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BATTERY POWERED HEAT GUN ASSEMBLY

1. 6 2 6 4 USE OF THE BB 390B U BATTERIES IN THE MCH 100 A 6 2 6 5 BATTERY TROUBLESHOOTING 6 4 6 5 2 CORREGTIVE ACTION eost oye A hh eee eb E DES 6 6 6 6 RECONDITION BATTERY 6 7 6 7 DISCHARGE PROCEDURE USING THE HEAT GUN 6 7 6 8 DISCHARGE PROCEDURE USING THE SELF DISCHARGE CAP 6 7 6 9 STATE OF CHARGE SOC BATTERY DISPLAYS 6 9 6 10 TESTING SPECIFICATIONS 6 9 6 11 REPAIR OF BB 390 BATTERIES 6 10 6 12 BB 390 TECHNICAL SPECIFICATIONS 6 10 CHAPTER 7 WARRANTY INFORMATION 7 1 MCH 100 A HOT AIR TOOL 7 1 7 2 BB 390 BATTERY WARRANTY 7 2 7 3 BATTERY CHARGER BB 390B U WARRANTY 7 2 SERVICE FORMS iia 7 2 MCH 100 A REV 7 15 MAY 2013 WARNING HOT AIR TOOL CAN PRESENT A FIRE AND EXPLOSION HAZARD The hot air tool must be used in a ventilated area The internal heating element and built in fan motor may present a hazard when exposed to certain flammable vapors associated with for example gasoline methane jet fuel and propane WARNING HOT AIR TOOL IS SHIELDED FROM ELECTROMAGNETIC EMISSIONS
2. Operating Temp Range Storage Temp Range Case Material Case ShIpImielltsc sas oho ord ecd 850036 1 REV E 13 73 inches 348 8 mm W x 10 28 inches 261 mm D x 7 65 inches 194 4 mm H 13 Ibs 5 9 kg Automatic Selection 90 to 260 VAC single phase 47 to 440 Hz 22 to 33 VDC 13A 11 to 18 VDC 20A BT C 70819 3 Only Automatically selected for each battery type Continuous Resettable circuit breakers AC 3A 28 VDC 13A 12 VDC 20A 4 F 20 C to 122 F 50 C 40 F 40 C to 158 F 70 C Solid Polypropylene Olive Drab 34088 per Fed Std 595B No restrictions 1 2 INTRODUCTION 1 3 DECLARATION OF CONFORMIT Y Ceriel to ta Bren Tronics Inc Intelligent Military Batteries amp Charging Systems Phone 631 489 5155 Fax 831 499 5504 E mail salesgbren tronics com Web site www bren Ironics com PSO 9001 2008 with design cuni ASO TOOT DECLARATION OF CONFORMITY EU Low Voltage Directive and EMC Directive Bren Tronics Inc located al the Commack NY USA address shown above certifies and declares under our sole responsibility thal the following apparatus Soldier Portable Charger Lite SPC Lite BTC 70819 series of charger conforms with the essential requirements of European Community Council Directive 2004 108 EC based on Ine following sp
3. BTC 70819 Universal Battery Charger Components BTC 70819 PC PAGZZ Battery Charger Power Cable MCH 100 A REV 7 15 MAY 2013 Figure 4 1 MCH 100 A Components Figure 4 2 Assembly Components 4 3 MCH 100 A REV 7 15 MAY 2013 4 3 ACCESSORIES FOR THE MCH 100 A 4 3 Over 500 nozzle accessories are available for the MCH 100 A Heat Gun including soldering and de soldering nozzles for SMD components speed welding tips for plastic welding and overlap welding tips for tent and tarp welding See Table 4 4 4 3 2 Higher power heating elements are available at 350w and 400w 4 3 3 Additional battery powered accessories such as the MCH 116 Soldering Iron MCH 100 HMD Hot Melt Iron MCH 100 HB Hot Bonder are available and can be designed for different applications TABLE 4 4 Part Number Sieve reflector nozzle for solder and shrink sleeves 111 476 Bayonet coupling to match 111 038 1 Heat Gun Fitting included with the MCH 100 A Assembly Spoon reflector nozzle for solder and shrink sleeves 112 028 Bayonet coupling to match 111 038 1 Heat Gun Fitting included with the MCH 100 A Assembly Sieve reflector nozzle for solder and shrink sleeves Six inch long extension nozzle with sieve reflector and bayonet 111 474 coupling to match 111 038 1 Heat Gun Fitting included with the MCH 100 A Assembly MCH 100 A REV 7 15 MAY 2013 Spoon reflector 20 mm for soldering shrink sleeves and mo
4. 207 HIGHT POINT AVE UNIT 7B PORTSMOUTH RI 02871 LA a Sy tf i Tt l OPERATION AND SERVICE MANUAL SPC LITE Universal Portable Charger Dual Position BTC 70819 NSN 6130 01 555 7817 Bren Tronic Inc Intelligent Military Batteries amp Charging System 10 Brayton Court Commack NY 11725 3197 USA Tel 631 499 5155 Fax 631 499 5504 email address sales bren tronics com www bren tronics com 850036 1 REV E WARNING HIGH VOLTAGES ARE PRESENT IN THE OPERATION OF THIS EQUIPMENT Avoid contact with AC supply voltage connections during installation operation or maintenance of the battery charger CAUTION ACID CONTAMINATES NICKEL CADMIUM LITHIUM ION LITHIUM POLYMER and NICKEL METAL HYDRIDE BATTERIES Every effort must be made to keep Nickel Cadmium Lithium lon Lithium Polymer and Nickel Metal Hydride batteries as far away as possible from Lead Acid batteries because Lead Acid batteries contain sulfuric acid Do Not use the same tools and materials such as screwdrivers wrenches syringes hydrometers and gloves for both types of batteries Any trace of acid or acid fumes will permanently damage Nickel Cadmium Lithium Ion Lithium Polymer and Nickel Metal Hydride batteries on contact WARNING NO SMOKING IS PERMITTED NEAR THE CHARGING STATION Batteries can produce explosive gases
5. E BB 3908 U TERY RECHARGE ui SEALED MA VOLTS 4 9 AMP HOURS NSN 6140 01 490 43 N BT 70790 6 1 SCOPE 6 1 1 The BB 390B U PN BT 70790 48v NiMH Rechargeable Battery is a state of the art high performance battery manufactured by Bren Tronics This battery is typically used in applications such as Communications Chemical CLU Computer Robotics and various other applications requiring battery power including powering devices such as SINCGARS amp ATCS AN PRC 104 117 119 FALCON AN PRC 138 117 KY 57 MXF430 V AN PSC 5 M22 JAVELIN LRAS and various other battery powered equipment The BT 70790 rechargeable battery was designed for the U S Department of Defense and its friendly allied nations and is manufactured in accordance with U S military specifications MIL PRF 32052 1 and ISO 9000 requirements 6 2 FEATURES High reliability due to all welded construction Durable high impact plastic housing and connector enclosure Gold Plated brass contacts for extended electrical hookup without corrosion State of charge display with LCD readout Protection against possible cell reversal Rechargeable up to 500 cycles depending on use and shelf life up to five years Improper charging prevented by built in temperature sensors Automatically displays remaining capacity of battery Precise discharge and low voltage control with patented safety circuit Power to the heat gun will automatically shut off when voltage dro
6. Figure 2 10 Heat Gun and Power Supply in Carry Case 2 4 SETUP PROCEDURES 2 4 1 As required push fit twist and lock appropriate nozzle 7 Figure 2 3 onto the heat gun Many air nozzles are available for various hot air applications like shrink tubes soldering and plastic welding 2 4 2 Aclip is provided on the tool for Electrostatic Discharge or ESD If you are using the tool on printed circuit boards where static discharge may cause damage to the electronics then you will need to earth the tool via the ESD lead connection located on the hot air tool 8 Figure 2 3 2 4 3 Switch on the power at the power pack Figure 2 1 2 4 4 Switch on the power at the hot air tool 2 Figure 2 4 and allow to warm up for about one minute prior to use 2 4 MCH 100 A REV 7 15 MAY 2013 2 5 CHANGE OF HOT AIR NOZZLES HOT AIR TOOL CAN CAUSE BURNS Every effort should be made to avoid contact with the hot air tool stainless steel heating element cover and attached nozzles during operation because this part of the tool becomes very hot and can cause burns Do not point the hot air flow in the direction of people or animals 2 5 1 To remove nozzle twist and pull away from the heating element cover 2 5 1 1 prevent burns while changing nozzles the tool should be allowed to cool down by turning off the heat using the switch on the heat gun 2 Figure 2 4 The fan should be kept running to cool the nozzle down If a hot nozzle
7. 1 1 2 The MCH 100 A Kit consists of J J JQTY Descipion Figure with a 300 watt element 24 volt NiMh Rechargeable Battery BB 390 B U 112 028 1 Spoon Sieve Reflector Figure 1 7 Nozzle BTF 70791 Battery Discharge Cap Figure 1 8 BTA 70834 Battery Adapter Plate Figure 1 9 MCH 110 Field Carry Case Figure 1 10 MCH 100 AM 1 Printed manual and Digital No Photo CD Copy MCH 100 A REV 7 15 MAY 2013 Figure 1 2 Heat Gun Figure 1 3 48DCV Power Supply 111 038 1 MCH 102NW Figure 1 4 BB 390 B U Battery Figure 1 5 Universal Portable BT 70790 Battery Charger BTC 70819 Figure 1 6 Sieve Reflector Nozzle 111 476 Figure 1 7 Spoon Reflector Nozzle 112 028 1 2 MCH 100 A REV 7 15 MAY 2013 Figure 1 8 Battery Discharge Cap Figure 1 9 Battery Adapter Plate BTF 70791 BTA 70834 Figure 1 10 Field Carry Case MCH 110 1 3 MCH 100 A REV 7 15 MAY 2013 1 2 1 2 1 1 4 1 4 1 HEAT GUN 111 038 1 The 111 038 1 Heat Gun Figure 1 2 consists of a 300 watt ceramic resistance two prong plug in type interchangeable heating element protected by a mica insulation tube and a 25 watt carbon brushed electric motor fan that provides air flow Heat Gun achieves operating temperatures within 30 seconds of operation A built in ON OFF switch within the hot air tool allows the operator to turn the heating element on and off as needed Changing various wattage heating elements and twist l
8. 2 11 1 2 Operation in Desert Climates Temperature extremes of 122 F 50 C and dryness associated with desert environment will not affect equipment usage However the built in thermal safety switch inside the batteries will automatically shut the power off if the interior battery temperatures reach 158 F 70 C 2 11 1 2 1 order to prevent thermal shutdown turn off the hot air tool once your work is complete Try to avoid running the tool longer than 10 minutes at one time 2 11 1 2 2 Dust storms associated with desert climates may cause poor electrical connections and prevent proper operation When operating in these conditions the filter on the back of the hot air tool should be kept clean by periodically brushing as it gets blocked 2 11 1 2 3 Charging batteries in hot desert environment may take two charge cycles 2 11 1 3 Operations in Salt Spray Keep equipment clean and dry at all times and immediately wipe salt spray from exposed surfaces cables and connectors 2 11 1 3 1 When not in use be sure that cover is fully latched and the hot air tool is stored in the storage bag with the bag flaps in place Any questions regarding operation maintenance repairs parts and accessories can be directed to Malcom Technologies through our toll free number from the USA at 800 289 7505 or from other parts of the world by calling 401 683 3199 We also have a web site at www malcom com where you can place orders and email us
9. MCH 100 A REV 7 15 MAY 2013 6 9 STATE OF CHARGE SOC BATTERY DISPLAYS The batteries are equipped with State of Charge displays that indicate the battery charge status using a five segment LCD readout segments otate of Charge 0 0 fully discharged 1 0 to 24 2 24 to 42 3 42 to 6596 4 65 to 92 D 92 to 100 fully charged NOTE 1 Batteries have two State of Charge SOC Indicators Both indicators have to be 100 for the battery to be 100 NOTE 2 If batteries have been recharged but State of Charge SOC indicators show less the 100 then the LCD readouts must be recalibrated as outlined in Section 6 6 of this manual OOO LILILISS X Ml Ml Ml Ml L 111 100 100 100 42 65 65 92 92 100 Figure 0 2 State of Charge Battery Display 6 10 TESTING SPECIFICATIONS 6 10 1 The BB 390B U has been tested to MIL PRF 32052 1 6 9 MCH 100 A REV 7 15 MAY 2013 6 11 REPAIR OF BB 390 BATTERIES 6 10 1 BB 390 batteries are not repairable If a fault occurs the battery must be replaced Dispose of faulty battery according to local environmental regulations 6 12 BB 390 TECHNICAL SPECIFICATIONS Description Rechargeable Nickel Metal Hydride with State of Charge Display National Stock Number 6140 01 490 4317 For Use In AN PRC 104 AN PRC 117F AN PRC 119 SINCGARS amp KY 57 Radios Heplacement for BB 390A U BB 590 U BA 5590 U BB 490 U BB 690 U Nominal Dimensions L
10. AND ENVIRONMENTAL EFFECTS The hot air tool is manufactured to meet certain EMI requirements as specified by the US Military Tampering with the electromagnetic EMI shield or not following repair instructions outlined in the technical manual may affect the integrity of the EMI shield and result in radiated emissions coming from the tool above the approved limits WARNING HIGH VOLTAGES ARE PRESENT IN THE OPERATION OF THIS EQUIPMENT Avoid contact with the DC and AC supply voltage connections during installation operation or maintenance of the MCH 100 A and its battery charging system Disconnect the batteries before opening the tool WARNING NO SMOKING IS PERMITTED NEAR THE CHARGING STATION AND AIR TOOL Batteries can produce explosive gases during charging or discharge cycles Never smoke or allow open flames near the charging station or the hot air tool while they are in use MCH 100 A REV 7 15 MAY 2013 HOT AIR TOOL CAN CAUSE BURNS Every effort should be made to avoid contact with the hot air tool stainless steel heating element cover and nozzles during operation because this part of the tool becomes very hot and can cause burns Do not point the hot air flow in the direction of people or animals ACID CONTAMINATES NICKEL METAL HYDRIDE BATTERIES Every effort must be made to keep Nickel Metal Hydride batteries as far away as possible from lead acid batteries because lead acid batteries contain sulfuric acid Do not
11. T Fault LED Red 13 Adapter Port 3 Power On Indicator LED Green e oa roa A ge Er eT OSO WI 3 4 Low Vehicle Power LED Red 5 Temp Fault LED Amber amp Blackout Switch FIGURE 2 1 1 17 Pressure Equalization Valve E gt A FIGURE 2 1 2 850036 1 REV E 2 1 Item 1 On Off Switch 2 AC Circuit Breaker 3 Power On Indicator LED Green 4 Low Vehicle Power LED 5 Temp Fault LED Amber 6 Blackout Switch 7 DC Circuit Breakers 8 Charge LED Amber 9 Ready LED Green 850036 1 REV E OPERATION Function Turns battery charger on or off Turns power to the charger off in an overload condition Remove the overload condition and push to reset The Power On Indicator LED lights when the charger has sufficient power from either AC or DC The Low Vehicle power indicator lights when external DC power is too low to charge batteries The charger will stop charging batteries until sufficient power is available from the DC course The Temperature Fault indicator lights when charger temperature is too high 50 C or too low 20 C The charger will stop charging batteries Enables Disables Blackout Mode Pressing it once turns off all panel LEDs Pressing it again turns on all panel LEDs Holding down the button during turn
