Operator's Manual. DPL-24A Differential Pressure Laminator. Revision E Software Revision Only 5/15/2014

Transcription

1 OPERATIONS TECHNOLOGY, INC. Operator's Manual DPL-24A Differential Pressure Laminator Revision E Software Revision Only 5/15/2014 1

2 THE DPL-24A... 4 INTRODUCTION... 5 Lamination Overview - Setup... 6 Lamination Overview - Lamination Cycle... 7 Lamination Detail... 8 Principles of Operation... 9 Facilities Requirements Substrate Specifications Productivity Substrate size Substrate Installing the DPL-24A Operating the DPL-24A Example Operation PRECAUTIONS MAINTENANCE Precision Digital Temperature Controllers Touch-Panel Controller Filter Regulator Diaphragm Platen Recommended Spares Package WARRANTY PERIOD OF WARRANTY LIABILITY OF WARRANTY TOUCH SCREEN PC & SOFTWARE Complete Changelog GETTING STARTED Front Panel Overview Front Panel - External Drive Access OPERATIONS PANEL Overview Heater Status Units Cycle Status Operations Vacuum Dwell Pressure Dwell Drawer Status Cycle End Options Auto Start SETTINGS PANEL Overview Pump

3 Dwell Timers Heater Controller - Top & Bottom Heater Controller Notes MAX Temperature Password Keypad Presets Preset Slots Save & Load Buttons Cycle End Options Auto Start SUPERVISOR PANEL Overview Completed Cycles Supervisor Options Save Logs Option Save Cycle Data Option Enable Preset save Enable Preset load Enable Preset rename Language Toggle units Display Units Update Software Exit Application Current Date & Time Machine Log Panel DATA PANEL Overview DATA PANEL Data Files Refresh Data Button Export Files Button Delete Files Buttons DATA PANEL Data Table PLC STATUS PANEL Overview Digital Outputs Digital Inputs Analog Inputs Connection ABOUT PANEL Overview Software & Contact Information Quick Guide

4 The DPL-24A 4

5 Introduction T he DPL-24A Differential Pressure Laminator has been designed to give the operator a superior method for laminating sheet supported emulsions such as dry film solder mask and primary imaging film. Such materials can be applied to various thicknesses and sizes of substrates. Experimentation is being done on alternative uses for this device, among them High Vacuum, Multi-Layer, Pressing of Printed Circuit Boards and micro-bga interconnects. The substrate can be pre-laminated manually, or by utilizing a cold-roll lamination technique. Once pre-lamination is complete, the substrate is then placed on the vulcanized rubber platen and finally pushed into the chamber. Products of differing thicknesses and geometries can be intermixed during a cycle if adequate hold-down techniques are employed. The massive 1000 LB chamber is constructed of Ductile Iron and uses only two o-rings. This design ensures a positive seal for best vacuum performance. Utilizing a high quality, high volume 65 CFM, 3 horsepower, rotary vane vacuum pump, an end point below two Torr is typically achieved. Vacuum lamination of printed circuit boards has been utilized for many years. But it was not until the development of the DPL-24A that a system provided vacuum prior to the application of positive pressure. No pressure is applied to the product during the vacuum dwell cycle. In this way maximum evacuation of air from between the substrate and the laminate is assured. During the pressure cycle a flexible diaphragm encapsulates the product and true isostatic lamination is achieved. Unlike roll laminators, the DPL 24A s diaphragm descends directly towards the platen. No lateral stress is applied, hence less distortion of the film can occur. 5

6 Introduction Lamination Overview - Setup Turn On Vacuum Pump Vacuum Dwell Set Timers Pressure Dwell Set Heaters Top Heater Set Point Bottom Heater Set Point Cycle Options Set Options Save Cycle Data Manage Cycle Data Refresh Export Delete 6

7 Introduction Lamination Overview - Lamination Cycle Substrate Placed Substrate Removed Vacuum Dwell Pressure Dwell Pre- Pressure 7

8 Introduction Lamination Detail The vacuum is displayed on the Operations Panel, computer calibrated, digital gauge integrated in the touch-panel controller. The temperatures of both the upper and lower heat platens are controlled independently by integral, precision, Temperature Controllers. The substrate is exposed to a Vacuum Dwell for a time determined by an integral digital timer. At the end of the Vacuum Dwell, a preheated silicone rubber diaphragm descends onto the work-piece and drives the spring-mounted drawer mechanism into intimate contact with the lower heater platen. A positive pressure of up to 10 PSI is applied to the top of the diaphragm to bring the combined differential to nearly 25 PSI. A short (1 second) Pre-Pressure step is taken to prepare valves for the Pressure Dwell. The Pressure Dwell is adjusted by an integral digital timer identical to that employed by the Vacuum Dwell. Upon completion of a cycle, the drawer mechanism is retracted and the product(s) removed for further processing. The entire process is governed by a microprocessor driven touch-panel controller. Programming modifications are available from the factory. 8

