Hakko HJ3100 User Manual

instruction manual

REVISION D - MAY 2000

- CONTENTS -

PAGE.

INTRODUCTION. 3.

CHARACTERISTICS AND SPECIFICATIONS. 4.

SAFETY. 5.

THEORY OF OPERATION. 7.

APPLICATIONS. 8.

INSTALLATION. 9.

SETTING UP THE HJ3100. 9.

OPTIONS. 10.

OPERATION. 16.

MAINTENANCE. 17.

TROUBLESHOOTING. 18.

WHERE TO GO FOR SERVICE. 19.

APPENDIX A. PARTS AND ACCESSORIES. 20.

APPENDIX B. TECHNICAL INFORMATION. 22.

OUTLINE DRAWINGS. 22. WIRING DIAGRAMS. 23.

APPENDIX C. WARRANTY INFORMATION. 25.

ILLUSTRATIONS AND DIAGRAMS.

THE HAKKO HJ3100 FRONTISPIECE FIGURE 1. THE HAKKO FILTER SYSTEM. 7. FIGURE 2. REQUIRED CLEARANCES FOR INSTALLATION. 9. FIGURE 3. BASIC HJ3100-02 INSTALLATION. 10. FIGURE 4. ALTERNATE INSTALLATION - TWO PORT COVER. 11. FIGURE 5. ALTERNATE INSTALLATION - ARTICULATED HOSES 12. FIGURE 6. TYPICAL INSTALLATION - FOUR PORT COVER. 13. FIGURE 7. TYPICAL INSTALLATIONS USING RIGID DUCTING. 14. FIGURE 8. TYPICAL INSTALLATION - FOUR ARTICULATED ARMS. 15. FIGURE 9. ILLUSTRATED PARTS BREAKDOWN, HJ3100. 21. FIGURE B-1. OUTLINE DRAWINGS. 22. FIGURE B-2. WIRING DIAGRAMS. 23-24.

TABLES.

TABLE I. SPECIFICATIONS, GENERAL. 4. TABLE II. SPECIFICATIONS, ENVIRONMENTAL. 4. TABLE A-I. ACCESSORIES. 20-21. TABLE A-II. ALSIDENT SYSTEM

®1

ACCESSORIES. 21.

TABLE B-I. WIRING DIAGRAM GUIDE. 23.

1 A registered trademark of Alsident System AS, Hammel, Denmark. See figure 7 and table A-II.

MERICAN HAKKO PRODUCTS, INC. RESERVE THE RIGHT TO CHANGE THE SPECIFICATIONS CONTAINED IN THIS MANUAL

AT THEIR DISCRETION AT ANY TIME

, WITHOUT NOTICE.

For the latest specifications pertaining to the Hakko HJ3100, or any Hakko product, contact your nearest authorized Hakko distributor, your regional Hakko manager, or American Hakko Products’ Customer Service.

Additional copies of this manual or other Hakko literature may be obtained from:

American Hakko Products, Inc. Customer Service 25072, Anza Drive Santa Clarita, California 91355

USA Telephone: (661) 294-0090 Toll free: (800) 884-2556 Facsimile: (661) 294-0096 E-mail: Customer Service: support@hakkousa.com Technical: engineering@hakkousa.com Marketing: marketing@hakousa.com

INTRODUCTION.

Congratulations! You have purchased the most adaptable and efficient small fume extraction system on the market - the Hakko HJ3100. To get the most out of your system, please read this manual thoroughly before installing and operating the HJ3100.

NOTE.

American Hakko Products strongly recommends that especial attention be given the sections

on ‘Safety and Applications’ and ‘Operation’.

THE PURPOSE OF FUME EXTRACTION.

Soldering work involves both metallic and organic compounds. The solders themselves contain, besides tin and lead, various levels of zinc, arsenic, cadmium, antimony and other metals. Fluxes necessary for soldering contain activators to enhance their cleaning properties; these activators are typically organic acids. Such compounds, when heated, release byproducts of incomplete combustion, which in turn can contain noxious fumes, particulate matter, aerosols, and gasses. Prolonged breathing of these contaminants can lead to both short- and long-term operator irritations and illness.