12. Troubleshooting 2 8 2 9 Upgrade Update Information 3 7 3 5 850036 1 REV E INTRODUCTION CHAPTER 1 INTRODUCTION 1 1 SCOPE The Soldier Portable Charger Lite P N BTC 70819 is a state of the art high performance lightweight portable battery charger designed for field deployment or shop usage It provides fast reactivation of various rechargeable batteries It is capable of simultaneously charging two batteries completely unattended The Soldier Portable Charger Lite SPC Lite is simple to use by design Without any user intervention the SPC Lite typically charges two batteries The charge time for a fully discharged BB 2590 U or BB 390B U is less than 3 5 hours The Charge times are substantially less for partially discharged batteries The charger automatically identifies the specific battery type and provides the appropriate charge profile Based on the current operating environment the SPC Lite automatically customizes the charge profile to provide the quickest charge in a safe manner The charge status for the two batteries is conveyed to the user via three easy to understand panel mounted LED indicators amber CHARGE green READY and red FAULT The SPC Lite is universal by design It can readily use either AC or DC input power whichever is most convenient for the user The universal AC input fully allows 90 264 VAC and 47 440 Hz operation without any adjustment or user intervention Additionally
13. and the accessories that were ordered with the tool Check the itemized packing list and or Chapter 1 against what was delivered to be sure that every item was received Save the packaging in a dry storage area should you need to transport this tool to another location Pressure release valves are installed on the power pack and charging case to equalize pressure where an imbalance may have occurred during transportation The valve on the MCH 102NW 48VDC Power Supply is a push button type equalizer simply push the black button to equalize the pressure The pressure equalizer on the BTC 70819 Battery Charger is a black twist valve located below the handle CONNECTION OF BATTERY TO THE HEAT GUN Batteries must be fully charged before it is used with the heat gun See Chapter 5 for instructions on charging the batteries Open battery case on a flat surface Figure 2 5 Install the battery connector by push fitting it onto the two batteries as shown in Figure 2 6 and 2 7 Push fit the batteries together with the connector into the case as shown in Figure 2 8 Tuck power cord between battery side and case as shown in Figure 2 8 Close the lid and secure the latches Figure 2 9 Install the power pack case into the carry case if provided Figure 2 12 Figure 2 7 Battery Converter Enclosure Figure 2 6 Batteries 2 3 MCH 100 A REV 7 15 MAY 2013 Figure 2 8 Batteries Inserted Figure 2 9 Heat Gun and Power Supply
14. display the battery condition NOTE After removing a battery from the charger wait for the corresponding battery status LED s to turn off before installing a new battery 850036 1 REV E 1 7 INTRODUCTION 1 6 UPDATING CHARGER SOFTWARE The software in the charger is field upgradeable By loading new software into the charger it is possible to alter its operation and add or change the charging profiles for the batteries Loading new software into the charger is accomplished via the use of a standard RS232 interface of a personal computer PC running Windows 95 or higher Utilizing special software running on the PC in conjunction with the boot program resident within the charger a two way communication link is established and the revised operational parameters and battery charge profiles can be loaded into the charger opecific instructions for upgrading the Charger software are provided with the software upgrades 850036 1 REV E 1 8 OPERATION SECTION 2 OPERATING PROCEDURES 2 1 PANEL CONTROLS AND INDICATORS Battery charger panel components are described below and shown in Figure 2 1 1 and 2 1 2 7 DC Circuit Breaker 2 AC Circuit Breaker 12 DC Input Connector AS i Y JA JAM XL X S B Charge LED Amber 11 AC Input Connector 15 Recondilion LED Amber 16 R5 232 Port Cover mt et o ar 2 T mmm 1 E A E 9 Ready LED Green 14 Recondition Switch
15. during charging or discharge cycles Never smoke or allow open flames near the charging station Table of Contents CHAPTER 1 INTRODUCTION Para Pg Para Pg cire 1 1 1 1 Operation in Extreme Environmental Technical Specifications 1 2 1 2 CONTO Susini 2 9 2 1 Declaration of Conformity 1 3 1 3 Preparation for Movement 2 10 2 1 ACCESSOS vicus ernie erie ates 14 1 4 Battery State of Charge Displays 2 11 2 1 Charge Cycle Description 1 5 1 7 Battery Capacity Retention 2 12 2 1 Updating Charger Software 1 6 1 8 Battery Storage 2 13 2 1 CHAPTER 2 OPERATING PROCEDURES CHAPTER 3 MAINTENANCE INSTRUCTIONS Panel Controls and Indicators 2 1 x1 ANTOAUCUON 3 1 3 1 Preliminary Setup Procedures 2 2 224 CIC ANING Re Us nas 3 2 3 1 Charging A 3 3 3 1 Battery Revitalization and De Storage 2 4 2 6 Basic Functional Test 3 4 3 2 Black Uva a 2 5 2 7 Simplified Operator Battery Charger Labels 2 6 2 8 Troubleshooting Procedures 3 5 3 3 oolid Red Fault LED Troubleshooting 2 2 9 Warranty Repair Information 3 6 3 5 Flashing Red Fault LED
16. full State of Charge SOC readings and providing 13 25 volts or better at pins 1 4 and 2 5 after a charge there may be internal damage to one of the cells or the printed circuit board that will prevent normal use in either or both 12 volt sections 2 One of the internal cells may be asleep and needs to be conditioned 6 5 2 CORRECTIVE ACTION 1 Check each BB 390 with the Self Discharge Device CAP PP 8497 U shown in Section 6 7 of this manual which places a load and provides a quick check on each 12 volt section of the BB 390 6 5 2 1 BB 390 Quick Check Instructions Using the Self Discharge Device CAP PP 8497 U 1 Ensure the BB 390 has been charged in the last 60 days If not then charge the battery 2 Place Self Discharge Device CAP on the BB 390 a If both LED s light green your battery is OK Both 12 volt sections are discharging properly Remove CAP and go on to next battery b If one or both LED s do not light green then the BB 390 requires reconditioning or is damaged See Section 6 6 NOTE Ensure Self Discharge Device CAP is working with known good battery when you first use device If the battery fails just after a charge wait one hour for the battery low temp cut off to reset and then retest with cap Condition Batteries Batteries must be completely discharged before they are charged again It is recommended that you do this twice There are two ways to discharge the BB 390 battery outline
17. in Chapter 2 of this manual 3 6 WIRING DIAGRAM MOTOR ON OFF SWITCH QUICK DISCONNECT BLOWER MOTOR SHIELDED POWER CORD HEATER ON PFF SWITCH 42VDC BATTERY PACK 24VDC HEATING ELEMENT d QUICK DISCONNECT PLUG MALE AND FEMALE Figure 3 3 Wiring Diagram Any questions regarding operation maintenance repairs parts and accessories can be directed to Malcom Technologies through our toll free number from the USA at 800 289 7505 or from other parts of the world by calling 401 683 3199 We also have a web site at www malcom com where you can place orders and email us with questions at any time Email address jono bixby malcom com 3 20 MCH 100 A REV 7 15 MAY 2013 4 1 4 1 1 4 2 4 2 1 4 2 2 4 2 3 4 2 4 4 2 5 CHAPTER 4 MCH 100 A Spare Parts INTRODUCTION This chapter lists and illustrates authorized repair parts required for maintenance and repair of the MCH 100 A Battery Powered Heat Gun Assembly The four most commonly replaced MCH 100 A components and recommended spare parts for the repair shop are spare Heat Guns 111 038 1 Heat Gun Heating Elements 111 182 Power Supply Power Cords MCH 103 2 and NiMH BB 390 BU Rechargeable Batteries BT 70790 Table 4 3 provides a list of additional available replacement parts for the MCH 100 A EXPLANATION OF COLUMNS Table 4 3 includes the following information ITEM NO Indicates the number used to identify
18. items called out in Figures 4 1 and 4 2 PART NO Indicates the Malcom Part Number which controls the design and characteristics of the item DESCRIPTION Provides a brief description of the referenced part QUANTITY Indicates the quantity of the item used in the MCH 100 A 4 1 MCH 100 A REV 7 15 MAY 2013 4 2 1 TABLE 4 2 SPARE PARTS LIST Item No Part No SM amp R Code Description Quantity MCH 100 A Components 111 038 1 PAOGG Heat Gun MCH 102NW PAGZZ 48VDC Power Supply MCH 110 PAGZZ Carry Case BTA 70834 PAOZZ Battery Charger Adapter BT 70790 PAOZA BB 390 BU 24 volt rechargeable battery NiMH BTC 70819 PAOZA Universal Battery Charger BTF 70791 PAOZA Battery Discharge Caps 111 476 Sieve Reflector Nozzle 112 028 Spoon Reflector Nozzle 111 038 1 Heat Gun Components 111 182 PAGZZ Heating Element 42V 300W MCH 114 PAGZZ Heat Gun Power Cord 100 811 PAGZZ Commercial screw Heat Gun Handle M3x 5x6mm Commercial screw Element Cover M3x 5x8mm Mica tube separation distance ring 100 817 PAGZZ 100 819 PAGZZ 100 802 PAGZZ 100 816 100 775 100 808 100 807 9d 22 02 107 227 PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ Commercial screw Power Cord Clamp M3x 5x8mm Commercial washer Power Cord Clamp M3 Power Cord Clamp plastic Cable Restraint rubber Heat Gun Element Cover bayonet type Ground clip MCH 102NW 48VDC Power Supply Components MCH 103 2 PAGZZ Power Supply Power Cord
19. of up to five years Intrinsic overheating and improper charging prevention is controlled with a built in temperature sensor system Precise discharge and low voltage control is featured with a patented safety circuit to protect the batteries and overall system NOTE The BB 390B U Nickel Metal Hydride battery is the only battery that is approved for use with the MCH 102NW Power Supply 1 4 MCH 100 A REV 7 15 MAY 2013 159 1 5 1 1 5 2 1 5 3 1 6 1 6 1 UNIVERSAL PORTABLE BATTERY CHARGER BTC 70819 The BTC 70819 Universal Portable Battery Charger is an intelligent high performance portable battery charging system that will reactivate two 24 Volt BB 390 B U Rechargeable Nickel Metal Hydride batteries in approximately two hours The battery charger is housed in an impact resistant molded equipment case that is completely watertight when the cover is latched securely and the pressure equalizer relief valve on the bottom of the case is closed The charging system is capable of charging many battery types The appropriate battery adapter for the supplied BB 390 B U batteries is included in the MCH 100 A Kit and serves as the electrical interface between the batteries being charged and the charger circuits Two automatic cycles occur during a typical battery charge 1 a fast rate charge cycle and 2 a low current trickle charge which maintains the battery until it is removed LED Light Indicators provide moment t
20. seizing compound like Loctite Blue Part No 24200 when reinstalling the Handle Screws 4 SS 7 Figure 3 19 High Temperature Figure 3 20 Wrap shield around Figure 3 21 Handle Key Fit Insulation Tape and Heat Gun internal components and replace on Heat Gun EMI Shield Placement handle 3 16 MCH 100 A REV 7 15 MAY 2013 3 4 48 VDC POWER SUPPLY MAINTENANCE INSTRUCTIONS 3 4 1 REMOVE POWER SUPPLY POWER CORD 3 4 1 1 3 4 1 1 1 3 4 1 2 3 4 1 3 3 4 1 4 3 4 1 5 3 4 1 6 3 4 1 7 3 4 1 8 Open the MCH 102NW Battery Power Supply Case and remove the failed MCH 103 2 Output Wire Harness ON OFF switch from the MCH 102NW by loosening the ON OFF Switch External Locking Nut oave the ON OFF Switch Rubber Boot and ON OFF Plate to use when installing the replacement Output Wire Harness Inside the Power Supply Case remove the failed Output Wire Harness Grounding Wire from the Power Supply Handle Screw Cut the failed Output Wire Harness Power Cable near the base of the Failed NC3FX HD Quick Disconnect Female Connector Loosen the Power Supply Case Power Cord Feed through Restraining Clamp and pull the failed Power Cord through Positively identify the failed Power Cord as failed and discard or segregate from other replacement parts REPLACE POWER SUPPLY POWER CORD PN MCH 103 2 Feed the prepped cable end of the MCH 103 2 Output Wire Harness Figure 3 21 through the inside of the Pow
21. thermal protection or low voltage shuts the tool down This is a protective circuit built into the battery pack The battery will then require a cooling down period and normal recharge on the standard military PP 8444A U Universal Battery Charger with the BB 390 adapter plate MCH 100 A REV 7 15 MAY 2013 6 In a very hot operating environment run time of the heat gun may be less Protect the Power Pack from extremes of ambient temperatures Sitting on the tarmac in a desert sun will preheat the BB 390s and shorten the run time of the heat gun Batteries should be cooled to room temperature before they are recharged and the batteries should be cooled to room temperature after charging is complete before using the MCH 100 A NOTE The BB 390 battery is the only battery that has been approved to be used with the MCH 100 A Heat gun The PP 8444A U Charger manufactured by Bren Tronics is the only charger that can be used to recharge the BB 390 batteries 6 5 BATTERY TROUBLESHOOTING 6 5 1 When should the batteries be replaced Batteries are fully charged when a voltmeter shows 13 25 volts or greater If the voltage in any of the sections is less than 13 25 volts after being charged then the battery needs to be placed on the charger again If after the second charge cycle they do not show 13 25 volts then the batteries must be discarded and replaced with a new battery NOTE The PP 8497 U BB 390 self discharg
22. use the same tools and material such as screwdrivers wrenches syringes hydrometers and gloves for both types of batteries Any trace of acid or acid fumes will permanently damage Nickel Metal Hydride batteries on contact COPYRIGHT STATEMENT The manufacturer MALCOM Company Inc of Portsmouth Rhode Island grants the United States Government the right to reproduce update or otherwise change the contents of this Technical Manual for Government or their contractors use only Any questions regarding operation maintenance repairs parts and accessories can be directed to Malcom Company through our toll free number from the USA at 800 289 7505 or from other parts of the world by calling 401 683 3199 We also have a web site at www malcom com where you can place orders and email us with questions at any time MCH 100 A REV 7 15 MAY 2013 CHAPTER 1 Introduction Figure 1 1 Battery Powered Heat Gun Kit MCH 100 A 1 1 SCOPE 1 1 1 The MCH 100 A Battery Powered Heat Gun Kit manufactured by Malcom Technologies is an intelligent maneuverable adaptable and self sufficient sustainment repair tool designed for field deployment or shop usage in applications such as contact less soldering and de soldering heat shrink recovery plastic welding drying deicing and other hot air applications Additional accessories can be attached for contact soldering composite curing and for applications requiring a custom design tool