9 Introduction Principles of Operation When the DPL-24A is initially turned on, two precision controllers independently drive the top and bottom heaters to heat the diaphragm and drawer platen to the specified temperatures. After a brief warm-up time, the laminator is ready for use. The drawer is pulled open to allow access to load the vulcanized rubber platen with materials ready for lamination. Products of differing thicknesses and geometries can be intermixed during a cycle if adequate hold-down techniques are employed. The layered material is placed on the platen mounted in the sliding drawer. When the drawer is closed, the platen is positioned in the vacuum chamber and an O-ring seal on the drawer face contacts the opening in the vacuum/pressure vessel. Prior to the start of the cycle there is a vacuum drawn above the diaphragm. Air at atmospheric pressure is in the bottom of the vessel holding the diaphragm upwards. As shown in Figure 1, the diaphragm is suspended above the material on the drawer platen. The drawer platen is spring loaded upwards to allow the drawer to be opened and closed. 9

10 Introduction Principles of Operation - Continued When the cycle starts, vacuum is drawn on both ports, above and below the diaphragm. Utilizing a high volume vacuum pump, an end point approaching two Torr is achieved. This vacuum is displayed on a digital gauge located on the touchpanel controller. A programmable timer determines the Vacuum Dwell time before continuing to the next step Figure 2. It is important to note that this dwell time will allow air between the layers of material to be evacuated before the lamination pressure cycle begins thereby eliminating trapped bubbles. Because the vacuum is equal above and below the diaphragm, the diaphragm does not move and does not contact the material in the drawer. 10

11 Introduction Principles of Operation - Continued At the end of the Vacuum Dwell, positive air pressure at up to 10 PSI is applied to the port above the diaphragm bringing the pressure differential to nearly 25 PSI Figure 3. The preheated silicone rubber diaphragm descends onto the work-piece. This action drives the spring-mounted drawer platen into contact with the lower heater platen. Isostatic pressure is transferred to the material by the diaphragm. The stretching effect that occurs with roll type laminators is minimized. The flexible diaphragm conforms to the surface shape assuring positive contact between the layers, thereby eliminating voids. The pressure dwell time is controlled by another timer identical to the vacuum dwell timer. 11

12 Introduction Principles of Operation - Continued At the end of the Pressure Dwell cycle, the top port is connected to the vacuum pump again, and the bottom port is vented to atmospheric pressure. As shown in Figure 4, this returns the diaphragm and drawer platen to their original positions and allows the drawer to be opened for unloading. 12

13 Specifications Facilities Requirements Dimensions: 44" Wide X 44" Deep X 60" High, exclusive of leveling feet (1" to 2") Weight: 2,200 LBS (shipping) Electrical Requirements: 208/220 VAC, 3 Phase, 40 Ampere/Phase Compressed Air: Dry, Filtered, 80 PSI, 3 CFM Substrate Specifications Productivity Cycle time is adjustable from 0 to infinity and is determined by application parameters such as part complexity, thickness, mass, etc. Typical times for a circuit board may be 30 seconds for Vacuum Dwell and 20 seconds for Pressure Dwell. Substrate size Items up to 24" X 24" can be laminated. Smaller substrates can be processed in multiples if space permits and can be intermixed providing adequate holddown techniques are observed. Substrate Thicknesses from.001" to.375" can be accommodated utilizing standard holddown bars. 13

14 Installation Installing the DPL-24A IMPORTANT! Due to the weight of the unit, a forklift is mandatory for removal of the DPL-24A from the pallet and, for final positioning. 1. Upon receipt of the equipment please inspect for obvious external damage. 2. Remove wooden crating (if provided) and inspect for damage to the machine itself. Do not attempt to slide the chamber drawer! 3. Using a forklift roughly place the DPL-24A utilizing the attached pallet,. 4. Remove lower back panel. 5. Remove the four bolts securing the unit to the pallet. LIFT HERE 6. Raise unit with forklift blades positioned under the main vessel, being careful not to damage the main valve (see illustration below) 7. Install leveling feet (included) into holes formerly occupied by shipping bolts. VACUUM PUMP 8. Position, lower, and level the unit. 9. WARNING: IT IS IMPERATIVE THAT OIL BE ADDED TO THE VACUUM PUMP BEFORE OPERATION! Operations Technology, Inc DPL-24A PC & Software Manual Rev. C - 07/18/

15 Installation Installing the DPL-24A - Continued 10. Supply Compressed Air to input nozzle on right side rear of the machine. 11. Adjust primary regulator to PSI. 12. Adjust secondary regulator to 5-10 PSI. WARNING: DO NOT ATTEMPT TO ADJUST REGULATOR PAST STOP!!! DO NOT REMOVE PIN UNDER ANY CIRCUMSTANCES!!! 13. Wire and Connect 220 VAC, 3 Phase, 40 Ampere power to input cable. 14. Activate Main Power switch on front panel. 15. Activate Vacuum Pump switch on touch-panel. 16. With one person at switch and one person at the pump, JOG the vacuum pump switch on the touch-panel and monitor the pump to ensure proper rotation indicated by the arrow found on motor end case. ROTATION LABEL (REAR OF PUMP) Note: If the rotation is opposite to that indicated - reverse the connection on any two phases of incoming power. The DPL-24A is now ready for operation. 15

16 Operation Operating the DPL-24A 1. Ensure circuit breaker is in the ON position. 2. Activate MAIN POWER switch. 3. Activate VACUUM PUMP switch on touch-panel in the Settings Panel. 4. Chamber drawer may now be opened for inspection. WARNING: PLATEN MUST BE IN POSITION WHEN CYCLING MACHINE! 5. Return drawer to home position. 6. Activate TOP and BOTTOM Heaters on touch-panel controller. 7. Adjust controllers for desired temperature. 8. Allow minutes for unit to reach set-point and stabilize (if under 200 degrees F). 9. Product may now be processed through laminator. 16

