slide plates; these will have to be loosened before the motor can be slid
forward.
• The belt can now be removed from the motor pulley.

Page
82
• Fully remove the four motor fixing bolts and the motor can now be removed from the
drive hub.

NOTE: Take a note of the direction the motor wiring is facing before removing the
motor.
Replacement
• The replacement motor can now be put into position. Make sure that the motor is
orientated with the wiring in the original position.

• Replace the motor fixing screws.

Page
83
• Pull the motor away from the drive gear to tension the belt, once sufficient tension is
applied then lock down the two slide clamp bolts to secure the motor in position.

NOTE: If the drive hub is fitted with tension screws then these can be tightened to apply
tension to the belt. Care should be taken to tighten the two tension screws equally and that the
system is not put under excessive force.
• The drive hub can now be put back onto the carriage plate and the four hub bolts
replaced. Check that the drive gear meshes firmly with the Y axis rack.

Page
84
• Once fully reassembled, run the carriage along the full length of the Y axis. Check that
the drive gear remains in firm contact with the rack along its entire run.

• If at any point along the axis the engagement lessens, the Y rack should be very lightly
loosened and pushed into full engagement.

Page
85
 Y Belt Replacement
Follow the instructions for the Y Motor change to replace the Y belt.

Z Motor
The Z Motor is located on the underside of the XYZ Carriage. To gain access to the Z motor
the Electronics Control box will need removing.

Removal
• Power down machine.
• Remove electrical connectors from the motor.
• Remove the 4off pillars that retain the Z-motor on position. Note: check the Z-belt
tension before removing the motor as this will need resetting when the new motor is
fitted.

Z-motor
pillars

Replacement
Replacement of the motor is the reverse of the removal procedure.

Z Belt Replacement
Follow the instructions for the Z Motor change to replace the Z belt.

Solder Bath
It is recommended that the machine parts are allowed to cool down before implementing
maintenance procedures. Exercise extreme caution when removing the solder bath.
Ensure that the solder bath is sufficiently cool and the solder has solidified, before
attempting removal and ensure that heat resistant gloves are worn as a precaution.

Page
86
Removal
• Power down machine and allow enough time for the solder bath to cool down
sufficiently and for the solder to solidify, before handling the solder bath.
NOTE: The solder bath temperature should be no greater than 100°C when handling the
bath.
• Disconnect the quick release connector.
• Use a 10mm spanner to release the two pump clamp bolts on either side of the bath.
These are captive within the bath so should not be physically removed; only loosened.

• Position the lift cradle (pictured below) over the bath so the four hooks line up with the
lift pegs located on each corner of the pot.

• The bath can now be lifted from the carriage. If the bath is hot, extreme caution must be

Page
87
 exercised; the bath must be lifted up squarely to prevent a solder spillage. Once the bath
has been lifted enough for the pump motor to disconnect, the stainless steel flap will
drop over the connections to protect them from any accidental solder spillage.
NOTES:
1. As the bath is lifted away from the carriage, a hiss of escaping gas will become
audible. This is only the compressed air that is used for the pump cooling and is
nothing to cause concern.
2. The bath has four location legs that must be clear of the top plate before the assembly
can be moved away from the carriage

Replacement
• Implement any necessary maintenance to the bath before replacement, e.g. cleaning the
bath.
IMPORTANT: DO NOT UNDER ANY CIRCUMSTANCES ATTEMPT TO
SEPARATE THE SOLDER BATH CASING WHEN ATTEMPTING TO CLEAN
THE SOLDER BATH.
• Replacement is the reverse of removal.
• Hold the pump motor cover flap open.
• Place the bath onto the top plate, confirm that the location legs are lined up with the
appropriate holes Press the assembly firmly down onto the plate to ensure all
connections are firmly made.
• Tighten the two pump clamp bolts using a 10mm spanner as before. Be sure to tighten
the bolts evenly else the bath will not sit flat on the plate.
• Following replacement, fill or top-up the solder level, as required.