THIS MANUAL.

This manual provides the user with the basic information required to properly use and maintain the Hakko HJ3100 fume extraction system. Spare parts and accessories are described in the Appendix.

THE HAKKO HJ3100.

The Hakko HJ3100 fume extraction unit is designed expressly for use at soldering stations. It extracts the contaminated air directly at the source. This contributes to a healthier and more productive work environment, and assists in achieving recommended health and safety requirements for local exhaust ventilation and contaminant removal.

Salient features of the Hakko HJ3100 include:

A heavy-duty, maintenance-free brushless motor adaptable to either 100/125 or 220/230VAC, 50/60 Hz A three-stage HEPA filtering process One to four station fume extraction capability A wide range of accessories (see Appendix A)

CHARACTERISTICS AND SPECIFICATIONS.

CONTROLS.

The only control for the HJ3100 is a power switch. The motor is equipped with a thermal overload sensor, which will turn power off should the motor temperature exceed 160 to 180

F. Units manufactured after August 15, 1997 (serial numbers HJ3100-7001 and up)

are fitted with circuit breakers as well.

TABLE I. TECHNICAL SUMMARY.

Characteristic

Input voltage

Current, amperes

Power consumption, watts

Motor power rating, hp

Vacuum pump rating, one port, ft3/min

Motor and blower data.

100 v.

115 v._

100 v, 50/60 Hz 115 v, 50/60 Hz 230 v, 50/60 Hz

†

4.25

365

1/5

3.0

350

1/5

100

1.50

350

1/5

100

230 VX

60 Hz

†

With pre-filter and HEPA/carbon filter installed.

Vacuum pump rating, two ports, ft3/min

Vacuum pump rating, one port, ft3/min

Vacuum pump rating, two ports, ft3/min

Fasco 70624794, revn A

†

160

140

260

180

150

280

180

150

280

Noise level at 2 meters: 59 dBA without optional 999-171 muffler

54 dBA with optional 999-171 muffler

Filters:

Pre-filter Per Hakko specification 999-136

HEPA/carbon filter Per Hakko drawing 999-137

Dimensions (all dimensions in inches; see Figure B-1 for outline drawings):

Width 11.00

Depth 9.00

Height 18.00

Weight (approx.) including HEPA/carbon filter 18 lbs.

TABLE II. ENVIRONMENTAL SPECIFICATIONS.

Ambient operating temperature

Storage temperature

Ambient operating humidity

Storage humidity

to 50o C (32o to 122o F.)

-40

to 125o C (-40o to 257o F.)

90% relative humidity maximum (non-condensing)

SAFETY.

For maximum operator and workplace safety, as well as optimum performance, be sure to follow all

safety, application and maintenance instructions and guidelines in this manual. Where material safety data sheets or other relevant information is available regarding the substances and equipment generating the fumes to be extracted, read them carefully and compare the data contained therein with the warnings and limitations in this manual.

DISCLAIMER.

American Hakko Products hereby disclaims all responsibility for any personal injury, property damage, fine, citation, or penalty imposed by any government or private entity resulting from any use, misuse or misapplication of this product; for any failure of the user to regularly maintain the product according to the instructions contained herein; or any failure of the user to adequately monitor fume extraction exhaust air and the ambient workplace air for the presence of harmful levels of gases, fumes and particulates.

COMPLIANCE WITH APPLICABLE ENVIRONMENTAL AND PERSONNEL SAFETY REGULATIONS IS

THE SOLE RESPONSIBILITY OF THE USER.

WARNING.