17 Operation Example Operation 1. Set both Temperature Controllers to 160 Degrees F. 2. Set Vacuum Dwell to 30 Seconds. 3. Set Pressure Dwell to 20 Seconds. 4. Place Pre-laminated product on Platen. 5. Slide Hold-Down Device into place. 6. Slide Drawer into Vessel. 7. Press the START button. 8. Machine will complete one Automatic Cycle 9. Cycle Status will show Cycle Ready, and START button will be active. 10. Slide the drawer out, and remove substrate. NOTE: If at any time the operator desires to exit the cycle, depress the STOP button and machine will return to a Cycle Ready state. Atmospheric pressure will be vented to the chamber and the drawer may be opened. NOTE: If at any time the operator wishes to hold the cycle at a given step, depress the STEP button. The machine program will hold at the present step indefinitely. To resume the program sequence, press the STEP button. NOTE: If the operator wishes to step through the program manually, depress the STEP button. The unit will advance one program step with each pressing of the button, maintaining that step s conditions after completion of the timer setting. 17

18 Precautions CAUTION: NEVER ATTEMPT TO REMOVE DRAWER FROM VESSEL WITH VACUUM PUMP OFF. EMERGENCY RESET BUTTON MUST BE DEPRESSED. IN STEPS OTHER THAN STEP 0, VACUUM IS APPLIED TO THE DOOR AND WITHDRAWAL IS IMPOSSIBLE. IF VACUUM PUMP IS OFF, THE DIAPHRAGM MAY BE IN CONTACT WITH THE VULCANIZED PLATEN AND PERSISTENT PULLING MAY CAUSE DAMAGE. 18

19 Maintenance Precision Digital Temperature Controllers These integral devices provide precise control of temperature for the upper and lower heater platens independently. They are calibrated at the factory and should not need further adjustment. Touch-Panel Controller This unit controls activation, deactivation, and timing of the various valves in the DPL-24A as well as the temperature control functions. A program stored in memory is utilized to direct the sequence of events. Custom programming can be accomplished by the customer or by the factory for specialized applications. The controller does not require preventive maintenance. Filter Regulator Normally, clean, filtered, dry air should be supplied to the machine. The DPL-24A, however, has an additional filter incorporated into the primary regulator. This filter requires minimal maintenance (open petcock and drain out water occasionally). Diaphragm The 50 Durometer,.125" thick, Silicone Rubber Diaphragm is the major wear item in the system. It is advisable to keep a replacement Diaphragm on-hand in the event of a puncture or rupture. This unit is available pre-punched from the factory. Cleaning of the Diaphragm is accomplished with Isopropyl Alcohol only. Platen All work is pressed on this Vulcanized Rubber Platen. It is advisable to keep a standby Platen on hand if replacement becomes necessary due to normal wear or abrasion. Cleaning is accomplished either on or off the machine with a soft cloth, moistened with Isopropyl Alcohol only. 19

20 Maintenance Recommended Spares Package PART # DESCRIPTION QUANTITY 1008 HEATER, SILICONE 1 PIECE 1027 O' RING, DOOR 1 PIECE 1028 O' RING, VESSEL 1 PIECE 1041 FAN, EXHAUST, 220V 1 PIECE 1045 COVER SHEET (SILICONE) 1 PIECE 1070 VALVE, ACTUATOR 1 PIECE 1077 DIAPHRAGM, 1 PIECE 1078 PLATEN, 24" X 24" 1 PIECE 1089 VACUUM PUMP OIL 5 GAL 1094 SPRING, DRAWER 4 PIECES RELAY, MAIN 1 PIECE RELAY, SOLID STATE 1 PIECE POWER SUPPLY (24VDC) 1 PIECE DRAWER SLIDE, LARGE 1 PAIR MINIMUM ORDER FOR SPARES AND REPAIR PARTS IS $50.00 ORDER PARTS FROM: OPERATIONS TECHNOLOGY INCORPORATED PO BOX LAMBERT ROAD BLAIRSTOWN, NJ PHONE (908) FAX (908) info@optek.net 20

21 Warranty 1. PERIOD OF WARRANTY Operations Technology Incorporated warrants this product to be free of defects in material or workmanship for a period of 180 days commencing on the shipping date from Blairstown, New Jersey. 2. LIABILITY OF WARRANTY Operations Technology Incorporated warrants to the original purchaser that equipment sold under this agreement shall be free from defects in material and workmanship. Defective materials will be replaced or repaired at the discretion of Operations Technology Incorporated. Liability will be determined by Operations Technology Incorporated. All liability is expressly limited to said repair or replacement of defective parts, all other damages and warranties, statutory or otherwise, being expressly waived by the purchaser. This warranty is null and void if the equipment failure is due to negligence, accident, abuse, or improper operation. It is also nullified by tampering, alteration, or unauthorized repair of subject equipment or components. This warranty does not include filters, oil, Platen, and Diaphragm as they are generally considered to be consumable items. The user shall return all allegedly defective materials to Operations Technology Incorporated via approved routing charges prepaid. Upon determination of liability, Operations Technology Incorporated will either submit a quotation for repairs or rectify the defect at no charge. This warranty cannot be countermanded by the purchaser and is the only warranty relative to the transaction. No other warranty, expressed, implied, or statutory shall apply. Effective Date 12/1/11 Revised 12/1/11 21