23. 13 3 3 13 REPLACE POWER CORD CLAMP PN 100 808 and 100 775 3 3 13 1 Remove the Handle as directed in Section 3 3 8 3 3 13 2 Remove the yellow High Temperature Kapton Insulation Tape that covers the Heat Gun Power Cord Lead Screws and Clamp 3 3 13 3 Remove the screws and Power Cord Clamp Washers PN 100 775 from the Power Cord Clamp PN 100 808 Figure 3 17 3 3 13 4 Remove the Power Cord Clamp from the Heat Gun 3 3 13 5 Replace the Power Cord Clamp PN 100 808 Power Cord Clamp Washers PN 100 775 and Power Cord Clamp Screws Figure 3 18 3 3 13 6 Replace the Handle as directed in Section 3 3 14 Figure 3 17 Power Cord Clamp Figure 3 18 Power Cord Clamp Screws Screws Washers and Clamp 3 15 MCH 100 A REV 7 15 MAY 2013 3 3 14 REPLACE HEAT GUN HANDLE 3 3 14 1 Wrap internal components in new High Temperature Insulation Kapton tape Figure 3 19 3 3 14 2 Replace Heat Gun Handle EMI Stainless Steel Shield by positioning shield so that the bottom edge of the shield touches the stainless steel Heat Gun Filter where the Power Cord is connected to the Heat Gun Figure 3 19 3 3 14 3 Wrap the shield around the Heat Gun Internal Components Figure 3 20 3 3 14 4 Slide the Heat Gun Handle over the EMI Shield Figure 3 21 The Handle is keyed to fit the Heat Gun Filter 3 3 14 4 1 The shield will slightly overlap as the Handle is reinstalled 3 3 14 5 Replace removed Heat Gun Handle Screws Use a
24. 2 in x7 in 15inx12inx7in J O Olive Drab 34088 Grey 26173 per FED STD 595B Chemically Resistant PVC Polyvinyl chloride 1 7 MCH 100 A REV 7 15 MAY 2013 BTC 70819 4 Universal Battery Charger Power e 90 to 125 Volts AC single phase 60 Hz 2 ampere with 5 ft Hequirements e AC Automatic Selection 90 to 260 VAC single phase 47 to 440 Hz e DC 22 to 33 VDC 13A Charging Automatically selected per installed charge adapter Output Voltage Duty Cycle Resettable circuit breakers for AC and DC 13 Features Environmental e Operating Temp Range 4 F 20 C to 122 F 50 C and e Storage Temp Range 40 40 C 158 F 70 C Performance e Loose Cargo Bounce Test Meets requirements of MIL STD 810E Tests Method 514 4 Category 3 Dimensions Any questions regarding operation maintenance repairs parts and accessories can be directed to Malcom Technologies through our toll free number from the USA at 800 289 7505 or from other parts of the world by calling 401 683 3199 We also have a web site at www malcom com where you can place orders and email us with questions at any time Email address jono bixby malcom com 1 8 MCH 100 A REV 7 15 MAY 2013 CHAPTER 2 Operating Procedures 2 1 HOT AIR TOOL CONTROLS 2 1 1 The MCH 100 A has two simple controls Figure 2 1 shows the ON OFF switch located on the MCH 102NW Power Supply that a
25. 30 01 555 7821 BTA 70774 9940 01 573 9679 Motorola NNTN7032A NTN9816A NTN9815A BTA 70807 BB 388 U NiMH 6140 01 490 4313 BTA 70810 5940 01 493 6751 THALES MBITR Lilon BTA 70811 5940 01 493 7622 AACELLS NIMH BTA 70812 5940 01 492 7238 BB 2557 U Li lon BB 557 U NiCd 6140 01 071 5070 70817 DCELS NiMH BTA 70834 5940 01 501 3312 BB 2590 U 6140 01 490 4316 BT 70791A zee BT 70791E oe BB 390B U 6140 01 490 4317 BB 590 U 6140 01 063 3918 BT 70876 zs SAFT SAI 2590 BB 2590 U 6140 01 490 4316 BB 390B U i 6140 01 490 4317 BT 70791A i BT 70791E BT 70899A BT 70876 Saft SAI 2590 Ultralife UBI 2590 BTA 70899 7058 DRT44534411 BTA 70406 3 7 BA386 NiCd BTA 70851 1 Racal9881 NiCd BTA 7085 PTR 349 BTA 7083 Loral RT1606_ NiCd 2 BTA 70872 4 0 4 1 4 mew LI 80 Li lon BTA 70700 1 1414 85598 Lilom BTA 70406 1BB 5886 amp NiCd 6140 01 084 1460 BTA 70661 BT 7060 BTA 706885 J ALKABAT NiCd MET IL mima BT 70838 2 3 IdZ Li lon NOTES 1 The BB 516A BB 326 and RACAL 931 can only charge with AC power on the BTC 70819 There is no limitation on the BTC 70819 3 2 The Adapter BTA 70480 3 is not compatible with
26. 4 RAIN INTRUSION 509 4 SALT FOG 516 5 SHOCK CE MARKED Available through Authorized Representative Dimensions MCH 110 Carry Case 15 in x 12 in x 7 0 in BTC 70819 Charger 14 in x 11 in x 8 0 in MCH 100 A REV 7 15 MAY 2013 111 038 1 Heat Gun Voltage 42 VDC Ampere 8 O Wattage Total 325 W e111 182 Standard Element 300 W e Internal Fan 25 W 2 66 CFM 75 L min 2 66 CFM 75 L min 16 mbar maximum Temperature 825 F 440 C with standard element Adjustable w interchangeable elements and nozzles Case Material Black ABS Acrylonitrile Butadiene Styrene Dimensions Size of hot air tool is 9 5 long x 3 x 1 6 diameter handle stored inside MCH 110 Field Carry Case Weight 1 Ib 0 45 kg 30 continuous minutes with standard element Length 1 5 ft MCH 102NW 48 VDC Power Supply Batteries Ea e Voltage 24 V Two 2 12 V Sections e Capacity 4 9 Ah in 24 V Mode 9 8 Ah in 12 V Mode e Operating Temperature 4 F to 131 F 20 C to 55 C e Storage Temperature 40 F to 104 40 C to 40 C e State of Charge Display 5 Segment LCD s with Constant Display e Disposal Environmentally safe See Material Safety Data Sheet MSDS e Safety Internal thermal shut down at 158 F 70 C e Safety Internal low voltage shutdown at combined 35 V 9 0 in x 10 in x 6 5 in stored inside MCH 110 Field Carry Case Grey MCH 110 Field Carry Case 15 in x 1
27. A 70360 6130 01 555 7818 BB 4600 6140 13 113 0171 BTA 70394 5940 01 427 9247 BB 503A U 6140 01 419 8193 70395 1 9940 01 427 9183 BB 326 U NiMH 6140 01 533 7674 BB 516A U NiCd 6140 01 419 8191 BTA 70396 BB 2847 U Li lon 6140 01 419 8194 BB 2600A U Li lon 6140 01 490 4311 70492 5940 01 513 5662 70477 6140 14 513 5369 BT 0492 Lilon 6140 01 523 9840 70492 Li lon 6140 01 523 9840 BTA 0581 B m mM 6130 01 564 8116 BTA Mose BTA 70589 i BTA 70598 850036 1 REV E ALI 124 ALI 142 BA 682A BA 682B BA 684A ALI 124 ALI 142 BA 682A BA 682B BA 684A ALI 116 ALI 124 ALI 142 BA 682A ALI 143 BA 687A ALI 243 BA 684A BA 685A BA 682B ALI 147 ALI 247 ALI 142 BA 682A ALI 143 BA 687A ALI 243 BA 684A BA 685A BA 682B ALI 147 ALI 247 6140 1 4 328 2258 6140 14 561 1542 6140 14 529 5971 6140 14 328 2258 6140 14 561 1542 6140 14 529 5971 6140 14 328 2258 6140 14 530 0061 6140 14 553 4062 6140 14 529 5971 6140 14 529 5973 6140 14 561 1542 6140 14 328 2258 6140 14 530 0061 6140 14 553 4062 6140 14 529 5971 6140 14 529 5973 6140 14 561 1542 70598 titer BTA 70715 OES 01 573 9693 BT 70593 Li lon BT 70715 Li lon INTRODUCTION BTA 70721 6130 01 573 4962 BT 70721 BTA 70732 73 EPA MAS 7040 0050 amp Llilon ___ BTA 70763 61
28. ATE REQUIRED INSUFFICIENT DC VOLTAGE TO S 86 9 GHarce THis Bartery TYPE USE AN Ac POWERSOURCE 850036 1 REV E 2 8 OPERATION 2 SOLID RED FAULT LED TROUBLESHOOTING 1 Remove the battery and inspect all the contacts clean if necessary Note the battery location 2 Reinstall at the same location for another charge cycle 3 If the Fault LED Fig 2 1 1 10 is lit again at the same location remove battery and do the following a If the battery is NiCad or Ni Mh and was in storage try to revitalize the battery see section 2 4 b Check battery If the battery is older than 3 yrs it may be ready for disposal c Check the warranty instructions on the battery If the warranty is expired or no instructions were given on the battery dispose of the battery d Note success failure of the future battery charges at this battery location If the Fault LED Fig 2 1 1 10 is lit again the adapter may need to be changed 2 8 FLASHING RED FAULT LED TROUBLESHOOTING 1 This condition is telling you that some of the battery contacts are not connecting to the charger a For BB 390 and other batteries with thermistors the thermal contacts may not be making proper contact with the adapter b For Falcon CSEL MBITR and other batteries the communication pin s may not be making proper contact with the adapter c To minimize this issue before you first start using the charger ensure the battery contacts are clean and the
29. CARBON BRUSH 3 11 3 3 10 REPLACE AND RESET CARBON BRUSH PN 100 066 3 12 3 3 11 REPLACE HEAT GUN SWITCH PN 102 969 3 13 3 3 12 REPLACE HEAT GUN POWER CORD PN MCH 114 3 14 3 3 13 REPLACE POWER CORD CLAMP PN 100 808 AND 100 775 3 15 3 3 14 REPLACE HEAT GUN 3 16 MCH 100 A REV 7 15 MAY 2013 TABLE OF CONTENTS CONT 3 4 48 VDC POWER SUPPLY MAINTENANCE INSTRUCTIONS 3 17 3 4 1 REMOVE POWER SUPPLY POWER CORD 3 17 3 4 2 REPLACE POWER SUPPLY POWER CORD PN MCH 103 2 3 17 3 9 CHECKOUT AFTER REPAIR cod 3 20 3 6 WIRING DIAGRAM uo 3 20 CHAPTER 4 SPARE PARTS 4 1 INTRODUCTION As 4 2 EXPLANATION OF 4 1 4 21 TABLE 4 2 SPARE PARTS 4 2 4 3 ACCESSORIES FOR THE MCH 100 A CHAPTER 5 SPC LITE UNIVERSAL PORTABLE BATTERY CHARGER PN BTC 70819 5 1 SPC OPERATION AND SERVICE MANUAL INCLUDED WITH BATTERY CHARGER CHAPTER 6 48V NIMH RECHARGEABLE BATTERY BB 390B U PN BT 70790 5 1 SCOPE atta ce D eb cc 6 1 6 2 Featules adds 6 1 6 3 BB 390B U
30. CH 100 A heat gun The PP 8497 U Self Discharge Device Cap NSN 6130 01 490 4310 is available from Malcom Company The PP 8497 U device will assist in conditioning and maintaining BB 390 batteries Figure 6 1 MCH 100 A REV 7 15 MAY 2013 Figure 0 1 BB 390 Self Discharge Device Cap and Good Battery Quick Check Device NOTE The discharge device is not intended to measure how long the battery will run your equipment The device is intended as a quick sanity check for ensuring both 12 volt sections are working and for discharging the battery You still must ensure the BB 390 is fully charged prior to use 6 7 2 Discharging Ihe cap will discharge the BB 390 without requiring a power outlet or running the heat gun Discharge times will vary A fully charged BB 390 will require 24 hours using the self discharge device Discharge times will drop dramatically If the BB 390 s have been discharged during use A full discharge recharge cycle is recommended quarterly to ensure good operating performance of the BB 390 s 6 7 2 1 Discharging Instructions 1 Ensure cap is working with known good battery when you first use device 2 Place Self Discharge Device CAP on the BB 390 a If both LED s light green your battery is OK Both 12 volt sections are discharging properly The discharge will continue until the lights turn off i If one or both LED s DO NOT light green then the BB 390 requires troubleshooting
31. CONTAMINATES NICKEL METAL HYDRIDE BATTERIES Every effort must be made to keep Nickel Metal Hydride batteries as far away as possible from lead acid batteries because lead acid batteries contain sulfuric acid Do not use the same tools and material such as screwdrivers wrenches syringes hydrometers and gloves for both types of batteries Any trace of acid or acid fumes will permanently damage Nickel Metal Hydride batteries on contact 2 6 MCH 100 A REV 7 15 MAY 2013 2 7 PREPARATION FOR MOVEMENT AFTER USE 2 1 Set the Heat Gun power switch to OFF to let the tool cool down 2 7 2 When Heat Gun is cool set the Power Supply power switch to OFF on the to stop the fan in the tool 2 3 Remove any installed nozzles and place them into the appropriate storage pockets in the carry bag Figure 2 12 2 7 4 Disconnect the Heat Gun s NC3MX HD Quick Disconnect Connector from the Power Supply s NC3FX HD Quick Disconnect Connector 2 7 5 Insert the Power Supply Heat Gun and Coiled Power Supply Cable into the appropriate locations as indicated on the screen print on the inside of the MCH 110 Carry Bag Lid Figure 2 13 2 7 6 Close and secure the Carry Bag Lid Figure 2 12 Carry Bag With Figure 2 13 Properly stowed Compartments components 2 7 MCH 100 A REV 7 15 MAY 2013 2 8 PREPARATION FOR SHIPMENT AND STORAGE 2 8 1 Begin with Section 2 7 to properly store components 2 8 1 1 Disconnect batteries from the Powe
32. Cable conductors Solder the white conductor of the Power Cable into terminal 1 of the Pin Connector Solder the black wire into the terminal labeled 2 Solder the braided shield onto the stainless steel terminal Note Be sure to distinguish between the black conductor and the twisted braided shield insulated with shrink tube that may also be black Carefully push the parts together The threaded end of the Quick Disconnect Connector is keyed to fit the Pin Connector and Internal Plastic Cable Restraint correctly Twist together hand tight the External Cable Restraint to the Quick Disconnect Connector Install the Output Wire Harness Battery Terminal into the Power Supply Case by running the Battery Terminal Cable down the side of the Power Supply Case that is closest to the Power Cord Feed through Restraining Clamp Press the cord into the Power Supply Case Foam Cord Opening to prevent the cable from pinching when the case is closed Place the Battery Terminal in the foam insulation structure of the Power Supply Case so that the Battery Terminal Pins are facing the hinges of the Power Supply Case and the open side of the three sided flange is towards the top of the Power Supply Case 3 19 MCH 100 A REV 7 15 MAY 2013 3 5 CHECKOUT AFTER REPAIR 3 5 1 Once the repair has been completed install freshly charged batteries into the battery pack as described in Chapter 2 3 5 2 Follow the operating instructions as described
33. Check by pushing down the pins and releasing The pins should spring up If not or are missing you may be able to replace pins adapter C You can still charge Batteries with contact pins missing or damaged it will just take eager The FAULT LED will continue to ink 2 If flashing red condition after this check Mark location of condition and battery affected 3 You can pull batteries and clean thermal contacts on the battery 4 Check adapters again Mark for future review If a problem continues at this location change the Adapter Charger never tries to charge a 1 Possible poor connection inspect and clean battery battery and adapter contacts 2 Defective adapter use a different adapter 3 Defective battery replace the battery Port LED goes to Amber 1 Poor connection inspect and clean battery CHARGE but never turns Red and adapter contact FAULT or Green READY 2 Defective adapter use a different adapter instead it turns off 3 Defective battery replace the battery Recondition LED will not turn on 1 The Battery or Adapter does not support when Recondition Switch is Reconditioning or Destorage pressed or turns off when the battery is Found Recondition LED is blinking and 1 The charger is too hot over 45 C to the Port s Status LEDs are all off discharge the battery Move the charger to a cooler area 2 The air vents at the left and right side of the charger are blocked 3 Ope