FAILURE TO COMPLY WITH THE APPLICATION AND MAINTENANCE INSTR UCTIONS, FILTER

REPLACEMENT SCHEDULES, MONITORING RECOMMENDATIONS AND SAFETY GUIDELINES GIVEN IN THIS MANUAL, OR WITH OTHER RELEVANT PRODUCT SAFETY INFORMATION SUCH AS MATERIAL

SAFETY DATA SHEETS PROVIDED WITH THE SUBSTANCES AND EQUIPMENT GENERATING THE FUMES TO BE EXTRACTED MAY RESULT IN RISK OF SERIOUS INJURY, FIRE OR EXPLOSION.

SAFETY GUIDELINES.

WARNING

Fume extraction systems are not to be used as substitutes for personal protective devices such as respirators for removing substances such as carbon monoxide, methane, ethylene, acetylene and other potentially hazardous or noxious gases. Failure to use such personal protective devices may result in serious injury or death. If in doubt, consult your industrial hygienist or American Hakko Products.

For safe and effective performance, American Hakko recommends these guidelines be followed:

1. HEPA filters - hazardous particulate matter

The filter used in the Hakko HJ3100 is certified to be a 'hospital grade' HEPA-type filter

. HEPA (High Efficiency Particulate Air) filters will become loaded with particulates during normal operation. It must be replaced at regular intervals to ensure proper operation. The level of use, and the amount and composition of the contaminates peculiar to a given application, will dictate the frequency of replacement. As the filter becomes loaded, air-flow through the system will be reduced; this will eventually become noticeable to operators at the several stations being serviced.

The exhaust air from the Hakko HJ3100 and the ambient air in the workplace should be monitored, using appropriate and adequate measuring and detection devices, to guarantee compliance with applicable OSHA and NIOSH regulations.

2. Particle filters. American Hakko offers a cellulose particle filter as an option for the HJ3100. This filter is intended for use in grinding and shaping operations where dust and chips are produced. It is rated at 85% ASHRAE against particles of 1 micron and larger in size. The particle filter can be cleaned and reused up to five times; the preferred method of cleaning is to vacuum out the detritus with an industrial vacuum cleaner. It is possible to clean the filter with water or compressed air. If that is the method of choice, take extreme care lest the debris find its way into the operator's eyes or the local aquifer.

2 Hospital grade filters have efficiencies greater than 95% per MIL-STD-282.

3. Activated carbon filters. The standard filter used in the Hakko HJ3100 contains an activated carbon element built into the filter. It, too, will become saturated with adsorbed contaminants. The activated carbon portion of the main filter unit is designed to last the life of the main HEPA filter; however, if the fumes being extracted are other than soldering flux fumes, measuring the exhaust air for the presence of such contaminants will indicate when this portion of the filter is depleted.

Hakko also offers an activated carbon filter cartridge, part number 999-182, for applications where odor removal is the prime consideration. This filter should be used with a pre-filter, to keep particles out of the main filter.

Both carbon filters have an adsorption rating of 80-85%.

4. Pre-filters. The pre-filter is a treated fiberglass pad, rated at 86% arrestance. It removes coarse particles from the intake air. Because it traps these particles before they can reach the main HEPA/carbon filter, it will become clogged far more rapidly. It will require more frequent replacement than will the main filter; its useful life depends upon use and the nature of contaminants being removed.

5. Flammable vapors and gases. If flammable vapors or gases (e. g. isopropyl alcohol used for cleaning) are present in the workplace air, even in small concentrations, they will be adsorbed by the filters. The user has the responsibility of ensuring that such vapors or gases do not constitute a personnel hazard.

-DANGER!-

NEVER USE THE HAKKO HJ3100 TO EXTRACT FUMES FROM HIGHLY FLAMMABLE LIQUIDS AND GASES!

THERE IS A SERIOUS RISK OF SEVERE INJURY OR DEATH DUE TO EXPLOSION OR FIRE.

Certain airborne contaminants, when in contact with activated carbon, can undergo chemical reactions resulting in heat. The Hakko

HJ3100 MUST NOT be used to extract fumes from these substances.