22 Other Products OPERATIONS TECHNOLOGY INC. #30 LAMBERT ROAD P. O. BOX 408 BLAIRSTOWN, NJ Phone (908) FAX (908) Regular & Large Format X-Ray Inspection & Measurement The OPTEK 1272XA The OPTEK 712XA Regular & Large Format Video Inspection & Measurement The OPTEK 713VSA 5 SIZES AVAILABLE For information, demos, data sheets, applications, 3D models and much more visit 22

23 CURRENT REVISION : 0.9 RELEASE DATE : 11/21/2013 Touch Screen PC & Software Complete Changelog *VERSION 0.1 Release Date:12/06/2011 As Issued *VERSION 0.2 Release:03/06/2012 Changed font to 6pt on Data Management table Fixed a bug for upper limits on MAX Temperature setting Enabling "Auto start on drawer close" no longer immediately starts a cycle The active settings will be saved immediately after leaving the Settings Panel Increased MAX Temperature upper limit to 400F/204C Added checkbox to Supervisor options to enable/disable Preset Save Added checkbox to Supervisor options to enable/disable Preset Load Various source code cleanup, misspellings, added documentation. *VERSION 0.3 Release:03/14/12 Made MAX temp setting load before setting temperature, which may be higher than MAX, causing the Set Point temperature to be lower than expected. The Start and End times on the in the cycledata Window are now correct. Settings are saved after every run to ensure the Lifetime Cycle is updated correctly. Fixed bug where Cycle End Option "Turn heaters off" would sometimes not turn controllers off. Added two logging options to the log window, these only filter the log window, every line is still sent to the external logging drive. Added a Remember button to the password group 23

24 *VERSION 0.4 Release:03/23/12 Added option to Supervisor Panel to allow user to change Units Allowed the Units to change on Settings Panel when the password is entered *VERSION 0.5 Release:05/02/12 Auto-start would happen if user switched panels. Now auto-start will only happen if user is in Operations Panel Rounding errors for temperature conversions have been compensated for with 99.9% accuracy. Rarely it may be off by no more than a degree. The Turn Off Heater and Auto Start options have been moved to the Settings Panel, active only with password. The vacuum dial has been updated to be more meaningful. Note that its maximum display is 120 Torr, although atmospheric is around 850 Torr. The temperature set point now displays under the actual temperature. The timer set point now displays under the timer progress bars. The currently loaded preset will show under the Operations buttons. If a change is made in the Settings Panel, the Loaded Preset label will reflect that. Auto Start indication on the Operations Panel. The total number of presets has been raised to 20. Presets can now be renamed, but will require the user to attach a USB keyboard. Presets cannot be blank. Enable this option in Supervisor Settings. Preset rename option added to Supervisor Options User password can now be changed. There is no limit to the number of digits. PASSWORD CANNOT BE RETRIEVED, ONLY RESET BY A CALL TO OPTEK OR A REPRESENTATIVE VISIT. There is a button in the password box that will allow the supervisor to remain logged in. You can now delete single data files. Highlight the one you wish to delete and press Delete One. Confirmation required. The GUI will now check to ensure the correct PLC Program is loaded before activating any functions. It may be necessary in future releases to updated the PLC software. This will allow for ease of installation. The PLC Status Tab now carries the current PLC program ID as well as an Update Button and an output window. *VERSION 0.6 Release:06/14/2012 The Vacuum pump and dwell timers under the Settings Panel are now disabled by default. They can only be enabled by inputting the supervisor password. 24

25 *VERSION 0.7 Release:07/02/2012 Fixed a bug that caused some supervisor options to not be enabled after entering a correct password. *VERSION 0.8 Release:09/10/2012 Add Compl. column to Cycle Data Table. Software checks for an interruption of a normal cycle and records a complete cycle as YES or NO under the Compl column in the cycle data table. *VERSION 0.9 Release:11/21/2013 CRITICAL BUG FOUND - DO NOT USE THIS RELEASE Moved Cycle Data to its own Tab/Panel. Moved Display Settings to Supervisor Panel. Added language translation support in Supervisor Tab Added Different Pressure Units to the Display Settings. Software can now load.qm files compiled from.ts files. Software will changed the displayed pressure unit if changed in the Supervisor panel. Both the pressure unit and selected language is now a preset. *VERSION 0.10 Release:4/4/2014 Fixed critical bug in DPLgui.spec. Duplication of binaries and zip files was marking 40MB of disk space as used on each startup, without deallocating the space on exit. 25

26 Getting Started Front Panel Overview Front Panel 2. Thumb Screw 3. Main Power Switch 4. Emergency Stop Switch 5. Touch Screen PC 6. USB Port 1. Front Panel - The main user interface for the DPL-24A. 2. Thumb Screw - Use these to access the rear of the Touch Screen PC. 3. Main Power Switch - Turns machine ON and OFF. 4. Emergency Stop Switch - Immediately powers down machine. 5. Touch Screen PC - Used to operate the DPL-24A. Powers on with machine. 6. USB Port - Used to export cycle data and update software. 26