34. E CHARGE CHECK RAPID BUNKING TWO BATTERIES CAN CHARGE SIMULTANEOUSLY BATTERY READY TO USE REMOVE WHEN READY BATTERY 5 READY TO USE REMOVE WHEN READY CONSULT STANDARD OPERATING PROCEDURE ELECTRICAL HAZARD 2 VOLTAGE PRESEN TT ont ns ARE DIRTY OR DAMAGED CLEAN BATTERY CONTACTS CHECK ADAPTER PINS ep STATION AVODCOMIACIWIMAC s s RECONDION DESORE CYCLE IN PROCESS PECONDIMON Hi DESTORE JU BATTERES CAM PRODUCE VOLTAGE DURHG i C EQUIPMENT OPEFATON OR F _ EXCESSIVETEMPERATURE FOR RECONDITIOHING PELOCATE TO COOLER ENVIRONMENT EXPLOSIVE GAS DURING MAINTENANCE s 8 _ INCOMPATIBLE BATTERY OR ADAPTER UNSUPPORTED OR SOFWARE UPDATE REQUIRED CHARGE OK 258 1 NO BATTERY E AWAITING BATTERY TO CHARGE SLOW BLIMKING E LIGHT INDICATIONS FOR EACH BATTERY F Flashing RECON DEFINITION REMARKS ee PEN T CHARGERSTARTUP START UP LIGHTS SCROLL MOMENTARILY SCROLL MOMENTARILY MUST AWAITING BATTERY TO PRE E CHECK RAPID TWO BATTERY IS READY USE BATTERY IS READY TO USE CONSULT STANDARD CONTACT PINS ARE DIRTY OR CLEAN BATTERY CONTACTS DAMAGED CHECK ADAPTER PINS RECONDITION DESTORE CYCLE r anc DESTORE IN PROCESS CONSULT STANDARD F EXCESSIVE TEMPERATURE FOR RELOCATE TO COOLER RECONDITIONING ENVIRONMENT S S S INCOMPATIBLE BATTERY OR UNSUPPORTED OR SOFTWARE ADAPTER UPD
35. MCH 100 A REV 7 15 MAY 2013 TECHNICAL MANUAL OPERATION AND SERVICE MANUAL BATTERY POWERED HEAT GUN ASSEMBLY PART MCH 100 A DISTRIBUTION STATEMENT Distribution authorized to U S Government agencies and their contractors to protect publications required for official use or for administrative or operational purposes determined on 01 October 1999 Other requests for this document shall be referred to The Malcom Company 207 High Point Rd Suite 7B Portsmouth RI 02871 MCH 100 A REV 7 15 MAY 2013 TABLE OF CONTENTS CHAPTER 1 INTRODUCTION 1 1 SCOPE 1 1 1 2 HEAT GUN TS LT 1 3 48DCV POWER SUPPLY MCH 102NW ES 1 4 1 4 24 VOLT BATTERY BT 70790 1 4 1 5 UNIVERSAL PORTABLE BATTERY CHARGER BTC 70819 1 5 1 6 SIEVE REFLECTOR NOZZLE 111 476 1 5 1 7 SPOON REFLECTOR NOZZLE 112 028 1 6 1 8 BATTERY DISCHARGE CAP BTF 70791 1 6 1 9 BATTERY ADAPTER PLATE 70834 1 6 1 10 FIELD CARRY CASE MCH 110 1 6 1 11 MCH 100 A TECHNICAL SPECIFICATIONS 1 6 CHAPTER 2 OPERATING PROCEDURES 2 1 AIR TOOL CONTROLS 2 1 2 2 UNPACKING TOOL m n 2 3 CONNECTION OF BATTERY TO THE HEAT GUN E 2 3 2 4 SETUP PROCEDURES ias n 2 5 CHANGE OF HOT AI
36. R NOZZLES acd s c ee iter MINE dici 2 5 2 6 CHARGING BATTERIES cui 2 6 2 7 PREPARATION FOR MOVEMENT AFTER USE 2 7 2 8 PREPARATION FOR SHIPMENT AND STORAGE 2 8 2 9 PREPARATION FOR STORAGE OF BB 390 BATTERY 2 8 2 10 PREPARATION FOR SHIPMENT OF BB 390 B U BATTERY 2 8 2 11 OPERATION IN UNUSUAL WEATHER CONDITIONS 2 8 CHAPTER 3 MAINTENANCE INSTRUCTIONS 3 1 PREVENTATIVE MAINTENANCE Gree vnus 1952 3 1 1 HEAT GUN PREVENTATIVE MAINTENANCE pa cc 3 2 3 1 2 BATTERY PREVENTATIVE MAINTENANCE 3 3 3 2 TROUBLESHOOTING 3 3 3 2 1 TABLE 3 2 TROUBLESHOOTING PROCEDURES 3 5 3 3 HEAT GUN MAINTENANCE INSTRUCTIONS 3 4 3 3 1 REMOVE HEATING ELEMENT COVER 3 7 3 3 2 REPLACE SEPARATION RING PN 100 802 3 7 3 3 3 REPLACE GROUND CLIP PN 107 227 3 8 3 3 4 REMOVE HEATING ELEMENT 3 8 3 3 5 CHECK CONTINUITY OF HEATING ELEMENT 3 9 3 3 6 REPLACE HEATING ELEMENT 3 9 3 3 7 REINSTALL HEATING ELEMENT COVER 3 9 3 3 8 REMOVE HEAT GUN HANDLE 3 10 3 3 9 CHECK
37. adapter contact pins are in place and retain their spring action Check by pushing down the pins and releasing 2 You can still charge batteries with thermal communication pins missing or damaged it will take longer and may not fully charge in one cycle 3 If the flashing red condition continues note the adapter battery location and battery affected a Remove the battery and clean the thermal contacts b Check adapters again If problem continues at this location the adapter may need to be changed 850036 1 REV E 2 9 OPERATION 2 9 OPERATION IN EXTREME ENVIRONMENTAL CONDITIONS Observe these precautions when the charger is operated in areas where severe climatic conditions may exist a Operation in Arctic Climates The battery charger is designed to function in temperature extremes as low as 4 F 20 C However when operating in arctic climates the following precautions should be observed 1 Handle the equipment carefully The plastic components may become more brittle 2 Keep the equipment clean and dry 3 Prevent ice from forming on the charger and the batteries Ice formations may prevent proper electrical connections Melting ice may allow water to enter the charger When not in use be sure the cover is fully latched and the Pressure Equalization Valve Fig 2 1 2 17 is fully closed tighten by turning the knob in clockwise direction b Operation in Desert Climates The charger is designed
38. alibration If the heat gun is used in the continuous mode then internal heat will build up within the batteries The thermal safety switches within the battery will automatically turn the batteries off As a result of thermal switch activation the internal program that controls the LCD displays will indicate less capacity than is actually present in the cells once the batteries are recharged MALFUNCTION 2 One 12 volt section shows full charge when checked with a voltmeter and the other 12 volt section does not If one of the 12 volt sections in the BB390 battery does not fully charge while the other section shows a less than full charge then maybe one of the small cells within the 12 volt section has fallen asleep and needs to be woken up or itis faulty Follow the procedures in Sections 6 6 and 6 7 to wake up the sleeping cells a Long term storage without recharging every two months or improper storage in very cold or very hot conditions can cause a deactivated cell Before discarding the battery reset the internal cells by completely discharging the battery Follow the discharge procedure outlined in sections 6 6 and 6 7 as well as in the corrective action section below MCH 100 A REV 7 15 MAY 2013 6 5 1 3 MALFUNCTION 3 The MCH 100 A run time is less than 20 minutes even after a fresh complete discharge and recharge cycle 1 Each BB 390 has two 12 volt sections Although your BB 390 s may charge up well displaying
39. and dust from the charger Low pressure air may be used to remove heavy dust from the case connectors and power switches Avoid blowing dust into the unit Low pressure air may be blown into the left and right air vents at the edge of the control panel to help remove internal dust 2 Wipe surfaces with a damp not wet rag Non solvent cleaners may be used Windex Fantastik and Formula 409 Do not spray or drip water or cleaners onto the panel or into the connectors 3 The flush mounted adapter connectors may be cleaned with electronic grade spray cleaner Allow the cleaner to dry before installing the adapters and or applying power to the charger 4 The connections on the adapters may be cleaned with electronic grade spray cleaner or isopropyl alcohol Insure the adapters are dry before using them INSPECTION 1 Inspect case for cracks and other damage 2 Insure the lid gasket is in place Insure the Hinge Pins are fully inserted some models of charger also include cover stays Insure the lid closes and can be properly latched Insure all Screws are in place and are not loose Inspect the panel and connectors for damage Inspect all adapters for excessive wear and damage a Inspect charger connector for bent or corroded pins b Inspect battery connector pins for damage or corrosion c Insure all spring pins are not bent and move freely d Note that spring pins can be removed and replaced 8 Inspect power
40. arge levels at manufacture They might even have gone into sleep mode therefore it is strongly recommended that each battery be preconditioned before initial use see Section 6 4 NOTE Even though the battery manufacturer rates the BB390B U battery for 500 cycles the actual cycles of these batteries when used in the MCH 100 A tool will most likely be less than 500 How much less will depend on the way the tool is used and the environmental conditions it is subjected to 6 4 USE OF THE BB 390B U BATTERIES IN THE MCH 100 A 1 Prior to first use each individual BB 390B U battery must be preconditioned This requires two 2 full charge recharge cycles Follow the discharge procedures outlined in Sections 6 6 and 6 7 of this manual This will prepare the battery for optimal performance This procedure is critical to the longevity of the battery in actual operation Failure to conduct these initial charge recharge procedures may shorten the life of the battery MCH 100 A REV 7 15 MAY 2013 2 Always ensure that the batteries are carrying a charge prior to going out on the job Using a standard volt ohm meter measure the voltage of each side of the battery section to be sure that is a minimum of 13 25 Volts Check the LED indicators for charge condition Each segment indicates about five minutes operating time If this is not the case recharge the batteries NOTE If there is any doubt that the batteries are not fully charged
41. cords for damage 9 Insure power switches move freely 10 Insure the Pressure Equalization Valve Fig 2 1 2 17 can be tightened po oh as 850036 1 REV E 3 1 MAINTENANCE 3 4 BASIC FUNTIONAL TEST 1 Set the On Off Switch Fig 2 1 1 1 to OFF position and remove any adapter installed 2 Connect the charger to AC power 3 Set the On Off Switch Fig 2 1 1 1 to ON position 4 The front panel LED s should light in sequence Amber then Green then Red Insure all LED s light 5 Insure the Power On Indicator LED Fig 2 1 1 8 is lit and that all other indicator LEDs are off 6 Place an adapter into the Adapter Port Fig 2 1 1 13 7 Verify that the two Charge LEDs Fig 2 1 1 8 start to blink 8 Press each of the Recondition Switch Fig 2 1 1 14 several times Verify the Recondition LED Fig 2 1 1 15 alternates on then off with each press 9 Place a battery on Channel A Insure that the Charge LEDs Fig 2 1 1 8 blinks rapidly then turns on solid 10 Repeat Step 9 for Channel B 11 Set the On Off Switch Fig 2 1 1 1 to OFF position and disconnect AC Power 12 Connect the charger to 28 Volts DC power 13 Set the On Off Switch Fig 2 1 1 1 to ON position 14 The front panel LED s light in sequence Amber then Green then Red Insure all LED s light 15 Press the Blackout Switch Fig 2 1 1 6 Verify that all panel LEDs turn off 16 Press the Blackout Switch Fig 2 1 1 6 again Veri
42. ctivates the power to the 111 038 1 Heat Gun When the MCH 102NW switch is on the fan in the heat gun will activate Figure 2 2 shows the ON OFF switch located on the handle of the heat gun When the 111 038 1 switch is on the heating element will activate ON OFF ON OFF Figure 2 1 Power Supply Switch Figure 2 2 Heat Gun Switch ON OFF switch on battery box Turns power on and off to the hot air tool The fan starts up in the tool when the switch is on Figure 2 1 Hot Air Tool switch on back of tool Turns the power on and off to the internal heating element Figure 2 4 2 MCH 100 A REV 7 15 MAY 2013 1 3 4 9 8 6 7 Figure 2 4 Hot Jet Switch 1 Power Supply Cable 6 Element housing 2 On Off switch 7 Push fit nozzle with twist lock 3 Handle 8 ESD lead connection 4 Rubber stands 9 ool stand can be removed rotated and fixed 1 Air filter HOT AIR TOOL CAN PRESENT A FIRE AND EXPLOSION HAZARD The hot air tool must be used in a ventilated area The internal heating element and built in fan motor may present a hazard when exposed to certain flammable vapors associated with for example gasoline methane jet fuel and propane 2 2 MCH 100 A REV 7 15 MAY 2013 2 2 2 2 1 2 2 2 2 2 3 2 2 4 2 3 2 3 1 2 3 2 2 3 3 2 3 4 2 3 5 2 3 6 Figure 2 5 Battery UNPACKING TOOL Carefully remove from the packaging the heat gun power pack batteries charger
43. d in Sections 6 6 and 6 7 in this manual MCH 100 A REV 7 15 MAY 2013 6 6 RECONDITION BATTERY Batteries will operate properly even with L CD s out of calibration 1 Completely discharge battery according to Section 6 6 or section 6 7 2 Recharge the batteries using the P 8444A U Universal Charger After the charge is complete the LCD segments should be calibrated a If not allow batteries to cool and then run another charge cycle If not after a second charge cycle ensure voltages at pins 1 4 and 2 5 are at least 13 25 volts If voltages are correct then repeat discharge charge cycle If voltages are under 13 25 volts then the battery charger or adapter may be damaged 3 Allow batteries to cool before use 6 7 DISCHARGE PROCEDURE USING THE HEAT GUN 1 Turn heat gun fan on DO NOT turn on the heating element 2 Run heat gun on fan only until it automatically turns off due to the internal voltage cutoff switch This protects the batteries and the heat gun from low voltage operation This will empty the battery The discharge time will vary depending on how much capacity was remaining in the batteries 3 Remove the batteries from the MCH 100 A battery case Let them stand and cool down for one hour Recharge the batteries using the P 8444A U Universal Charger 6 8 DISCHARGE PROCEDURE USING THE SELF DISCHARGE CAP 6 7 1 This is the preferred method of discharge as it does not require the use of the M
44. dition Switch Fig 2 1 1 14 for the A or B channel 850036 1 REV E 2 6 OPERATION the amber Recondition LED Fig 2 1 1 15 will light for the corresponding channel 4 Plug the battery into the activated channel 5 De storage will commence upon recognition of the battery Autonomously the Charger will perform the following de storage sequence a Check environmental temperature if the temperature is above 45 C it Will not proceed Fully discharge the battery Fully charge the battery while measuring its capacity Discharge the battery to 4596 of it measured capacity The green Ready LED Fig 2 1 1 9 will light the Recondition LED Fig 2 1 1 15 remains lit and the process is complete 2 5 BLACKOUT Pressing the Blackout Switch Fig 2 1 1 6 will turn off all the LEDs Pressing the switch again will turn the LEDs back on The charger will remember the correct state for all batteries The blackout mode is disabled each time the charger is turned on Holding the Blackout Switch Fig 2 1 1 6 down while turning the charger power switch on will suppress the startup LED Test 850036 1 REV E 2 1 OPERATION 2 6 BATTERY CHARGER LABELS Shown below are the instructions contained on the SHORT FORM OPERATING PROCEDURE label attached inside the charger cover LED INDICATIONS FOR EACH BATTERY S STEADY F FLASHING LIGHTS SCROLL MOMENTARILY ADAPTERS MUST BE INSTALLED PR
45. e storage Lights amber during revitalization de storage process Remove this cover to upgrade the charger s software Otherwise leave the cover in place This valve must be loosen before the cover is opened and latches unfastened 850036 1 REV E 2 3 OPERATION 2 2 PRELIMINARY SETUP PROCEDURES Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Place the unit on the work surface Loosen the Pressure Equalization Valve Fig 2 1 2 17 by unscrewing the knob two full turns in a counterclockwise direction Unfasten latches and open cover Set the On Off Switch Fig 2 1 1 1 to OFF position The cover may be removed by removing both hinge pins with pliers For AC operation Connect the AC power cord from AC Input Connector Fig 2 1 1 11 to an AC power source and set the On Off Switch Fig 2 1 1 1 to ON position Observe that the Power On Indicator LED Fig 2 1 1 3 lights the fan operates and all the indicator LEDs blink in order amber then green then red briefly when power is first applied For DC operation Connect the DC cable from the DC Input Connector Fig 2 1 1 12 to a DC power source such as the NATO slave receptacle found in most military vehicles Set the On Off Switch Fig 2 1 1 1 to the ON position Observe that the Power On Indicator LED Fig 2 1 1 3 lights the fan operates and all the status indicator LEDs Fig 2 1 1 8 9 and 10 blink in order amber green then