Set-Up
After replacement, the following will require resetting:
• Bath Offset.
• Solder Level Offset.
• Wave Height Offset (option).

Page
88
Heaters
The heaters are located in 4 vertical positions within the solder bath assembly, as shown
below.

Removal
• Power down machine.
• Remove nitrogen covers.
• Remove the Solder Pump assembly.
• Wait for the machine to cool down (a minimum of 2 hours)
• Remove the solder bath from the machine.
• Invert the Solder Bath to allow access to the underside.
• Undo the fixings for the heater wires and carefully extract the heater.
Note: If the heater is tight then the topside cap can be removed and a gentle pressure
applied from the top to easy removal.

Replacement
The Replacement procedure is the reverse of removal.
Note: It is important that Heat Paste (AA1150) is applied to each heater before fitting into the
solder bath.

Page
89
Thermal Trip Sensor
Replacement of the Thermal Trip Sensor requires the solder bath to be removed from the
machine. The
Thermal Trip Sensor is fitted at the rear of the solder.

If the Solder Bath is removed and refitted/replaced, the following offsets MUST be reset.
• Bath Offset.
• Solder Level Offset.
• Wave Height Offset (option).

Removal
Once the Solder Bath is removed from the machine and cool, remove the Thermal Trip
Sensor, as follows:
• Remove the 2 off M3 screws securing the disc to the solder bath.
• Carefully remove the whole sensor assembly from the bath

Replacement
• Carefully fit the replacement Thermal Trip Sensor assembly into the solder bath.
• Fit the 2 off M3 cap head or grub screws removed earlier to secure the disc to the solder
bath. Take care to tighten the screws evenly until the disc just touches the outer bath.
This will ensure that the sensor is correctly positioned in the bath assembly.
• Fit the washer and locking nuts to the grub screws (where fitted) and tighten to secure
the sensor in position
• Refit the Solder Bath to the machine.

Page
90
Level Detect Sensor
The Level Detect assembly is part of the Solder Feeder and is located on the rear right-hand
side of the machine. The Level Detect proximity sensor is mounted on the underside of the
Solder Feeder assembly.
Note: The setting dimension for this sensor is critical for the correct performance of the Solder
Top-up system.

Removal
• Power down machine.
• Open the rear door of the machine.
• Remove the 4off screws securing the access panel to the Solder Wire Feeder box and
remove the panel, to gain access to the Level Detect Sensor wiring connector.
• Disconnect the Level Detect Sensor wiring connector.
• Carefully remove the nut securing the proximity sensor and withdraw the sensor from
the mounting block.

Replacement
The Replacement procedure is the reverse of removal.
Note: When fitting the new sensor the distance between the base of the sensor and the setting
block on the solder bath (when at Z-datum) must be 55mm.

Set-Up
Before setting-up the detector, check that the solder level is correct:
• Switch OFF the solder pump.
• Adjust the level as necessary.

Solder Bath Level Check

Lift off the solder nozzle shroud and check that the level of the solder is correct.

Page
91
NOTE:
The solder should be a measurement of between 14-16mm at the float. Ensure that the washer
at the base of the Float Pin is floating above the float chamber and not resting on top of the
chamber.

• Set the Level Detect Offset.

Solder Pump Assembly

The solder pump assembly forms p art of the solder bath assembly and comprises the pump
body, impellor assembly and the pump motor.
If the Solder Pump is removed from the bath and refitted/replaced, the following resetting
procedures must be implemented before returning the machine to use:
• Bath Offset
• Check that the Solder Level in the bath is correct.
• Solder Level Offset
• Wave Height Offset (option)

Pump Removal
• Power down machine.

Page
92
• Carefully lift off the nitrogen shroud as shown below, there will be drips of solder from
the base of the assembly. Ensure that no solder lands on any part of the X Y assembly
or the viewing camera.
• Using a 10mm nut spinner or spanner, loosen the two indicated hex pillars. This will
release the pump body from the bath so the unit can now be lifted directly upwards
NOTE: Inserts prevent the pillars from being fully removed from the pump body; this
feature is to aid re-assembly.