27 Getting Started Front Panel - External Drive Access To access the external USB drive, loosen both thumb screws (2), and pull them towards you. The front panel will swing down, allowing you to access the rear of the Touch Screen PC. The drive is located on the left hand side of the Touch Screen. The drive shown may vary from the one depicted. To remove the drive, gently pull it out, as you would any other USB device. Location of external USB drive. IMPORTANT: The drive must be re-inserted into the same USB port for logging to function correctly. 27

28 Operations Panel Overview Top Heater Status 2. Bottom Heater Status 3. Toggle Fahrenheit / Celsius Button 4. Operations Box 5. Vacuum Status 6. Pressure Status 7. Cycle Status 8. Drawer Status 9. Auto Start Status 10. Loaded Preset Operations Panel - The main panel used on the DPL-24A. 28

29 Operations Panel Heater Status The Heater Status boxes display information about the Top and Bottom heaters inside the DPL-24A. The Top and Bottom Heater boxes operate in an identical manner. CURRENT TEMPERATURE - The large red LCD numbers indicate the current temperature. The current units are displayed in the center of the two Heater Status boxes. CONTROLLER ACTIVE - Will read either CONTROLLER ON or CONTROLLER OFF. These controllers can be independently activated on the Settings Panel. CONTROLLER STATUS - Displays the current state of the controller. There are 4 states: OFF, HEATING, COOLING and SET-POINT, described in detail below. OFF - The controller is turned OFF in the Settings Panel. HEATING - The controller is continually sending voltage to the heater. COOLING - The controller is not sending voltage to the heater. The Set-Point has been lowered. SET-POINT - The controller is pulsing the voltage off and on to stay at the desired Set-Point. ACTIVE SET-POINT - Displays the currently active set-point found in the Settings Panel. 29

30 Operations Panel Units Displays the Current units, either F for Fahrenheit or C for Celsius. TOGGLE UNITS BUTTON - Switches the current units between Fahrenheit and Celsius. The changed units will also be reflected in the Settings Panel for Set-Points, and MAX. Cycle Status The cycle status box shows the current Cycle Status of the DPL-24A. The following lists all statuses: Cycle Ready - DPL-24A is ready to cycle. Vacuum Dwell - Air is being evacuated from the vessel. Pre-Pressure - Valves are manipulated in preparation for Pressure Dwell. Pressure Dwell - The vessel is opened to atmospheric pressure, and the diaphragm descends. SS - Vacuum Dwell - Single Step mode for Vacuum Dwell. SS- Pre-Pressure - Single Step mode for Pre-Pressure. SS - Pressure Dwell - Single Step mode for Pressure Dwell. 30

31 Operations Panel Operations Allows the user to start an Automatic cycle, step through a cycle, hold an Automatic cycle, or completely stop a cycle, regardless of current step. START and STEP Buttons will be disabled and grayed out while the drawer is in the open position START BUTTON - Starts an Automatic cycle. The machine will automatically step through the Vacuum Dwell, Pre-Pressure, and finally Pressure Dwell. Times may be set for Vacuum Dwell and Pressure. Pre-Pressure is Factory set for 1 second. Upon cycle completion, the drawer may be opened. Once started, the button will be disabled until the STOP BUTTON is pressed, or until the cycle has completed. Pressing the STOP BUTTON at anytime will return the machine to a Cycle Ready state. Pressing the STEP BUTTON at any time during an Automatic cycle, will cause the machine to HOLD at the current step until the STEP BUTTON or STOP BUTTON is pressed. You may not continue the automatic cycle. The Settings Panel, Supervisor Panel and About Panel will be disabled during cycles. STEP BUTTON -Steps through each cycle step in order; Vacuum Dwell, Pre-Pressure, Pressure Dwell. The timers are inactive while in Single Step Mode. You must press the STEP BUTTON again to complete each state. Pressing the STOP BUTTON at anytime will return the machine to a Cycle Ready state. Single Step mode is indicated by the prefix SS in the CYCLE STATUS BOX. You may press this button at anytime during an Automatic Cycle initiated by the START BUTTON. Doing so will cause the machine to HOLD at the current cycle step. STOP BUTTON - Stops the cycle regardless of mode (Automatic or Single Step) and returns the machine to a Cycle Ready state. For an emergency situation, the large red EMERGENCY STOP BUTTON located to the left of the Touch Screen, should be used immediately. 31

32 Operations Panel Vacuum Dwell This box shows the status of the Vacuum Dwell cycle step CURRENT PRESSURE READING - This box shows the current pressure in units selected in the Settings Panel. There is a dial indicator to quickly indicate that pressure is dropping. A more precise reading is shown below the dial. ACTIVE CYCLE INDICATOR - In addition to the Cycle Status read-out, this icon will blink when the step is currently active. PROGRESS BAR and COUNT-DOWN TIMER Visually shows time remaining with a green progress bar, with a more precise count-down timer directly below. The small grey numbers between indicate the current set-point found in the Settings Panel for the vacuum dwell. 32