46. e Cap shown in section 6 7 in this manual can be used as a quick checker that ensures that both 12 volts sections within the battery are working fully Thus in a matter of minutes you could quickly check all your BB 390 s stocks to ensure they are good to go on both 12 volt sections The batteries are SMART and contain internal printed circuit boards with electronics that control the way the batteries function The batteries are fully sealed However due to mishandling the case and or the connectors can crack exposing the inside of the batteries to the environment which could affect the performance of the battery If the case becomes cracked then the battery should be discarded and replaced MCH 100 A 6 5 1 1 1 6 5 1 2 REV 7 15 MAY 2013 MALFUNCTION 1 The batteries are fully charged yet the LCD screens do not indicate a full charge The LCD displays can become out of calibration thus displaying false LED segments under two circumstances as described below a Long term storage If the battery has not been used for a period exceeding two months then the internal program that controls the LCD displays will indicate less capacity than is actually present in the cells some cells could go into sleep mode Follow the procedures in Sections 6 6 or 6 7 to wake up the sleeping cells Continuous battery d the heat gun being on for extended periods of time could WARNING ry LCD displays to become out of c
47. e charger The State of Charge displays on the Batteries should now show 5 five segments completely filled in If not then repeat discharge charge sequence 1 one additional time Voltages at Battery Pins 1 4 and 2 5 should show 13 25 volts 3 2 TROUBLESHOOTING PROCEDURES 3 2 1 The following paragraphs provide instructions for fault isolation testing component replacement procedures and checkout of the equipment 3 2 1 1 Visual Inspection Visually inspect the Heat Gun and Power Supply to find faults 3 2 1 1 1 Check to see that the Power Supply and Heat Gun switch is in the ON position 3 2 1 1 2 Check to see that the BB390 B U NIMH Batteries PN BT 70790 are charged and securely connected 3 2 1 1 3 Check to see that the Heat Gun is securely connected to the Power oupply Check to see that the Power Supply cable is not compromised Abraded Chaffed or Charred 3 2 1 2 Operational Checkout Perform the operating procedures given in Chapter 2 Note at which point in the procedures that the Heat Gun does not function or operates improperly No Heat No Air No Power 3 3 MCH 100 A REV 7 15 MAY 2013 3 2 1 3 Troubleshooting Method Troubleshooting procedures described in Table 3 1 are based on observing problems that occur during operation under conditions that occur during normal use of the unit Proceed with step by step checkout of the Heat Gun and its components until the defective part is found and rep
48. eating Element air holes at the internal heating coils If coils are dirty dusty then spray clean the internal heating coils through the Heating Element air holes with compressed air 3 1 1 1 3 1 Ifthe Heating Element internal heating coils require cleaning then remove the Heat Gun Handle as described in Section 3 3 8 and spray clean the internal components with compressed air Use a water dipped cotton swab for especially hard to remove dirt dust 3 1 1 1 4 Replace the Heating Element Heating Element Cover and Heat Gun Handle as required and as described in Section 3 3 3 2 MCH 100 A REV 7 15 MAY 2013 3 1 2 BATTERY PREVENTATIVE MAINTENANCE 3 1 2 1 BATTERY CONDITIONING AND CALIBRATION Annual conditioning and calibration of the BB 390 Batteries PN BT 70790 will ensure maximum performance of the MCH 100 A system 3 1 2 1 1 Remove batteries from the 48 VDC Power Supply 3 1 2 1 2 Visually inspect each battery for visible damage 3 1 2 1 3 Push fit the Self Discharge Cap PN BTF 70791 onto each Battery and allow each Battery to completely discharge as indicated by the unlit Self Discharge Cap LEDs 3 1 2 1 3 1 Afully charged BB 390 will require 24 twenty four hours to completely discharge using the Self Discharge Cap Discharge times will decrease as the charge in each Battery decreases 3 1 2 1 4 Install Batteries onto the charger and allow Batteries to recharge 3 1 2 1 5 Remove the Batteries from th
49. ecifications applied EMISSIONS Per 61000 6 3 2007 Emission Standard for Industrial Environments EM 55022 1988 Class B Conducted Emissions EM 55022 1898 Class B Radiated Emissions IEC 61000 3 2 2000 Harmonics IEC 61000 3 3 1994 Flicker IMMUNITY Per EN 61000 6 1 2007 Immunity Standard for Industrial Environments IEC 61000 4 2 2001 Electrostatic Discharge IEC 61000 4 3 Edition 3 1 2008 04 Radiated Immunity IEC 61000 4 4 2004 EF T Burst Power Leads IEC 61000 4 5 2005 Surge Immunity Power Leads IEC 61000 4 6 Edition 3 0 2008 10 Conducted Immunity Power Leads IEC 61000 4 11 2004 Voltage Dips and Interrupts The given models also conform to European Community Council Directive 2006 95 EC based on the following specifications applied SAFETY EN 60950 1 2006 Low Voltage Directive The supporting technical documentation is maintained at the Commack NY USA address shown above Certifiad and Declared as described above 2 3 Nov 20 Don Fagon site Vice President Quality BREN TRONICS Inc ZEN Zoi Date Vice President Engineering BREN TRONICS Inc 850036 1 REV E 1 3 1 4 ACCESSORIES INTRODUCTION Table 1 shows the various batteries and appropriate adapter plates the SPC Lite supports at the time this document was written Table 2 shows various power cables and accessories Table 1 Supported Batteries and Adapters ADAPTER ADAPTER NSN BATTERY BATTERY NSN BT
50. ed under a six month warranty If the Tool is under warranty repairs will be performed and the tool returned to sender For warranty repairs the sender must provide a shipper number for the tool to be returned on If repair and or replacement charges are required estimated costs will be advised to the sender prior to any work starts Minimum Hepair Rates 35 inspection fee on all repairs waved if repair is authorized 80 Hand Tools 150 Process Heaters amp Blowers 275 Automatic Machines amp Extruders Labor Rate 80 hour 4 malcom REV 100513 SERVICE FORM Page 3 of 3 The repairs will not be performed without customer approval and payment arranged for the service have read the Warranty and Service Policy and agree to the terms Print Name Signature Date PLEASE COMPLETE PAGE 1 AND 3 OF THIS FORM AND INCLUDE ALL 3 PAGES WITH YOUR RETURNS PRINT AND ATTACH THE FOLLOWING LABEL WITH THE RMA FILLED IN ON PACKAGE THAT CONTAINS THE RETURNED PRODUCT OTHERWISE THE SHIPMENT WILL BE REFUSED AND WILL BE RETURNED TO YOU A BM MALCOM COMPANY ATTN SERVICE SERVICE CENTER
51. element Any attempted repair or disassembly by other than an authorized repair station will void the warranty Warranty repairs are done at the Malcom Company Service Center Portsmouth Rhode Island RMA Returned Material Authorization is required prior to any shipment of product to Malcom Company Repairs and or replacement will only be performed on authorized returns If a shipment does not include Authorization Label the shipment will be refused and the product returned to sender When requesting an RMA number please provide the serial number of the product if available For RMA and Shipping Control Label contact Jono Bixby Repair Service at jono bixby malcom com Or call Toll Free 800 289 7505 outside the US 401 683 3199 Fax 401 683 3177 All tools returned to Malcom Company for warranty work or general service must be shipped prepaid to Malcom Company Inc Service Center RHMA 207 High Point Ave Unit 7b Portsmouth RI 02871 Please include your name and telephone number so that we can contact you with the repair estimate Tools returned for service should not include nozzles or accessories as we cannot be held responsible for their return Repairs are generally done within 24 hours of receipt Estimates will be given before any work is started Damaged tool reassembly without repair will be charged for the inspection Tools repaired will be credited for the inspection charge Replacement parts and Labor are cover
52. ength Width amp 4 400 in 112 mm 2 450 in 62 mm 5 000 in 127 mm Height Nominal Weight 3 880 Lb 1 76 Kg Nominal Voltage 24 0 V Two 2 12 0 V Sections Nominal Capacity 4 9 Ah 9 24 0 V 9 8 Ah 12 0 v Cutoff Voltage 20 0 V 10 0 V Operating Temperature 20 C to 55 C 4 to 131 F Range Storage Temperature 40 C to 55 C 40 to 131 F Range Case Material amp Color Modified ABS plastic Olive Drab 434088 with White printing Connector Floating Type Per U S Army DWG SC C 179495 Operational Life 10 0 Hours 0 360 Amps When used in 24 Volt Mode Applicable Q A MIL STD 105 MIL STD 810 MIL STD 454 Specification Applicable Battery MIL B 49436 B ER and Proposed U S Army NMH Specification Specification Shelf Life Up to five years dependent on storage conditions Recommended PP 8444A U PP 8481A U COTM PP 8498 U SPC Chargers Standard Charge Charge each section at constant current of 480 mA for 12 hour Disposal Environmentally Safe Contains Zero 0 Mercury or Cadmium Check with local regulations for proper disposal Any questions regarding accessories can be directed to Malcom Company through our toll free number from the USA at 800 289 7505 or from other parts of the world by calling 401 683 3199 We also have a web site at www malcom com where you can place orders for parts and accessories and email us with questions at any time 6 10 MCH 100 A REV 7 15 MAY 2013 CHAPTER 7 Warranty I
53. er Cord Feed through Restraining Clamp of the MCH 102NW Battery Power Supply Case Figure 3 21 MCH 103 2 Output Wire Harness Remove one Output Wire Harness ON OFF Switch Locking Nut from the ON OFF Switch Toggle Switch and tighten the second Locking Nut to the base of the Switch Install the ON OFF Switch in its through hole so that the Switch is facing the outside of the Power Supply Case 3 17 MCH 100 A REV 7 15 MAY 2013 3 4 1 9 3 4 1 10 3 4 1 11 3 4 1 12 3 4 1 13 3 4 1 14 Install the ON OFF Switch Plate on the Switch so that the plate is parallel to and the OFF side of the Switch Plate is closest to the handle of the Power Supply Case Install and tighten the Switch Locking Nut on top of the ON OFF Toggle Switch Plate Install the ON OFF Switch Rubber Boot so that the part number and text of the Rubber Boot is facing outward and closest to the outside of the Switch Locking Nut Install the Wire Harness Ground Wire to the Power Supply Case Handle ocrew on the inside of the Power Supply Case farthest from the Switch Pull the excess Power Cord through the MCH 102NW Battery Power Supply Case Power Cord Feed through Restraining Clamp and tighten the Clamp Take the NC3FX HD Quick Disconnect Female Connector apart by unscrewing the External Cable Restraint from the Quick Disconnect Connector 3 4 1 14 1 There should be four pieces to the NC3FX HD From Left to Right in Figure 3 22 there is a
54. fy all panel LEDs resume normal operation 17 For the BTC 70819 3 Only a Set the On Off Switch Fig 2 1 1 1 to OFF position and disconnect the 28 Volts DC Power Connect the charger to 12 Volts DC power c Set the On Off Switch Fig 2 1 1 1 to ON position d The front panel LED s light in sequence Amber then Green then Red Insure all LED s light 18 End of test 850036 1 REV E 3 2 MAINTENANCE 3 5 SIMPLIFIED OPERATOR TROUBLESHOOTING PROCEDURES Item MALFUNCTION POWER ON LED is not lit during DC operation The LED s do not blink in sequence at start up TEMP FAULT LED is lit LOW VEH PWR LED is lit All 3 LED s CHARGE READY FAULT are lit FAULT LED is lit 850036 1 REV E POWER ON LED is not lit during AC operation All LED s light and stay lit after the charger is turned on POSSIBLE CORRECTIVE ACTION 1 Inspect Power Cord and AC Switch 2 Reset AC Circuit Breaker Note The Circuit breaker is tripped if the white band is visible 1 Inspect Power Cord and DC Switch 2 Reset DC Circuit Breaker Note The Circuit breaker is tripped if the white band is visible 1 The unit has lost its program a Re program the unit b Theunit requires repair Call or e mail Bren Tronics Info on warranty tag 1 Verify the Temp Fault and Veh Power indicators are not lit 2 The unit requires repair Call or e mail Bren Tronics Info on warranty tag 1 The Charger is too hot o
55. ge on the battery 2 10 PREPARATION FOR MOVEMENT a Set the On Off Switch Fig 2 1 1 1 to OFF position b Remove any installed batteries c Disconnect the AC power cable d Disconnect the DC power cable e Unplug cable type adapters Plate type adapter may be left installed f Replace the charger cover if it was removed 0 Close the charger cover and secure latches h Close the Pressure Equalization Valve Fig 2 1 2 17 by turning clockwise until tight 2 11 BATTERY STATE OF CHARGE DISPLAYS Batteries equipped with state of charge SOC displays indicate battery charge status on a five segment LCD bar graph readout The number of LCD segments activated corresponds to the battery s state of charge as follows segments State of Charge 0 fully discharged 1 to 2096 21 to 4096 41 to 6096 61 to 8096 81 to 100 fully charged oR WON oO NOTE The BB 390A U BB 390B U BB 2590 U BB 2557 U and other batteries have two SOC indicators Each SOC indicator provides state of charge indication for each of the two 12V sections Both SOCs must display 100 for the battery to be fully charged 850036 1 REV E 2 11 OPERATION 2 12 BATTERY CAPACITY RETENTION As shown in the adjoining graph fully 100 w zm charged batteries that are stored lose a portion of their charge due to battery chemistry This is normal and should not be interpreted as battery failure otorage at higher temperatures increases capacit