• Carefully lift the pump body directly upwards so all the electrical and pneumatic
connections are disengaged.

• Lift the pump body out of the solder bath tilting it back slightly as shown in the picture
below. This will allow the solder that is inside the pump casting to drain back into the
solder bath, so should be left a few moments until the solder flow stops.
Make sure that there is a suitable place to put the pump body once it has been removed,

Page
93
 such as a metal try or the service tray provided. Even with the best heat proof gloves on
the heat will eventually transfer to the user’s hands, this is why it is vital that the area is
clear and free from hazards and obstructions.

Pump Motor
The Pump Motor is located at the rear of the Solder Bath Assembly.

Removal
• Power down machine.
• Remove the Pump assembly as detailed above.
• Allow the assembly to cool.
• Remove the 4 off screws securing the top cover and remove.

• Remove the 4off screws securing the motor cover and remove, to gain access to the
Pump motor.

Page
94
• Disconnect the electrical connections for the motor, making note of which colour wire
connects to which terminal.

• Remove belt from the pulley, by rotating the belt in an anti-clockwise direction and lift
off as it slides up the gear wheel.
• Whilst supporting the motor, remove the 4 off screws securing the motor to its
mounting.
• Remove the motor.

Replacement
The Replacement procedure is the reverse of removal. Note: When re-fitting ensure that the
belt is lightly tensioned.

Pump Belt
The Pump Belt is located inside the top of the pump drive assembly.

Removal
• Power down machine.
• Remove the Pump assembly as detailed above.
• Allow the assembly to cool.
• Remove the 4 off screws securing the top cover and remove.

Page
95
• Remove the 4off screws securing the motor cover and remove, to gain access to the
Pump motor.

• Loosen the 4 off screws that retain the motor. Note: Do not remove these screws.
• Simply rotate the belt in an anti-clockwise direction and lift the belt from the pulley as it
slides upwards.

Replacement
Replacement of the belt is the opposite of removal.
NOTE: The belt is tensioned by adjusting the motor position within its mounting holes and
should be lightly tensioned.

Impeller Assembly
There is normally no requirement to remove the impellor assembly for cleaning, However if
the impellor becomes excessively worn it may require replacement.

Removal
• Power down machine.
• Remove the Pump assembly as detailed above.
• Remove the two remaining hex pillars using a 10mm nut spinner or spanner. This will
free the pump casting from the main body.

Page
96
NOTE: Inserts prevent the pillars from being fully removed from the pump body; this feature
is to aid re-assembly.
• The pump body can now be separated from the pump casting; if this maintenance has
not been undertaken for some time then the two halves can be hard to separate.

1) If the pump is difficult to separate simply use two M8 bolts in the positions indicated
below.

Page
97
2) Remove the M4 fixing on at the top of the impellor and gently the impellor by pushing
it out.

Sono-Tek Setup

Nitrogen Shroud Adjustment

The nitrogen shroud is used as a method of delivering the vaporised flux from the head to the
board. The shroud sits around the flux head where it uses the conical shape of the nozzle to
change the shape of the gas shroud. Varying the position of the nitrogen shroud has much the
same effect as changing the height of the nozzle e.g. the size of the contact area.

The shroud is adjusted by using the tool shown in the below picture, the two pins are inserted
into the recess on the shroud allowing to adjust up or down as necessary.

Page
98
The effects of raising or lowering the shroud are show below, when the shroud is fully
screwed down the crossover point is close to nozzle and the gas shroud is wider, as the shroud
is wound out the effect is a narrower gas shroud and a higher crossover point.

Page
99
For general use a 6mm diameter flux area is sufficient, this can be simply achieved by setting
the flux head 10mm from the board, then using the indent on the shroud adjustment tool as
spacer.

Camera (Programming) Assembly

The Camera is used for programming the machine. The cross-hair lines which appear on the
screen are generated by an external system and not by the camera. The Programming Camera
is located in front of the of the solder bath.