33 Operations Panel Pressure Dwell PRESSURE DWELL - Visually shows time remaining with a green progress bar, with a more precise count-down timer directly below. The small grey number below the progress bar shows the total time. The number below shows the time remaining. ACTIVE CYCLE INDICATOR - In addition to the Cycle Status read-out, this icon will blink when the step is currently active. PROGRESS BAR and COUNT-DOWN TIMER Visually shows time remaining with a green progress bar, with a more precise count-down timer directly below. The small grey number below the progress bar shows the total time. The number below shows the time remaining. NOTE: The readings from the Vacuum Dwell status box will continue to drop during the Pressure Step. 33

34 Operations Panel Drawer Status DRAWER STATUS - Indicates whether the drawer is OPEN or CLOSED. Cycles may not be started with the drawer in the open position. Cycle End Options LOADED PRESET DISPLAY - Shows the name of the currently loaded preset. Will alert the user if the preset has been changed from the default preset settings. Auto Start AUTO START STATUS - Shows whether the Auto Start feature has been activated from the Settings Panel. 34

35 Settings Panel Overview Pump ON/OFF 2. Dwell Timers 3. Top Heater Controller Settings 4. Bottom Heater Controller Settings 5. Max Temperature 6. Password Entry Box 7. Keypad 8. Presets Box 9. Cycle End Options 10. Auto Start Settings Panel - Use this panel to setup the machine for use and to activate specific options in the Supervisor Panel. 35

36 Settings Panel IMPORTANT: Press CLEAR on the Keypad before entering numbers. In case a box is highlighted unintentionally, simply change to the Operations Panel, or select another box. Pump *Requires password to enable. TOGGLE PUMP BUTTON - Toggles the Vacuum Pump ON and OFF. When ON, the symbol will turn ORANGE. Dwell Timers *Requires password to enable. DWELL TIMERS - To Change the timers (in seconds) for either the Vacuum Dwell or Pressure Dwell, first press the input box you want to change, then press CLEAR on the KEYPAD. You may now enter a new number using the KEYPAD. Timers are only active during an Automatic Cycle. Heater Controller - Top & Bottom *Requires password to enable. HEATER CONTROLLER SETTINGS (TOP) - Toggles the Heater Controllers ON and OFF. When ON, the symbol will turn ORANGE. When ON the Heater Status box on the Operations Panel will change from CONTROLLER OFF to CONTROLLER ON. To Change the Set Point for the heater, first press the input box, then press CLEAR on the KEYPAD. You may now enter a new number using the Keypad. 36

37 Settings Panel Heater Controller Notes NOTE: If you attempt to set a temperature higher than the MAX Setting, the temperature will default to the MAX Setting. For more information on changing this setting, see MAX below. NOTE: The Set Point will automatically update with the correct temperature conversion if the Toggle Fahrenheit / Celsius Button is pressed on the Operations Panel, and the Display Units Toggle on the Settings Panel. In some cases, the Set Point may be set lower or higher than anticipated due to rounding errors. Please adjust accordingly. MAX Temperature MAX TEMPERATURE - The maximum allowed temperature setting. This updates with the Toggle Fahrenheit / Celsius Button on the Operations Panel, and the Display Units Toggle on the Settings Panel. NOTE: The MAX Setting is a factory option and may be changed only when authorized by Operations Technology, Inc. Call the factory for consultation on changing the MAX Setting. 37

38 Settings Panel Password PASSWORD INPUT - This input will enable certain options in the Supervisor Panel. To enter a password, first press the PASSWORD INPUT BOX. You may now a number using the KEYPAD. When a correct number has been successfully entered, the check to the right of the input box will turn green. If you make a mistake entering the password, press CLEAR on the KEYPAD. Pressing Remember will keep you logged in until you press Remember again, or until the machine is powered down. To change password, press Change then follow instructions under the Change button. IMPORTANT: If Remember is checked, the supervisor will remain logged in until the Remember button is unchecked, or the machine is powered off. Keypad KEYPAD - Used to clear and input numbers into input boxes. 38

39 Settings Panel Presets *Requires password to enable. *Also requires option(s) to be checked in Supervisor Panel Preset Slots PRESETS - Manage custom presets. The presets are stored on internal memory. PRESET SLOTS - Up to 20 custom presets may be stored at a time. Pressing on a preset will highlight it. The preset will then be shown in the Preview box. No changes are made to a preset by selecting it in this box. 39

40 Settings Panel NAVIGATE - Navigate the presets by using the UP or DOWN ARROWS. *Requires password to enable. *Also requires option to be checked in Supervisor Panel RENAME PRESETS - A USB keyboard is required. Plug a USB keyboard into the external USB jack. Highlight the preset you want to re-name, the press Rename. You may now enter a new name for the preset. PREVIEW - The preview box automatically updates when a preset is selected in PRESETS. All information about the stored preset is displayed to the user. If a preset has not been saved to a preset slot, it will be indicated in this box. Depending on your specific machine configuration, this sample preview may be different than yours. 40