6. Disposing of used filters. All used filters must be handled with care. They may contain hazardous substances such as lead, flux residue, asbestos, organic compounds, or airborne pollutants extracted from the ambient air. Always use appropriate personal protection equipment (protective gloves, respirators, and the like) when handling used filters, and dispose of them in plastic containment bags. Local regulations will dictate the means of disposal.

Filters containing potentially hazardous substances must be handled with extreme caution. Use the material safety data sheet(s) pertinent to the substance(s) and dispose of such filters per instructions from your local environmental authority.

THEORY OF OPERATION.

The HJ3100 is a high-mass flow, low-vacuum system, which means that it depends upon air flow across the work area for effective fume extraction. Contaminated air is captured from the workplace surrounding the soldering station by the hood or hoods, and transferred to the HJ3100 by flexible or rigid ducts. Within the HJ3100, two filters, comprising three stages of filtering, remove the contaminants from the air. The purified air is then returned to the area where the HJ3100 is located.

Because the HJ3100 depends upon mass flow for its operation, free flow of air must be guaranteed between the station where fumes are to be extracted and the main filter unit. The maximum length of flexible duct recommended for greatest efficiency is 25 feet of unimpeded 3" duct. The maximum length of rigid duct is not significant, as this duct does not materially restrict air flow.

ILTERING.

There are three stages of filtering (Figure 1, below, illustrates the Hakko filtering process):

The pre-filter is made of a treated polyester material. It removes coarse particles, such as dust, that may be suspended in the air,

and thus extends the service life of the HEPA filter. Particles as small as 30 microns diameter are trapped by the pre-filter. It should be checked at least once a week, and replaced when clogged. Under normal conditions

this will be every two to three

weeks.

The main HEPA/carbon filter purifies the air in two ways:

•= The HEPA filter consists of a pleated fiberglass paper medium, thus providing the greatest amount of surface area within the volume of the filter case. It is rated as a 'hospital grade HEPA filter' - greater than 98% efficiency per the DOP test - and removes particles as small as 0.3 micron.

•= The activated carbon filter adsorbs gases and odors from the filtered air. Adsorption efficiency is 80%.

•= This filter should be changed every four months or 640 hours of use, whichever comes first.

 The carbon filter adsorbs gases and odors from the filtered air at an adsorption efficiency of 84%. It has a much larger surface area than the carbon portion of the standard HEPA/carbon filter, hence a longer life. It should always be used with a prefilter to preclude being clogged by particulate matter.

incoming

air

incoming

air

incoming

air

pre-filter

exhaust

air

HEPA/carbon

filter

activated

carbon

exhaust

air

activated

carbon

filter

exhaust

air

pre-filter

(optional)

cellulose

filter

Figure 1a

The standard Hakko filter.

The Hakko activated carbon filter

Figure 1b

Figure 1c

The Hakko particulate filter.

3 Normal conditions’ - Defined as single-shift operation, eight hours per day, five days per week.

APPLICATIONS.

SOLDERING STATION FUME EXTRACTION.

The Hakko HJ3100 is specially engineered to remove particulate and gaseous contaminants from soldering work stations. As many as four stations may be serviced by one HJ3100, depending upon the accessories selected. The HJ3100 is a high-mass flow, low-vacuum system, which means that it uses air flow across the work area for effective fume extraction. The user may choose from the following options, or mix them at need:

Bench hoods (‘plenums’) for work on printed circuit boards. Both large and small hoods are available. Supported or free-standing hoods and nozzles for solder pots or small flow systems. These devices may be mounted on either stiff or

flexible ducting. Several types of support hardware and ducting are offered.

Articulated arms for work where flexibility is desired.

Refer to the section on ‘Setup’ for some typical layouts. Appendix A contains descriptions of the accessories available for different applications.

PARTICULATE EXTRACTION FROM MACHINING OPERATIONS.

The Hakko HJ3100 can be used to remove fine particles and dust from machining and grinding operations, provided that these particles and dust do not contain, or are not coated by, flammable or corrosive materials. The pre-filter must be checked more frequently when the HJ3100 is so used.

+ 19 hidden pages