Version 2.8 - Pg:1 - Ver 2.8 This operation manual contains important information about your oven. All operators should review this manual before operating the oven. When you turn on the switch, the control panel will show a boot screen as the WinPLC boots up the operating system and runs internal checks. If you don't have a fault condition you will see the screen on the next page. If the fault screen appears you must clear the fault (see the fault screen section). Boot Screen New in Version 2.8: The maximum oven temperature setting has been raised to 500º This Operation Manual should remain with the oven. All operators should have access to it.
Version 2.8 - Pg:2 - Ver 2.8 After the control system boots up you will see the following screen. If the fault screen appears you must clear the fault (see the fault screen section). The Main Control Screen Touch here to see Temp Control setup screen Touch here to set time Oven Mode Set point. You can touch here to change the set point. 500º Max % Gas Valve is open L = Low H = High For 2 speed Fans only Optional thermocouples and High Heat Limit readings. Temperature trending Purge time is set in the Temperature Control screen. The oven fans will run for this time before the burner can ignite. This is set to provide 4 air changes in the oven before the burner ignites (when combined with the burner purge time). Exhaust fans with variable speed drives will run faster during the purge cycle then slow down when the burner ignites. Stops the current cycle Starts the cure cycle for the current setup. Opens the Setup screen to set the oven temperature and cure time for the cycle. Note: You can change the temperature set point for the current cure cycle while the oven is running by touching the Cure Temp number on the screen above. Touch the Setup button to set up a cure cycle (next screen)
Version 2.8 - Pg:3 Cure Cycle Setup Screen Touch to see the Temperature Control Screen Touch to set cure cycle temperature Touch to set cure cycle time Touch to clear data tables Used with optional DAQ software Touch to save this setup or load a previously saved setup Touch to return to the Run screen Gel Temp sets the temperature at which the re-circulating fan switches to high speed. Gel Time sets the time the oven must be above the Gel temp before the fan switches to high speed. The oven holds the set Gel Temp for the duration of the Gel Time before warming up to the Cure Temp. These settings have no affect on single speed fans however the oven temperature will still hold at the Gel Temp for the duration of the Gel Timer. In ovens with 2 speed fans, this allows the powder to Gel so it doesn t blow off before curing. For single speed fans the default setting is 70º and 0 min. When you touch a button to change a setting, a numeric pad will pop up. Enter the number and press ENT
Version 2.8 - Pg:4 Load/Save Cycle Setup Screen You can save up to 15 recipes for setups you use often and load them for use later. Note: This is the recipe you are loading or saving. Change selection number up or down Touch to overwrite the selection with the current setup on the setup screen. Touch to load the selection Touch to see the next screen of Recipes
Version 2.8 - Pg:5 Cure cycle run screen Purge The Door Closed Indicator is ON. If the door is opened during a cycle, the cycle will stop and the red light on the light tree will come on. The START button has been pushed. The Fans are ON. The Purge Timer begins to count down. Initialization Mode The Purge timer is complete and the burner is being initialized. The Comb Fan indicator verifies the combustion fan is on. The Pilot indicator shows the burner has completed the burner purge time and the pilot light is ON.
Version 2.8 - Pg:6 Cure cycle run screen Warm Up To Gel Temp Note: Indicators are all ON The oven has now ignited. Flame % shows the burner is at full fire. (100 = full fire). The oven is warming up to the Gel Temperature set point. During a cure cycle, the green light on the light bar will be ON. Gel Timer Mode Note: The Re-Circulation fan has not switched to High speed because the Gel Timer is running. Gel Temp and Gel Time are set on the Setup screen. The oven has reached the Gel Temp and the Gel Timer is counting down. Note: Setting the Gel Temp & Gel Time higher than needed will increase the total cure cycle time.
Version 2.8 - Pg:7 Warm Up To Cure Temp Note: The Re-Circulation fan has switched to High speed because the Gel Temp and Gel Time have been reached. These are set on the Setup screen. The oven has completed the Gel Timer and is now warming up to the Cure Temperature. The Flame % shows the burner is at 80% fire. (100 = full fire). During a cure cycle, the green light on the light bar will be ON. The temperature trending chart is starting to register. Cure Mode The oven has reached the Cure Temp and the Cycle Timer is counting down.
Version 2.8 - Pg:8 Done Mode The timer has counted down and reset for the next cycle. The burner has turned OFF The cycle is finished. The fans will continue to run until the oven is below 200
Version 2.8 - Pg:9 Temperature Control Setup Screen Touch the upper left corner of the Run screen to see this screen. Your control box comes with default settings and should not be changed without a clear understanding of the affects it will have on oven operation. Note: The settings for your oven will differ from those pictured. The burner turns OFF when the oven temperature goes over the cycle temperature set point by this amount. The burner will then reinitialize. This is a safety feature and should be set to 25-50. When Auto Tuning, set this to 50. Locks the Fuji keypad so parameters cannot be changed on the Fuji keypad Set the Purge Timer here. This time plus the burner purge time should allow for 4 air changes in the oven before the burner ignites. Displays the control algorithm in use by the temperature controller. These must be set from the Fuji keypad. This does not normally need to be changed. Initiate the Auto-Tune Cycle Return to the main screen P, I, & D indicate the terms being used by the temperature controllers PID control algorithm. This screen only refreshes these numbers when the screen loads. If you make changes on the Fuji keypad, exit this screen and reopen it to see the changes reflected. Important: The P, I, and D terms are unique to each oven. The P, I & D terms for your oven will not be the same as those shown here. To run a Auto-Tune cycle. Set the temperature on the main screen midrange of those most commonly used. Touch AT1 or AT2 to start the Auto-Tune Cycle. Try AT1 first. The main screen will appear with a flashing AT to show the Auto-Tune is in progress. Do not interrupt this cycle by opening the door or changing the temperature. When the Auto-Tune is finished, the flashing AT will go away and the Done indicator will come on. Note: Record the P, I, and D terms for your oven. If you get wacky numbers from the Auto-Tune: Wait until the oven temperature is below the cure temperature then run the Auto-Tune again. Once you have a good set of numbers, it is faster and easier to set the P, I, and D terms on the Fuji keypad. Remember to turn off the Lock Fuji Keypad switch if you are going to set the numbers manually on the Fuji controller. During the Auto-Tune cycle the Timer is set to 1:00:00 hrs. by the software. This is to prevent the timer running down before the Auto-Tune finishes. It usually takes the normal oven warm up time plus 10-15 minutes for the Auto-Tune to complete.