41 Settings Panel Save & Load Buttons *Requires password to enable. *Also requires option to be checked in Supervisor Panel SAVE & LOAD BUTTONS - Save and Load custom presets. To SAVE a preset, first highlight a PRESET slot by pressing on it, then press the SAVE BUTTON. All settings shown in the PREVIEW box will be overwritten by the currently selected settings and options throughout the software. If a preset already exists in the chosen preset slot, you will be prompted to confirm overwriting it. To LOAD a preset, first confirm in the Preview box, that these are the settings you wish to load. Any current setting in either the Settings Panel, or Operations Panel may be overwritten. Then, highlight a PRESET slot by pressing on it, then press the LOAD BUTTON. NOTE: The PUMP and HEATER CONTROLLERS will not be turned ON by loading a preset. You must turn them on manually. Cycle End Options *Requires password to enable. TURN OFF HEATERS - Enabling this option will turn off the heaters at the end of the cycle. The heaters must be turned again manually after using this option. For safety reasons this feature will reset when the machine is powered off. 41

42 Settings Panel Auto Start *Requires password to enable. AUTO START - Enabling this option will automatically start a cycle when the drawer is closed. There is about a three second delay. To stop the cycle, press the STOP BUTTON. For safety reasons this feature will reset when the machine is powered off. 42

43 Supervisor Panel Overview Completed Cycles Display 2. Supervisor Options 4. Machine Log Panel 5. Display Units 3. Current Date & Time 43

44 Supervisor Panel Completed Cycles COMPLETED CYCLES - Shows the Lifetime Machine Cycles as well as Cycles since the last time the DPL-24A was powered on. Cycles that were forced to stop with the STOP BUTTON do not add to the total. Supervisor Options SUPERVISOR OPTIONS - Options that become available after a successful Supervisor Password Login. You must login from the Settings Panel. See the Settings Panel chapter for information on how to do this. Save Logs Option SAVE LOGS OPTION - You may be asked to enable this feature to store machine logs to an external disk drive. The DPL-24A comes with an external drive pre-installed. For instructions on how to remove this drive, consult the Front Panel - External Drive Access section in the Getting Started chapter. 44

45 Supervisor Panel Save Cycle Data Option SAVE CYCLE DATA - Enabling this feature will store data from a successfully completed cycle. A cycle that has been stopped with the STOP BUTTON will not be logged. For more information on what data is saved, see the sub-chapter DATA TABLE below. Enable Preset save ENABLE PRESET SAVE OPTION - Checking or un-checking this item will enable or disable the Save Button in the Settings Panel. By default for security reasons, it is unchecked on startup, and will not be saved in a Preset or on Shutdown. You must manually enable this option each time the DPL-24A is started. Enable Preset load ENABLE PRESET LOAD OPTION - Checking or un-checking this item will enable or disable the Load Button in the Settings Panel. By default for security reasons, it is unchecked on startup, and will not be saved in a Preset or on Shutdown. You must manually enable this option each time the DPL-24A is started. Enable Preset rename ENABLE PRESET RENAME - Checking or un-checking this item will enable or disable the Rename Preset button in the Settings Panel. By default for security reasons, it is unchecked on startup, and will not be saved in a Preset or on Shutdown. Language *Requires software restart. LANGUAGE - Select a language from the dropdown. Shutdown using the button, then restart the machine or re-launch the software. 45

46 Supervisor Panel Toggle units ENABLE TOGGLE UNITS - Checking or un-checking this item will enable or disable the Units in the Settings Panel, and the Units on in the Operations Panel. By default for security reasons, it is unchecked on startup, and will not be saved in a Preset or on Shutdown. Display Units DISPLAY UNITS - Displays the currently selected units. Changing this setting will update Heater Controller Set-Points, MAX. Changing units will also update the temperatures display in the Operations Panel. NOTE: Toggling Units will not update the Presets. 46

47 Supervisor Panel Update Software UPDATE SOFTWARE - Press this button to begin the update procedure. WARNING! ONLY UPDATE SOFTWARE WITH APPROVAL FROM OPERATIONS TECHNOLOGY! Failure to gain approval may require you to send the PC back to the factory for service. Update Tools You will need the following to complete an upgrade: 1. An empty formatted USB drive. 2. A USB mouse. 3. Contact Operations Technology for a software update file. Update Procedure 1. Extract the files from the archive. 2. Copy the update folder named DPLgui onto the root of an empty formatted USB drive. 3. Enter the supervisor password on the Settings Panel. 4. Go into the Supervisor Panel and press the Update Software Button. 5. Follow the onscreen instructions to load the files from the USB Drive onto the computer. 6. Once finished the software will exit, and then launch an Explorer Shell. This may take a few minutes. 7. Once the Explorer Shell is on the screen, remove the USB drive and plug in the USB mouse. 8. Navigate to the c:\update.bat file and run the file by double-clicking on it. 9. The software will restart. 47

48 Supervisor Panel Exit Application EXIT APPLICATION - Exits the application and launches an Explorer Shell. Mainly used for troubleshooting. Only use this when directed to do so by Operations Technology. Current Date & Time Machine Log Panel CURRENT DATE & TIME - Displays the current date and time. MACHINE LOG PANEL - Pressing this tab will open the machine log window. This is mainly used for troubleshooting purposes. There will only be visible output if the SAVE LOGS OPTION is checked under SUPERVISOR OPTIONS. This view is used to ensure that the logging function is working properly. The output will move very quickly and as such, cannot be easily read. Once the log reaches a certain length, it is dumped to an external drive, the log is cleared, and the output will begin again. 48