56. gure 3 14 Heat Gun Switch Internal Wiring 3 13 MCH 100 A REV 7 15 MAY 2013 3 3 12 REPLACE HEAT GUN POWER CORD PN MCH 114 3 3 12 1 3 3 12 2 3 3 12 3 3 3 12 4 3 3 12 5 3 3 12 6 3 3 12 Remove the Heat Gun Handle as described in Section 3 3 8 Hemove the Heat Gun Power Cord Clamp as described in Section 3 3 13 Loosen the Heat Gun Power Cord Lead Screws Figure 3 15 Carefully cut the ground wires that are soldered to the Heat Gun Screen Filter on either side of the switch 0 25 in from the Filter without pulling on the screen Figure 3 16 Hemove the Heat Gun Power Cord by gently pulling it through the Heat Gun Rubber Cable Restraint Slide the replacement Power Cord MCH 114 through the Rubber Cable Restraint Insert the white power conductor into the left Lead Screw and tighten Insert the black power conductor into the right Lead Screw and tighten Figure 3 15 3 3 12 7 1 Polarity is not critical Tool left is defined by Technician s Point of View with 3 3 12 8 3 3 12 9 the Heat Gun Heating Element farthest from the Technician oolder the Power Cord s ground wires to the solder points on either side of the switch Figure 3 16 Replace the Power Cord Clamp as directed in Section 3 3 13 3 3 12 10 Replace the Handle as directed in Section 3 3 14 Figure 3 15 Power Cord Lead Screws Figure 3 16 Ground wires soldered to filter 3 14 MCH 100 A REV 7 15 MAY 20
57. laced and the problem is corrected WARNING Unless otherwise noted troubleshooting and repair procedures are performed with power switches OFF and power cables disconnected from the power source 3 4 MCH 100 A REV 7 15 MAY 2013 3 2 1 TABLE 3 2 TROUBLESHOOTING PROCEDURES NO AIR POWER 1 Is the Power Supply ON OFF Switch in the ON position 2 Isthe accessory Heat Gun securely connected via the Quick Disconnect Connectors 3 Are the 2 two Batteries used the correct type 390 B U NiMH PN BT 70790 4 Arethe Batteries charged and operational a See Chapters 2 for Operating Procedures Chapter 5 for Charger Information and Chapter 6 for Battery Information 5 Isthe Battery Connector securely connected to the Batteries a The Power Supply Power Cord should be replaced if the Battery Connector tabs are broken or the junction between Connector A and Connector B is loose See Power Supply Power Cord Replacement instructions in Section 3 4 6 Are any electrical connections compromised cut cracked abraded chaffed or charred that exposes the internal shield or conductors Check the Power Supply Power Cord Accessory Power Cord and connections inside the Power Supply container a The Power Supply Power Cord should be replaced if the external or internal Power Supply Power Cord is compromised See Power Cord Wire Harness Replacement instructions in Section 3 4 7 Arethe Heat Gun Fan Motor s Carb
58. lded parts 111 478 Bayonet coupling to match 111 038 1 Heat Gun Fitting included with the MCH 100 A Assembly 112 025 Round nozzle 5 mm for soldering Bayonet coupling to match 111 038 1 Heat Gun Fitting included with the MCH 100 A Assembly Any questions regarding operation maintenance repairs parts and accessories can be directed to Malcom Technologies through our toll free number from the USA at 800 289 7505 or from other parts of the world by calling 401 683 3199 Multimedia How To s Product Resources and Accessory Development Projects are available on our web site at www malcom com or by emailing Jono Bixby at jono bixby malcom com 4 5 MCH 100 A REV 7 15 MAY 2013 CHAPTER 5 SPC Lite Universal Portable Charger Dual Position PN BTC 70819 NSN 6130 01 555 7817 5 1 OPERATION AND SERVICE MANUAL See included Bren tronics Inc OPERATION AND SERVICE MANUAL SPC LITE Universal Portable Charger Dual Position BTC 70819 Any questions regarding accessories can be directed to Malcom Company through our toll free number from the USA at 800 289 7505 or from other parts of the world by calling 401 683 3199 We also have a web site at www malcom com where you can place orders for parts and accessories and email us with questions at any time 5 1 MCH 100 A REV 7 15 MAY 2013 CHAPTER 6 48v NiMH Rechargeable Battery BB 390B U Part BT 70790 NSN 6140 01 490 4317 meremur m BA NICK
59. lement Cover as described in Section 3 3 1 3 3 4 2 Unplug the Heating Element from the Heat Gun Handle by pulling straight upwards Figure 3 5 Figure 3 5 Heating Element Disassembled 3 8 MCH 100 A REV 7 15 MAY 2013 3 3 5 CHECK CONTINUITY OF HEATING ELEMENT 3 3 5 1 3 3 5 2 3 3 5 2 1 3 3 5 3 Remove the Heating Element as described in Section 3 3 4 Using an audible continuity tester connect one lead to one element prong and the second lead to the second element prong An audible beep means that the continuity is intact If continuity test fails then replace the Heating Element as described in section 3 3 6 If the Heating Element passes the continuity test then reinstall the Heating Element Cover as described in Section 3 3 7 and replace the Heat Gun Switch as described in Section 3 3 11 3 3 6 REPLACE HEATING ELEMENT 3 3 6 1 3 3 6 2 3 3 6 3 Remove the damaged Heating Element as described in Section 3 3 4 Push fit the new Heating Element to the Heat Gun Handle Slide the Heating Element Mica Tube over the Heating Element and reinstall the Heating Element Cover as described in Section 3 3 7 3 3 7 REINSTALL HEATING ELEMENT COVER 3 3 7 1 3 3 2 olide the Element Cover over the Heating Element and Mica Tube Fasten the Element Cover to the Heat Gun Handle using the three screws previously removed Use a seizing compound like Loctite Blue Part No 24200 when reinstalling the Eleme
60. linking or solid the battery may be removed and returned to service and another battery may be installed for charging NOTE The BB 390A U and the BB 390B U batteries include two independent 12 volt sections A relay clicking may be heard from the battery adapter when battery sections are switched Other types of adapters may also contain relays and click intermittently during normal operation NOTE Battery charger power may be left ON while batteries and or adapters are removed or replaced Batteries may be left on the charger for long periods of time without damaging the batteries or the charger This is true whether if the charger is on or off 850036 1 REV E 2 5 OPERATION 2 4 BATTERY REVITALIZATION AND DE STORAGE The procedures outlined below describe the means of invoking the Revitalization and De storage functions of the charger as well as the sequence of operations the charger will execute to perform the commanded tasks NiCd and Ni Mh Batteries are revitalized Li lon batteries are de stored The charger will decide what to do based on the batteries chemistry a NiCad and Ni Mh Revitalization Due to the increased power dissipation from discharging the batteries this function will not operate above 45 C The following procedure is used to invoke the Revitalization process 1 Power up the charger 2 Plug in adapter 3 Once the adapter is recognized the two amber Charge LED Fig 2 1 1 8 blink press the Rec
61. must be removed then turn off the power to the tool and use only combination pliers and or insulated gloves to remove the hot nozzle 2 5 2 To install nozzle push and twist into heating element cover See Figure 2 11 2 5 2 1 115 recommended to turn the fan off during nozzle installation HOT NOZZLES CAN CAUSE BURNS Do not touch hot nozzle with bare hands and make sure to place the hot nozzle onto a heat resistant surface or drop it into the insulated pocket in the MCH 110 Carry Case 2 5 3 Only MCH approved nozzles should be installed on the heat gun Figure 2 101 Sieve Nozzle Attached 2 5 MCH 100 A REV 7 15 MAY 2013 2 6 CHARGING BATTERIES 2 6 1 Carefully remove batteries from power supply 2 6 2 Install the BTA 70834 Battery Adapter Plate into the BTC 70819 Universal Portable Battery Charger 2 6 3 Place the batteries onto charger adapter plate as outlined in Chapter 5 of this manual 2 6 4 Batteries should be periodically completely discharged prior to charging to maintain calibration See Chapter 6 2 6 5 Charging status is indicated by the Battery Charging System s LED state of charge lights and should be complete within 2 hours See Chapter 5 WARNING NO SMOKING IS PERMITTED NEAR THE CHARGING STATION AND HOT AIR TOOL Batteries can produce explosive gases during charging or discharge cycles Never smoke or allow open flames near the charging station or the hot air tool while they are in use ACID
62. n and Chapter 6 for Battery Information 3 6 MCH 100 A REV 7 15 MAY 2013 3 3 HEAT GUN MAINTENANCE INSTRUCTIONS 3 3 1 REMOVE HEATING ELEMENT COVER 3 3 1 1 Disconnect Heat Gun from Power Supply Remove the three screws that attach the Heat Gun Element Cover to the Heat Gun Handle Figure 3 1 3 3 1 2 Slide off the Element Cover and Mica Tube Figure 3 2 Figure 3 1 Element Cover Figure 3 2 Cover Removed 3 3 2 REPLACE SEPARATION RING PN 100 802 3 3 2 1 Remove the Heating Element Cover as described in Section 3 3 1 3 3 2 2 Remove the damaged Heating Element Cover Separation Ring PN 100 802 by sliding it over the heating element 3 3 2 3 Install new Separation Ring Figure 3 3 by sliding over the heating element Reinstall the Heating Element Cover as described in Section 3 3 3 3 2 4 Replace the Heating Element Cover as described in Section 3 3 7 Figure 3 3 Separation Ring 100 802 3 7 MCH 100 A REV 7 15 MAY 2013 3 3 3 REPLACE GROUND CLIP PN 107 227 3 3 3 1 Loosen the Heating Element Cover screw that fastens the Heat Gun Ground Clip to the Heat Gun and remove damaged Ground Clip Figure 3 4 Figure 3 4 Heat Gun Ground Clip 107 227 3 3 3 2 Install the new Heat Gun Ground Clip PN 107 227 and tighten the screw Use a seizing compound like Loctite Blue Part No 24200 when reinstalling the Element Cover Screw 3 3 4 REMOVE HEATING ELEMENT 3 3 4 1 Remove the Heating E
63. n External Cable Restraint Internal Plastic Cable Restraint Pin Connector and Quick Disconnect Connector 3 4 1 14 1 1 The Internal Plastic Cable Restraint and Pin Connector may need to be pushed through the Quick Disconnect Connector house through the opposite opening from the Quick Disconnect Connector threads Figure 3 22 NC3FX HD Quick Figure 3 23 NC3FX HD Disconnect Connector Assembly 3 18 MCH 100 A REV 7 15 MAY 2013 3 4 1 14 2 Slide the External Cable Restraint onto the Power Cable making sure that the threaded end of the External Cable Restraint is facing the prepped Power Cable conductors 3 4 1 14 2 1 Note If the MCH 102NW Power Cable is not prepped then start by first stripping back the Power Cable jacket 1 one inch Strip back the two black and white conductors 1 4 one quarter inch and tin with solder Take the braided wire shield and twist into a 1 one inch tail Tin with solder and shrink 3 4 three quarters of inch tubing over tail 3 4 1 14 2 2 Note Talc powder or liquid soap may need to be applied to the end 3 4 bh 3 4 bh 3 4 1 16 1 3 4 1 17 3 4 1 18 3 4 1 19 3 4 1 20 15 16 of the Power Cable jacket to aid in sliding the External Cable Restraint onto the Power Cable Slide the Internal Plastic Cable Restraint onto the Power Cable making sure that the narrow conical opening of the Plastic Cable Restraint is facing away from the prepped Power
64. nformation 7 1 MCH 100 A HOT AIR TOOL 7 1 1 Malcom Company warrants goods supplied under the order conform to specifications supplied and are MERCHANTABLE and fit for the particular purposes for which goods are ordinarily employed 1 oeller further warrants to the Buyer and to any party ultimately using any item whether such third party is a customer of Buyer or not that all items delivered under the order will be free from defects in material and workmanship and will conform to applicable specifications drawings samples and descriptions The foregoing express warranties shall be in addition to any warranty customarily made by Seller of its products and any implied warranties shall be construed as conditions as well as warranties Seller s warranty shall extend for a period of 12 months 365 days after the item is delivered and accepted by buyer Heating elements are not covered by the terms of this warranty The warranties represented and covenants of parties outlined shall survive the delivery of the goods or completion of the work or services provided and is fully enforceable thereafter Seller s warranty is part consideration for the order any payment by buyer is conditional upon warranty remaining in effect and no modification or other change of this warranty shall be valid unless evidenced by Buyer s written change order Seller undertakes to repair free of charge and damage occurring to tools that is established by Selle
65. nt Cover screws 3 9 MCH 100 A REV 7 15 MAY 2013 3 3 8 REMOVE HEAT GUN HANDLE 3 3 8 1 3 3 8 2 3 3 8 2 1 Disconnect the Heat Gun from the Power Supply Remove the three screws from the handle Figure 3 6 Carefully slide the Heat Gun Handle back over the cable Excessive force may snap the Heat Gun Filter Screen and Heat Gun Switch Bracket Slowly work the Handle back and forth while the Handle is being pulled Figure 3 7 EMI protection in the 111 038 1 Heat Gun starting with Serial Number 992142 has been changed from a nickel metal painted shield to a Stainless Steel Sheet Shield Figure 38 Heat Gun Handles from kits or marked with Serial Numbers less than 992142 should be removed with extra care to prevent damage to EMI protective paint Removed paint may break the integrity of the EMI shield The continuity of the shield can be tested using an audible continuity tester amp Figure 3 6 Heat Gun Handle Figure 3 7 Exposed Heat Gun Figure 3 8 Exposed internal Screws Handle EMI Protection Heat Gun Components 3 10 MCH 100 A REV 7 15 MAY 2013 3 3 9 CHECK CARBON BRUSH 3 3 9 1 Remove the Heat Gun Handle as described in Section 3 3 8 3 3 9 2 Inspect the 2 two Carbon Brushes located on opposite sides of the fan motor in between the Heat Gun Heating Element and the Heat Gun Internal Components The Heat Gun Fan Springs should be hooked on to the Carbon Brushes Figure 3 9 3 3 9 3 Remove the br
66. o moment state of charge status including faults and can be disengaged with the charging system s blackout feature Computer controlled charge sequencing and automatic circuit switching regulates battery charging at the respective battery adapter ports The charger is designed for worldwide deployment with multi voltage input power capability An integral five foot power cable can be connected to the local AC supply receptacle when the unit is operated from an AC power source a separate cable assembly is provided for operation from a 24 Volt DC source through the vehicle battery box NATO slave connector The battery charger can also be used with shipboard 400 Hz AC systems NOTE The BTC 70819 4 Charger manufactured by Bren Tronics is the only charger that can be used to recharge the BB 390B U batteries SIEVE REFLECTOR NOZZLE 111 476 The 111 476 Sieve Reflector Nozzle is designed for the application of heat shrink tubing The nozzle uses a twist lock system to attach to the 111 038 1 heating element case Consistent air temperature is maintained throughout the reflector nozzle by forcing air through sieve holes along the entire concave surface of the nozzle 1 5 MCH 100 A REV 7 15 MAY 2013 1 7 SPOON REFLECTOR NOZZLE 112 028 1 7 1 The 112 028 Spoon Reflector Nozzle is designed for the application of heat shrink tubing The nozzle uses a twist lock system to attach to the 111 038 1 heating element case 1 8 Batter