Version 2.8 - Pg:10 The Fault Screen The Fault Screen will pop up when a safety fault is detected. In this example, the Emergency Stop button on the control panel door has been pushed. To clear this fault, pull the emergency stop button out and touch the Clear Button. The oven door is closed. The Door Open fault stops the burner and stops the current cycle. The red light on the light bar comes on but the fault screen does not pop up. Close the door and start a new cycle to clear this fault. High Temperature Fault means the high temperature limit is faulted. The high temperature limit is set before shipping and may need to be adjusted up a little at a time to eliminate this fault. The idea is to set this just high enough so it doesn't fault during normal operations. The thermocouple for the high temperature limit is located in the hottest part of the oven so it is normal for it to reach temperatures above the oven temperature. This is a safety feature to ensure the oven shuts down if something goes wrong. Gas Pressure High/Low Fault means the gas pressure is high or low. These are not monitored on all systems. Some systems monitor these in the burner controller and no indication of the fault will show on the screen. The neon light on the gas pressure switch is normally wired to be ON if the switch is faulted. The low gas pressure switch will be faulted on start up until gas pressure is present. Press the cover on the switch above the red button to reset the switch. Air Flow Switches are faulted if the fan is not ON. The controller waits after the Start button is touched and a cycle starts to see if the air flow switches close. If they don't, it assumes the fan is not running and the fault screen pops up showing which fan is not operating. Bad Thermocouple #1 fault probably means you don't have a thermocouple plugged into the primary socket in the jack panel. This thermocouple controls the oven so a thermocouple must be present. This fault can also follow a Comm Fault because communication to the temperature controller has been lost. Combustion Fan Air Flow Switch is faulted if the burner combustion fan is not ON when the burner is ON. Burner Alarm is faulted if the burner controller sends an alarm. Comm Fault means communication to the temperature controller has been lost. Turn the power off to the oven control panel then restart it if the Clear button does not resolve this fault. Note: The Setup button goes to the safety switch setup screen. These settings have been entered before shipping and should not be changed unless instructed to do so. Note: After fixing the problem causing the fault, touch the Clear button to return to the Run screen. Most faults occur during startup because of incorrect wiring or bad connections. The fault detection system is a major safety feature. If you cannot resolve the cause of a fault, please call and we will assist you.
Version 2.8 - Pg:11 Safety Switches Setup Screen This screen is set before we ship the unit to you and should not be changed unless instructed to do so. Note: Your switches may be set differently than those pictured
Version 2.8 - Pg:12 System Setup Screen If you see this screen, stop and touch User Mode. This screen is set before we ship the unit to you and should not be changed. Don't mess around here unless instructed to do so by Spray Tech Systems. Touch User Mode and go back to the operator control screens.
Version 2.8 - Pg:13 Fuji PXR4 Temperature Controller - Quick Reference WARNING This page is NOT intended to replace the Fuji manual for the temperature controller. Is is a quick reference guide to the most common settings you may need to change. Improper settings may cause the oven to function incorrectly and could create a potentially dangerous condition. Please refer to the Fuji manual for complete instructions before changing any settings on the Fuji controller. The Main Fuji Temperature Controller Screen PV - The temperature measured in the oven Parameter names are also displayed in the PV area SV - The temperature set by the operator on the touch screen. Parameter values are also displayed in the SV area SEL - Select a parameter block or parameter, or save a set value. Press about: 1 second for Parameter Block 1 3 seconds for Parameter Block 2 5 seconds for Parameter Block 3 Use the up and down keys to change the value displayed for the Parameter Block or Parameter selected. Ctrl Parameter - PID Control Algorithm (default is FUZY) Press SEL about 3 seconds to show Parameter Block 2. Use the Up & Down keys to find the Ctrl Parameter. Press SEL and the parameter setting will flash. Use the Up & Down keys to find the setting you want. Press SEL to save your selection The screen will return to main screen in a few seconds. P - Proportional band I - Integral time D - Derivative time P,I, & D Parameters Press SEL about 3 seconds to show Parameter Block 2. Use the Up & Down keys to find the Parameter. Press SEL and the parameter setting will flash. Use the Up & Down keys to find the setting you want. Press SEL to save your selection The screen will return to main screen in a few seconds. NOTE: See the Auto-Tune section of this manual. The Auto-Tune feature will set the PID Parameters automatically.