49 Data Panel Overview Files List 2. Data Table 3. Actions 49

50 Data Panel Data Files DATA FILES - These are the data files currently stored on internal memory. Each day, a new data file is created using the date as a name. Every time a cycle is completed successfully, the file is appended with a new line. The files are stored in CSV (Comma Separated Values) format for easy database and spreadsheet imports. Pressing a file, will update the Data Table. Refresh Data Button REFRESH DATA BUTTON - Forces a data refresh. To avoid constant writes to the internal drive, cycle runs are stored in memory and intermittently written to the internal drive. Pressing this button forces a write to the drive, and then updates the Data Table with the data. Export Files Button EXPORT FILES BUTTON - Press this button to export files to a USB drive. You will need to insert a USB drive into the USB slot to the right of the Touch Screen. To export a single file, highlight the file you want to export first, then press the Export Files Button. You can also export all files at once, by pressing the ALL button when presented with the Save Dialog box. IMPORTANT: It is recommended to press the Refresh Data Button before exporting files, to ensure that any cycles stored in memory are written to the internal drive first. Delete Files Buttons DELETE ALL BUTTON - Press this button to delete ALL the stored data files. You will be prompted for confirmation before deletion. The files will be deleted permanently. 50

51 Data Panel DELETE ONE BUTTON - Press this button to delete the currently selected data file. You will be prompted for confirmation before deletion. The file will be deleted permanently. Data Table DATA TABLE - Displays the data contained in the highlighted Data File. A more detailed description of each column is below. ID - The cycle ID. It is based on the lifetime runs found in Completed Cycles on the Supervisor Panel. Date - The date the cycle was started. Start - The starting time of the cycle. End - The ending time of the cycle. Total - Total elapsed time, in seconds, of the cycle from start to finish. Vac - The time entered for Vacuum Dwell. PrsD - The time entered for Pressure Dwell. Top - The temperature of the top heater at the time of cycle completion. Btm - The temperature of the bottom heater at the time of cycle completion. Unit - The pressure unit selected in the Settings Panel. P - The lowest recorded vacuum reading during the entire cycle. Compl. - Indicated is the Cycle completed normally or stopped using the STOP Button. 51

52 PLC Status Panel Overview Digital Outputs 2. Digital Inputs 3. Connection Status 4. Analog Inputs PLC Status Panel - This panel is used to monitor the Inputs and Outputs as reported by the PLC(Programmable Logic Controller). It's primary use is for troubleshooting. It may also be used to attempt a re-connect to the PLC in the unlikely event of a communications failure. 52

53 PLC Status Panel Digital Outputs DIGITAL OUTPUTS - The status of the Digital Outputs as reported by the PLC. A Green LED on a Digital Output indicates that the Output is active. The following list describes the different outputs in more detail. DO0 Vessel Valve Out - Voltage is being applied to the Vessel Valve relay DO1 Differential Valve Out - Voltage is being applied to the Differential Valve relay. DO2 Pressure Valve Out - Voltage is being applied to the Pressure Valve relay DO3 Vacuum Pump On - Voltage is being applied to the Vacuum ON relay. DO4 Top Heater On - Voltage is being applied to the Top Heater relay. DO5 Bottom Heater On - Voltage is being applied to the Bottom Heater relay. DO6 Not Used - Reserved for future use. DO7 Not Used - Reserved for future use. During normal operation, you will see changes in these outputs as the machine cycles. NOTE: You may notice the Top & Bottom (DO4 & DO5) Outputs are blinking intermittently. This is normal and will occur when either Heater Controller has reached it's Set-Point mode of operation. 53

54 PLC Status Panel Digital Inputs DIGITAL INPUTS - The status of the Digital Inputs as reported by the PLC. A Green LED on a Digital Input indicates that the Input is active. The following list describes the different Inputs in more detail. DI0 Drawer Closed - Indicates whether the Drawer is OPEN or CLOSED. DI1 Not Used - Reserved for future use. DI2 Not Used - Reserved for future use. Analog Inputs ANALOG INPUTS - The status of the Analog Inputs as reported by the PLC. This is reported in voltage. The following list describes the different Inputs in more detail. Top Heater - AN[0] - Voltage on Thermocouple Signal Conditioning Board for the Top Heater. Bottom Heater - AN[1] - Voltage on Thermocouple Signal Conditioning Board for the Bottom Heater. Vacuum Gauge - AN[6] - Voltage from Vacuum Sensor on rear of vessel. 54

55 PLC Status Panel Connection CONNECTION STATUS - Shows the current connection status for the PLC. Mainly used for troubleshooting. The Manual Reconnect Button will only become functional in the event of a communications failure, or a physical disconnect occurs between the Touch Screen PC and the PLC. 55

56 About Panel Overview Software & Contact Information 2. Quick Guide About Panel - A general information panel. You may be asked to view this panel to assist with troubleshooting, or with general machine maintenance. 56

57 About Panel Software & Contact Information Software & Contact Information - Contains the DPL-24A Software Version and Release Date as well as contact information for Operations Technology. To reiterate: ADDRESS Operations Technology, Inc. 30 Lambert Rd. P.O. Box 408 Blairstown, NJ USA SUPPORT Phone: Fax: WEB info@optek.net 57

58 About Panel Quick Guide QUICK GUIDE - Gives a general overview of the Panels. Quick Guide Bars information about a Panel. QUICK GUIDE BARS - Pressing one of these bars will open up more 58