67. ock nozzle types allows temperature adjustments from 500 to 1050 F 370 to 595 C The Heat Gun is designed for use in electromagnetic sensitive environments and is protected through intrinsic electromagnetic filtering and shielding 48VDC power is supplied by the MCH 102NW Power Supply Figure 1 3 when connected via the Heat Gun s NC3MX HD Quick Disconnect Connector 48DCV POWER SUPPLY MCH 102NW The MCH 102NW 48VDC Power Supply houses two 24 Volt BB 390 B U Nickel Metal Hydride Batteries and supplies power to the Heat Gun and additional MCH attachments and accessories The Power Supply consists of an environmentally protective watertight and electromagnetic shielded molded fiberglass case with a built in ON OFF switch power supply cable with NC3FX HD Quick Disconnect Connector push button air pressure equalizer valve DC Power Dual Battery Balancing Connector and anti skip protection to prevent slipping when placed on a slick surface 24 VOLT BATTERY BT 70790 The BT 70790 24 Volt BB 390 B U Rechargeable and Sealed Nickel Metal Hydride smart battery Figure 1 4 with state of charge liquid crystal display LCD is encased in a durable high impact ABS plastic housing The battery features gold plated brass contacts for extended electrical hookup without corrosion protection against possible cell reversal rechargeable with up to 500 cycles depending on use preventative maintenance and environment and a shelf life
68. on Brushes properly set a See Section 3 3 9 for checking carbon brushes b See Section 3 3 10 for resetting and replacing carbon brushes 8 Isthe Power Supply Switch operational a See Section 3 4 for replacing the Power Supply Cable DECREASED Decreased Run Time or Air Temperature PERFORMANCE 1 Is the Heat Gun clear of dirt and dust a See Section 3 1 for Heat Gun Cleaning 2 Are the batteries conditioned a See Section 3 1 2 for Battery Conditioning and Calibration 3 5 MCH 100 A REV 7 15 MAY 2013 NO HEAT The fan is running and is blowing ambient air 1 Is the Heating Element operational a See Section 3 3 5 to Check the Continuity of the Heating Element Replace if Heating Element fails a Continuity Test b See Section 3 3 6 to Replace the Heating Element 2 Is the Heat Gun switch operational a See Section 3 3 11 for replacing the Heat Gun Switch LOW BATTERY 1 Are the Batteries conditioned VOLTAGE a See Section 3 1 2 for Battery Conditioning and Calibration 2 Are the Battery Battery Charger and Battery Adapter operational a See Chapters 2 for Operating Procedures Chapter 5 for Charger Information and Chapter 6 for Battery Information INACCURATE 1 Are the Batteries conditioned STATE OF a See Section 3 1 2 for Battery Conditioning and CHARGE Calibration INDICATORS 2 Are the Batteries operational a See Chapters 2 for Operating Procedures Chapter 5 for Charger Informatio
69. on keeps the LED s off during the Lamp Test Turns power to the charger off in an overload condition Remove the overload condition and push to reset The Amber LED lights steady while the associated battery is being fast charged A slow blinking indication means the charger is trying to find a battery at the select position A fast blinking indication means the charger is preconditioning the battery before charging it The Green LED indicates the associated battery is fully charged and ready to be removed for use Steady light means the battery has completed fast charge A blinking indication means the battery is being topped off 2 2 10 Fault LED 11 AC Input Connector 12 DC Input Connector Adapter POr di 14 Recondition Switch 15 Recondition LED Amber 16 RS 232 Port 17 Pressure Equalization Valve OPERATION If the Red LED lights steadily the associated battery or adapter plate is defective or will not accept charge A blinking indication means the battery s temperature sensor or communication connection is not making contact with the adapter Input connection for AC cable assembly Input connection for DC cable assembly Provides interface connection for battery adapters Activates NiCd revitalization or Li lon d
70. ondition Switch Fig 2 1 1 14 for the A or B channel the amber Recondition LED Fig 2 1 1 15 will light for the corresponding channel 4 Plug the battery into the activated channel 5 Revitalization will commence upon recognition of the battery Autonomously the charger will perform the following revitalization sequence 1 Check environment temperature if the temperature is above 45 C it will not proceed 2 Discharge the battery without a capacity measurement 3 Fully charge the battery 4 Discharge the battery and calculate the capacity 9 Fully charge the battery 6 If the capacity in step 4 is greater than or equal to 80 of the battery specification the green Ready LED Fig 2 1 1 9 will light and the Recondition LED Fig 2 1 1 15 will remain lit and the process is complete 7 If the capacity in step 4 is less than 80 steps 4 and 5 will repeat second time If after the second cycle the capacity is less than 80 of the battery specification the red Fault LED Fig 2 1 1 10 will light The Recondition LED Fig 2 1 1 15 remains lit and the process is complete b Li lon De storage Due to the increased power dissipation from discharging the batteries this function will not operate above 45 C The following procedure is used to invoke the de storage process 1 Power up the charger 2 Plug in adapter 3 Once the adapter is recognized the two amber Charge LED Fig 2 1 1 8 blink press the Recon
71. ps below 35 volts 6 1 MCH 100 A REV 7 15 MAY 2013 6 3 BB 390B U OPERATION 6 3 1 The MCH 100 A is a robust tool that subjects the BB 390B U battery power source to rapid discharge Starting with a fresh charge and 75 F ambient temperatures the tool should operate continuously for 26 28 minutes Continual run generates greater internal heat and if combined with high ambient temperatures will ultimately cause the thermal protective circuitry to shut down the tool prematurely Using the tool in short bursts will not generate as much heat and the tool can be operated for a longer period before a recharge will be necessary 6 3 2 The batteries incorporate two LCD readouts for a visual state of charge display A full battery will display five LED segments in each of the two displays on the top of the battery As the battery is used during the heat gun operation the LCD will display a decreasing number of segments Each segment represents about 20 five minutes of run time of the heat gun Section 6 8 The two LCD displays should be identical when they are calibrated The last segment usually remains on the longest 6 3 3 The BB 390 batteries including with the MCH 100 A are fully charged as part of standard procedures before final test and assembly However all rechargeable batteries lose one percent of their charge in 24 hours of shelf time Thus when the tool is unpacked for use in the field the batteries may be well below ch
72. r Supply connector Store batteries in Power Supply Container as if they were connected to the Power Supply Connector and rotate Connector to protect flanges 2 8 2 Insert Universal Battery Charger and Carry Bag into shipping container with adequate padding and bracing to prevent damage 2 8 3 Secure shipping container and ship or store in cool dry area 2 9 PREPARATION FOR STORAGE OF BB 390 BATTERY 2 9 1 Remove Batteries from Power Supply 2 9 2 Fully charge batteries at room temperature 2 9 3 Store battery in cool dry area 2 10 PREPARATION FOR SHIPMENT OF BB 390 B U BATTERY 2 10 1 Remove Batteries from Power Supply 2 10 2 Fully charge batteries at room temperature 2 10 3 Pack batteries in a cushioned container Battery is not hazardous and has no shipping restrictions 2 11 OPERATION IN UNUSUAL WEATHER CONDITIONS 2 11 1 Observe these precautions when the MCH 100 A is operated in areas where severe climatic conditions may exist 2 11 1 1 Operation in Arctic Climates The hot air tool is designed to function in temperatures as low as 32 F 0 C However the following precautions should be observed 2 11 1 1 1 Handle equipment carefully 2 11 1 1 2 Keep equipment clean and dry 2 11 1 1 3 Prevent ice from forming on the equipment Ice formations may prevent proper electrical connections 2 11 1 1 4 Battery and hot air tool performance decreases as the temperature drops 2 8 MCH 100 A REV 7 15 MAY 2013
73. r according to Bren Tronics warranty 7 4 SERVICE FORMS 4 1 Any request for service repair must be authorized by the Malcom Company Service Department before the item is returned to the Company for Service The buyer shall pay any freight charges that may be incurred Please go to the Malcom website www malcom com and download the service form On the following pages are the required service forms that must accompany all tools returned for service Any questions regarding warranty issues operation maintenance repairs parts service and accessories can be directed to Malcom Company through our toll free number from the USA at 800 289 7505 or from other parts of the world by calling 401 683 3199 We also have a web site at www malcom com where you can email us with questions at any time Email address jono bixby malcom com 7 2 4 malcom REV 100513 SERVICE FORM Page 1 of 3 Date Customer Name Telephone Fax Email Address City State Zip Code Shipper Circle one UPS FED EX DHL OTHER Tool Type Tool Serial Description of Problem 4 malcom REV 100513 SERVICE FORM Page 2 of 3 To be completed by Malcom Company Service Center Service Repair Customer PO Date received by Malcom Date of Customer Authorization Customer Shipper Date shipped to Customer Total Labor Total Parts Warranty and Service Policy Warranty is twelve months on every tool except the heating
74. r to result from defects in production In order for repair to be effected in accordance with the provisions currently valid tools must be returned to Seller s works carriage paid and free of charges No replacement will be effected in the event of incorrect use unauthorized repair interference with the tool and normal wear and tear Seller s liability will exclusively comply with the sections specified under warranty as well as the currently valid general conditions of business and terms of delivery Any claims on the part of the buyer for compensation of damages against Seller which are not expressly granted in the above sections irrespective of the sort of claim or its basis in law particularly claims arising from violation of accessory contractual obligations for loss and damage in transit from positive breach of contract for consequential loss of damage arising from defects in as much as these are not covered by contractual guarantee from buyer s claims of recourse resulting from product liability from buyer s claims for commercial material damages due to defective products etc are excluded unless these are the result of unlawful intent or gross negligence 7 1 MCH 100 A REV 7 15 MAY 2013 7 2 BB 390 BATTERY WARRANTY 7 2 1 12 months 365 days from date code printed on battery according to Bren Tronics warranty 7 3 BATTERY CHARGER BB 390B U WARRANTY 7 3 1 12 months 365 days from date code printed on charge
75. r too cold Move the charger to a more suitable environment 2 The air vents at the left and right side of the charger are blocked 3 Operating the chargers edge to edge can cause overheating of the charger on the right 4 One of the internal fans has failed The unit requires repair Call or e mail Bren Tronics Info on warranty tag 1 If the unit is running from DC power verify the voltage is correct 2 If the unit is running from AC power the unit requires repair 1 Poor connection between Adapter and Charger Inspect clean and reseat Adapter 2 Defective Adapter use a different Adapter 3 The charger does not support the Adapter Update the charger software See para 3 7 1 Check battery older than 3 yrs Maybe ready for disposal Discharge amp recharge or Revitalize IF RED AGAIN 2 Check warranty instructions on battery If not covered or no instructions dispose of 3 Note success failure of future battery charges at this Port More RED lights Change adapter MAINTENANCE FAULT LED is blinking 1 his condition is telling you the thermal contacts on the BB 390 or communication contacts on other batteries are not making contact with the charger To minimize this Ee before you first start using the charger nsure a Two Thermal contacts are in place in each battery position on the BB 390 or all contacts on other batteries b Adapter contact pins are in place and retain their spring action
76. rating the chargers edge to edge can cause overheating of the charger on the right 4 One of the internal fans has failed The unit requires repair Call or e mail Bren Tronics Info on warranty tag 14 Fault LED stays lit after battery is 1 Battery is defective Cycle power to clear removed fault 850036 1 REV E 3 4 10 2 3 MAINTENANCE 3 6 WARRANTY REPAIR INFORMATION If the Charger or Adapters fail to function they must be returned to Bren Tronics for repair The warranty label gives the expiration date on each unit Contact Bren Tronics for a Return Material Authorization RMA number before returning any hardware to Bren Tronics The part numbers serial numbers and failure descriptions must be included for Bren Tronics to issue an RMA number Chargers that have been damaged by abuse or that are no longer under warranty may be returned for a repair quotation There are no user repairable parts in the charger Opening the charger will void the warranty For return authorization call 631 499 5155 or email sales bren tronics com 3 UPGRADE UPDATE INFORMATION The Charger Operation Software is field upgradeable Updates usually add support for additional battery adapters They may also include enhanced battery charging methods The upgrade can be done with a PC running Windows 95 or newer in about 15 minutes All that is required is a computer serial cable and a screwdriver Information about ne
77. red briefly when power is first applied Note If both Multiple Power Sources are connected e For the BTC 70819 3 if AC and DC are connected the charger will use AC power If 12 and 28 VDC power are connected the charger will use 28VDC e For the BTC 70819 if AC and DC are connected the charger will use DC power Observe that only the Power On Indicator LED Fig 2 1 1 3 is lit Install the appropriate battery adapter into the Adapter Port Fig 2 1 1 13 for battery type to be charged Install the adapter by first placing the back of the adapter into the rear retainer Note the alignment of the pins The connector can only be plug in one way do not force it Be sure that battery adapter is fully seated on the panel For Cable adapters line up the pins to the Adapter Port Fig 2 1 1 13 18 Pin Connectors will plug in toward the right side on the charger do not force the connector Observe after a short delay that the two amber Charge LEDs Fig 2 1 1 8 will blink for several seconds This shows battery charger circuits are initialized to the selected battery adapter and are ready to accept a battery or batteries for charging If all of the status indicator LEDs Fig 2 1 1 8 9 and 10 for a channel light at the same time the adapter could not be recognized or the adapter is damaged insure it is seated correctly If running on DC verify that the battery is supported by DC charging ex the BB516 is not Verify that the cha