Camera Set-Up
Following camera replacement the new camera requires setting up, as follows:
• Set the Focus of the camera lens as follows:
• Remove the diffuser plate from the top of the camera assembly.
• Unlock the focus ring at the base of the camera body and adjust until sharp focus is
obtained.

Page
100
• Adjust the Camera Body Position within its mounting, to align it square beneath the
calibration plate. The cross-hair on the Camera Set-up area of the plate should line up
with the cross-hair on the video window on the monitor screen.
• Refit the diffuser plate to the camera.
The Camera Offset must now be reset.

Pneumatics System
The main Pneumatics controls are located on a panel at the rear of the machine. A Nitrogen
Dump Valve is also fitted inside the rear enclosure. The system also includes two restrictors;
one for the solder bath diffusers nitro gen supply and one for the pump body air/nitrogen
supply. The Pneumatics panel comprises the Incoming Air and Nitrogen supply regulators and
the Flux Bottle pressure regulator.

Air/Nitrogen Regulators
Removal
• Power down machine, as described on r
• Disconnect the Air/Nitrogen pipes (as appropriate) from the regulator body.
• Remove the screws securing the regulator to the mounting panel and carefully lift the
regulator clear from its mounting.
• Disconnect the regulator from the gauge.

Replacement
The Replacement procedure is the reverse of removal.

Page
101
Nitrogen Dump Valve
The Nitrogen Dump (Exhaust) Valve is located inside the rear enclosure.

Removal
• Power down machine.
• Disconnect the electrical connections from the Nitrogen Dump valve.
• Disconnect the nitrogen pipes from the Nitrogen Dump Valve.
• Remove the screws securing the Nitrogen Dump valve to its mounting.
• Remove the Nitrogen Dump valve.
Replacement
The Replacement procedure is the reverse of removal.

Control Box
CAUTION: ENSURE THAT WHEN WORKING ON THE MACHINE WITH ANY OF
THE PROTECTIVE GUARDS/COVERS REMOVED THAT THE POWER TO THE
MACHINE IS SWITCHED OFF. ALLOW SUFFICIENT TIME FOR THE MACHINE
TO COOL DOWN BEFORE COMING INTO CONTACT WITH ANY OF THE
MACHINE PARTS. WORK SHOULD ONLY BE CARRIED OUT BY SUITABLY
QUALIFIED AND AUTHORISED PERSONNEL.

Removal
• Ensure that all electrical power is removed from the machine.
• Disconnect the air/nitrogen from the machine for added safety.
• Remove the external covers from the machine to gain access to the head control box
assembly.
• Remove the Electronics cover, by removing the two retaining screws and sliding the
cover off.

Page
102
• Disconnect each air and nitrogen pipe, whilst ensuring that a record is made of the
position of each pipe.

• Disconnect each connector from the underside of the Electronic box.

Page
103
• Remove the retaining screws and slide the Electronic box out of the assembly.

• To fit the new Electronics box reverse the steps detailed above.
Note: Care should be taken to ensure that the electrical and pneumatic connections are
correctly made and that no cables or pipes are trapped when sliding the cover back on.

Replacement
• Reassembly is in reverse order. All cables & pipes are clearly marked.

Post Replacement Setup

After fitting the replacement Electronics box it will require configuring to ensure that it has
the correct firmware and drive settings.
• Start PillarFLASH using either the icon on the desktop or from the Start Menu.

Page
104
• Once communications has been established select the Program Flash Memory tab.

• Select the EPROM.IMG file and click on the “Download” button.

• Wait for the data to be transferred; this process should take around 3-5 minutes and will
be confirmed with a “DOWNLOAD COMPLETE” message.
• Select the Program Motor Drives tab.

Page
105
• Select the appropriate machine type from the drop-down list.

• Select Program All to ensure all the correct drive parameters is set for each axis drive
and, if appropriate, the solder pump. This may take 3-5 minutes to complete.
• Select Close to shut the application down.
NOTE: It may also be necessary to re-teach the machine offsets as well as the camera
calibration.

Page
106