78. replace them with batteries that show full charge and operational readiness This can only occur by following good maintenance practice If only one set of batteries are available they must be routinely cycled for charge discharge freshening See Chapter 3 Preventative Maintenance Instructions 3 The MCH 100 A uses two BB 390B U batteries Always use batteries from the same lot Try to avoid mixed batteries from different lots and date codes It is essential for optimal performance that the batteries share equally in the operational requirements of the heat gun tool A weak battery will be the limiting factor in tool run time NOTE While it may be necessary to use whatever battery is available proper mating within the circuitry is good practice Whenever possible replace both batteries with matched performance pairs Check the date codes for warranty Do not mix BB 390A U older batteries with the newer version BB 390B U Both versions however will operate the MCH 100 A 4 Never attempt to force charge a warm battery Batteries should be cooled to room temperature prior to process Upper and lower extremes in temperature are damaging to any battery and rechargeable type batteries need to be handled with attention to longevity 5 he MCH 100 A Battery Powered Heat gun depends on the proper treatment of the power source Current versions of the tool that are using the 300 watt element will operate for approximate 26 28 minutes before
79. rger software revision supports the adapter and battery 850036 1 REV E 2 4 OPERATION 2 3 CHARGING BATTERIES Step 1 With the appropriate battery adapter installed insert the first battery to be charged into the channel A battery location Insure the battery is fully seated in the adapter Observe that the amber Charge LED Fig 2 1 1 8 for the corresponding location is lit or blinking rapidly The Charge LED Fig 2 1 1 8 for the B battery location will continue to blink if the channel B battery location is left empty If the red Fault LED Fig 2 1 1 10 is lit the battery or adapter may be defective check by removing the battery and the adapter Then reinstall the adapter and battery If the Fault LED Fig 2 1 1 10 still lights go to the Troubleshooting section section 2 7 2 8 and 3 5 of this Guide otep 2 Install the next battery into the Channel B battery location Step 3 After fast charging is complete the amber Charge LED Fig 2 1 1 8 will turn off and the green Ready LED Fig 2 1 1 9 will be lit The charger will then top off the batteries that have successfully completed fast charge The battery is slow charged to full capacity as indicated by the blinking green Ready LED Fig 2 1 1 9 For Lithium ion batteries the cycle will stop after the battery is 100 charged For other types the cycle is repeated indefinitely to keep the battery at 100 charge As long as the green Ready LED Fig 2 1 1 9 is lit b
80. the DC input power permits a range of 22 33 VDC standard on most military vehicles The Charger is available with an additional 12 VDC input This allows the Charger to be powered from an 11 18 VDC such as a standard 12 VDC automotive system When operated with either DC power source an Under voltage Lockout Circuit prevents the Charger from excessively discharging the vehicle battery so there is always enough power to restart the vehicle The SPC Lite is adaptive by design It is microprocessor controlled and is presently programmed to automatically charge over 50 different battery types and growing as listed in Table 1 With the appropriate battery adapter however it can be readily reprogrammed via the RS232 software upgrade port in the field to charge a countless number of additional battery types and chemistries including Nickel Metal Hydride Nickel Cadmium Lithium lon and Lithium Polymer The battery charger components are housed in a durable solid polypropylene case The assembled unit is watertight when the cover is securely latched and the pressure equalization valve is closed 850036 1 REV E 1 1 INTRODUCTION 1 2 TECHNICAL SPECIFICATIONS Weight less adapters and cables Power Requirements AC Operation 28V DC Operation 12V DC Operation Charging Output Voltage BN EG UU Protective Features
81. this charger 3 This list was complete at the date of publication Additional adapters may be available but may require updated software 850036 1 REV E 1 5 INTRODUCTION Table 2 Power Cables and Accessories DESCRIPTION BTI P N GENERAL P N NSN AC Power Cord US 7 591609 AC Power Cord EU 7 59235 O AC Power Cord 15902834 DC Power Cable wirings 70844 4 lA DC Power Cable w allig clips BTA 70844 24 AL Gabriel DC Power Cable BTA 70819 24 _ _ Fi TTN many BE HoT Figure 1 4 3 BTA 70816 for use with BTA 70835 Figure 1 4 4 BTF 70791 850036 1 REV E 1 6 INTRODUCTION 1 5 CHARGE CYCLE DESCRIPTION Each of type the battery that are capable of being charged by the Charger is connected to the charger via their respective battery adapter plate or cable Each adapter can charge two batteries simultaneously The appropriate battery adapter is installed on the control panel and serves as the electrical interface between the batteries being charged and the charger circuits The battery charger control circuits constantly monitor the following battery conditions during the charge cycle as appropriate to ensure that the battery is properly being charged a Temperature T b Voltage V c Current 1 d Time t e Voltage change AV f Temperature rate of change AT At The charger operation during a t
82. to operate in temperature extremes as high as 122 F 50 C and the dryness associated with a desert environment However the sand and dust accumulation on and in the charger may cause poor electrical connections and reduce the cooling effectiveness of the charger Follow proper cleaning and maintenance guidelines Section 3 2 to assure proper operation When not in use be sure the cover is fully latched and the Pressure Equalization Valve Fig 2 1 2 17 is fully closed tighten by turning the knob in clockwise direction c Operation in Salt Spray Keep the equipment clean and dry at all times and immediately wipe salt spray from all the exposed surfaces on the charger and cables and connectors When not in use be sure the cover is fully latched and the Pressure Equalization Valve Fig 2 1 2 17 is fully closed tighten by turning the knob in clockwise direction d Operation in Rain Keep the equipment dry at all times Water penetration in the charger cables and the connectors will cause equipment failure When not in use be sure the cover is fully latched and the Pressure Equalization Valve Fig 2 1 2 17 is fully closed tighten by turning the knob in clockwise direction 850036 1 REV E 2 10 OPERATION NOTE Battery charge acceptance varies with ambient temperature conditions At temperatures lower than 32 F 0 or higher than 104 F 40 C it may be necessary to initiate two complete charging cycles to achieve full char
83. ush to check for damage and to measure the length of the brush Figure 3 10 amp Figure 3 11 3 3 9 3 1 If the brush length is less than 0 25 in or is cracked then it should be replaced 3 3 9 4 Replace the Carbon Brushes as described in Section 3 3 10 Figure 3 9 Carbon Brush Figure 3 10 Remove Carbon Brush Figure 3 11 Carbon Brush Hooks Removed MCH 100 A REV 7 15 MAY 2013 3 3 10 REPLACE AND RESET CARBON BRUSH PN 100 066 3 3 10 1 Install Carbon Brush into the Heat Gun Fan slot with the notch facing outwards Figure 3 12 3 3 10 2 Use a small hook to latch the spring in the notch of the Carbon Brush Figure 3 13 Replace the Heat Gun Handle as described in Section 3 3 14 Figure 3 12 Replace Carbon Brush Figure 3 13 Reset Carbon Brush Spring 3 12 MCH 100 A REV 7 15 MAY 2013 3 3 11 REPLACE HEAT GUN SWITCH PN 102 969 3 3 11 1 Remove the Heat Gun Handle as described in Section 3 3 8 3 3 11 2 Remove the yellow High Temperature Kapton Insulation Tape from the Heat Gun Switch wire connection points Figure 3 14 3 3 11 3 Desolder the 2 two conductors from the back of the Heat Gun Switch 3 3 11 4 To remove the Switch press down on the clip on the top of the Switch near the break in the Heat Gun Filter Screen 3 3 11 5 Push fit the replacement Switch into place 3 3 11 6 Solder the desoldered leads onto the switch 3 3 11 7 Replace the Handle as described in Section 3 3 14 Fi
84. w adapters and software can be found at http www bren tronics com Call 631 499 5155 Or Email sales bren tronics com 850036 1 REV E 3 5
85. with questions at any time Email address jono bixby malcom com 2 0 MCH 100 A REV 7 15 MAY 2013 CHAPTER 3 Maintenance Instructions WARNING HIGH VOLTAGES ARE PRESENT IN THE OPERATION OF THIS EQUIPMENT Avoid contact with the DC and AC supply voltage connections during installation operation or maintenance of the MCH 100 A and its battery charging system Disconnect the batteries before opening the tool WARNING HOT AIR TOOL IS SHIELDED FOR ELECTROMAGNETIC EMISSIONS AND ENVIRONMENTAL EFFECTS The hot air tool is manufactured to meet certain EMI requirements as specified by USA Military and CE otandards Tampering with the electromagnetic EMI shield or not following repair instructions outlined in the technical manual may affect the integrity of the EMI shield and result in radiated emissions coming from the tool above the approved limits 3 MCH 100 A REV 7 15 MAY 2013 3 1 PREVENTATIVE MAINTENANCE PROCEDURES 3 1 1 HEAT GUN PREVENTATIVE MAINTENANCE 3 1 1 1 HEAT GUN CLEANING 3 1 1 1 1 Use compressed air to spray clean the Heat Gun intake air filter periodically approximately every 250 hours depending on use 3 1 1 1 1 1 The filter for the air intake to the hot air tool is located on the back of the heat gun 3 1 1 1 2 Remove the Heat Gun Heating Element Cover as described in Section 3 3 1 Remove the Heat Gun Heating Element as described in Section 3 3 4 3 1 1 1 3 Look through the H
86. y Discharge Cap BTF 70791 1 8 1 The BTF 70791Battery Discharge Cap is used to test and condition the BB 390 B U batteries 1 9 BATTERY ADAPTER PLATE BTA 70834 1 9 1 The BTA 70834 Battery Adapter Plate is used as the interface for the BB 390 B U batteries and the BTC 70819 Universal Charging System 1 10 FIELD CARRY CASE MCH 110 1 10 1 The MCH 110 Field Carry Case is designed with a shoulder strap for a technician to comfortably carry the Heat Gun and additional hot accessory such as the soldering iron attachment the 48 VDC Power Supply nozzle attachments and manuals or reference guides to the job site in the field The carry case utilizes a under the lid pocket system for storing nozzles a dual insulated packet for storing two hot accessories a rubber external traction system for preventing slipping when placed on a slick surface and is produced using a chemically resistant fabric to withstand the rigors of the field 1 11 MCH 100 A TECHNICAL SPECIFICATIONS MCH 100 A Weight Overall 31 lb 15 kg e Carry Bag MCH 110 w 111 038 1 MCH 102NW BT 70790 2 Qty 111 476 amp 112 028 Nozzles 17 lb 7 7 kg e Charger BTC 70819 4 w BTF 70791 2 Qty and BTA 70834 14 lb 6 8 kg Shipment No restrictions Disposal In accordance with local environmental regulations Design e MIL STD 461E EMI otandards MIL STD 464 EM ENVIRO EFFECTS MIL HDBK 235 EM ENVIRO MIL STD 810F 511 4 EXPLOSIVE ATMOSPHERE 506
87. y losses while storage at lower temperature decreases capacity losses The graph shows that Nickel based batteries like the BB 390 lose over 30 charge month 196 day on the shelf waiting to be used The BB 2590 3 p a Li lon based battery loses MONTHS STORED 20 less than 10 a month on the shelf CAPACITY LOSS IN STORAGE CURRENT CHEMISTRIES ASS HH 4 a CWS PERCENT CAPACITY REMAINING 2 13 BATTERY STORAGE Nickel based batteries may require 1 or more charge discharge cycles after a long period of storage They may not charge fully on the first charge cycle Repeat the charge if necessary using the Revitalizations feature see section 2 4 If the battery does not fully charge after 3 cycles it may no longer be serviceable Lithium based batteries must be charged yearly if held in storage Long term storage of fully discharged Lithium based batteries can permanently damage the battery They do not require charge discharge cycling after storage If the battery does not charge No SOC Bars place it back on the charger for one additional charge cycle Do not discharge it first If the battery does not fully charge it may no longer be serviceable 850036 1 REV E 2 12 3 1 MAINTENANCE SECTION 3 OPERATOR MAINTENANCE INSTRUCTIONS INTRODUCTION Periodic maintenance inspection and cleaning will help insure the Charger is kept at full readiness 3 3 CLEANING 1 Brush loose dirt
88. ypical charge sequence is automatic and the battery charge status is displayed to the user by the panel LED indicators as follows a Detection The charger tries to detect a battery in an adapter The CHARGE LED amber blinks slowly during this process b Pre charge The charger brings the battery voltage up to a safe level before the rapid charge process begins This step may take several minutes for a very discharged battery The CHARGE LED amber blinks rapidly during this process c Fast Charge A timed fast charge cycle brings the battery to approximately 90 of full charge capacity The CHARGE LED amber is lit solid during this process d Ready The fast charge cycle is complete The Battery may be removed and used at this time The READY LED green is lit steadily at this time e Trickle Top off When fast charge is complete the charger will top off of the battery to 100 For Lithium lon and Lithium Polymer batteries the top off cycle will stop after the battery is 100 charged For all other types the Trickle Top off cycle is repeated indefinitely to keep the battery at 100 charge Leaving the battery on the charger will not harm the battery The battery may be removed and used at this time The READY LED green blinks during this process NOTE The Battery may be removed and used at anytime during the charge cycle without damage to the charger or battery If present the state of charge indicator SOC will

BATTERY POWERED HEAT GUN ASSEMBLY

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