TC-150 CONVEYORIZED OVEN OPERATION AND MAINTAINANCE MANUAL Ovens with Omron PLC and Touchscreen Rev F CIRCUIT AUTOMATION 5292 System Drive Huntington Beach, CA 92649 U.S.A. Copyright CAI 2014 Tel 714.763.4180 Fax 714.763.4181 www.circuitautomation.com
2 Heater Removal Access Door
Table of Contents PREPARATION FOR INSTALLATION... 4 INTRODUCTION TO THE TC-150 CONVEYORIZED OVEN... 6 OPERATOR CONTROL PANEL... 8 DISCONNECT SWITCH... 9 SYSTEM... 10 WORK STATION... 13 COOL DOWN MODE... 13 FAST CONVEYOR... 14 TIMED CONVEYOR... 15 CHART RECORDER... 17 OVEN TEMPERATURE CONTROLLER... 19 TEMPERATURE CONTROL ALARM SET-POINT... 19 SYSTEM STATUS... 20 OVEN START-UP PROCEDURE... 26 SHUT-DOWN PROCEDURE... 27 Oven Fuse List380 Volt... 31 Oven Fuse List380 Volt... 33 PREVENTATIVE MAINTENANCE... 33 ELECTRICAL SCHEMATICS.... BILL OF MATERIALS 3
TC-150 CONVEYORIZED OVEN PREPARATION FOR INSTALLATION The TC-150 should be wrapped and bolted to a shipping pallet or bolted to a shipping container. Remove the protective wrap from the oven and inspect the oven for noticeable shipping damage. Any shipping damage should be immediately reported to the carrier. Unpack ancillary parts packaged and shipped with the oven. Locate leveling pads for the oven. The leveling pads are packaged in a box. Remove shipping bolts and lift the oven off of the pallet with a forklift certified to carry more than 5000 lbs. The oven weighs approximately 5700 lbs. While elevated with a forklift, install leveling pads. Use care not to slide the oven on the leveling pads, as this will bend the jacking bolts. A minimum of three feet clearance for maintenance access is recommended at all sides of the oven. A clearance of 77 inches (3 meter) beyond the exit end of the oven is recommended in order to install and/or replace the heating element. Consult local codes for minimum clearance at high voltage electrical enclosures. Generally, a minimum of three feet (one meter) is required. Exhaust requirements of the TC-150 oven include two pipe openings of six inch diameters at 275 CFM (153mm diameter and 368 cu. m/hr) and one of eight inch diameter of 325 CFM (203mm diameter and 553 cu. m/hr). Please prepare for the required ventilation ducts before installation. The fans and blowers are already included. Page 4
Specifications and Utility Requirements Electrical Requirements Maximum Panel Size 480 V, 100A, 60Hz 26" x 30" (660 mm x 762 mm) 400V, 110A, 50Hz Panel Thickness Rack Dependant Exhaust 0.010" - 0.75" (0.25 mm - 19 mm) 3 top ducts with blowers Temperature Range Dampeners recommended 900 CFM (1291 cu m/hr) 100 F to 375 F (50 C to 190 C) Interlocks Temperature Display Over Temperature F or C Main Blower Emergency Stop Heater Type 6 High-density incolloy elements 7100 Watts each Page 5
INTRODUCTION TO THE TC-150 CONVEYORIZED OVEN The Circuit Automation TC-150 Conveyorized Oven is the most flexible conveyorized oven available for tack-drying or final curing of soldermask and legend ink. Conveyorized ovens are used most effectively to improve productivity, decrease variability, and increase yield in soldermask and legend ink processes. The TC-150 has a heated chamber of 3.0 meters using a variety of racks with different pitch and spacing available separately. Air distribution in the TC-150 is extremely even throughout the oven, achieving 3 C (TIR) temperature distribution across the panel at tack-dry temperatures and 6 C (TIR) at final cure temperatures. The TC-150 ramps up to temperature rapidly, smoothly, and consistently. The oven maintains the selected temperature throughout the heated chamber. SSR controllers maintain temperature sensitive to 0.5 C temperature changes. Temperature variants from one end of the oven to the other end are rectified by a shutter system that directs hot air just slightly enough to counter any variance. To ensure operator safety, the panels are cooled to a lukewarm temperature with cooling fans before reaching the end of the exit cabinet. The air is circulated through the oven in a laminar flow pattern, ensuring even temperature distribution across the panel. The TC-150 recirculates almost 7,000 CFM of air. The high flow promotes rapid removal of solvent and monomer from the panels. The TC-150 exhausts 900 CFM of air, exchanging air in the oven 2.5 times per minute. Air is taken into the oven through a Clean Air Filter System at each end of the oven. Operation of the TC-150 is simple. A programmable logic controller and operator interface allows direct input of process parameters including temperature and process time. A linear chart recorder is Page 6
included. HEATING ELEMENTS The heating element can be found in the back lower corner panel at the ends of the oven. The TC-150 has six heater elements Part number HE15 (480V) HE10 (380-400V). These are continuously monitored for burnout or over heating. If either should occur, an audible signal will sound. To replace a heater element, remove the panel bolts, one at each end of the oven, and open the corner panels. Remove the four screws from the cover plates and remove the plates. Remove the insulation and wires. Slide the element rack out. Remove the burnout element and replace with a new element. Follow the previous steps in reverse to reassemble the TC-150. Figure 1 Electrical Connection Figure 2 Jumper Connection Page 7
1. 2. 4. 8. 5 6. 7. 3. OPERATOR CONTROL PANEL 1. Chart Recorder 2. Temperature Controller 3. Work Station 4. Emergency Stop 5. System Status Indicator - Green 6. System Status Indicator - Amber 7. System Status Indicator - Red 8. System On/Off Switch Page 8
DISCONNECT SWITCH Electrical power is supplied to the TC-150 oven through a fused DISCONNECT SWITCH located at the upper right side of the electrical enclosure. To start the oven, move the DISCONNECT SWITCH to the ON position. To disconnect electrical power from the oven, move the DISCONNECT SWITCH to the OFF position. Figure 3 Electrical Disconnect CAUTION: Electrical power is supplied to the topside of the disconnect switch when the switch is in both the ON and OFF position. A facility installed circuit breaker or disconnect switch must be installed in accordance with local electrical codes to completely remove electrical power from the TC-150 electrical enclosure. Use extreme caution when servicing this equipment! Electrical power should always be disconnected at a facility installed disconnect device prior to all maintenance or service activity. Page 9
SYSTEM SYSTEM ON/OFF switches electrical power on and off to control components located in the oven's electrical enclosure. When starting the oven, the SYSTEM switch must be set to the ON position. When stopping oven operation set this switch to the OFF position. OPERATOR WORK STATION When the system powers up, the operator workstation will display the introduction screen. Touching the screen will open the machine interface to allow for system settings. Page 10
OPERATOR WORK STATION 1 1. Message Display Area 2. Function On/Off Indicators and Labels A. Conveyor page 15 B. Start page 14 C. Cool Down page 13 D. More pages 16 E. Heater page 14 F. Alarms page 23 G. Shut Down page 14 H. Time Set page 15 Page 11
I. Inputs page 22 J. Outputs page 23 K. Shutter and Temperatures page 25 L. Fast Conveyor - page 14 Page 12
WORK STATION The WORK STATION is an operator interface utilized to control all selectable oven functions except oven temperature set point. Switches are labeled with each oven function they control and light when they are active. The following control functions are available at the WORK STATION. Each function is selected ON/OFF by pressing the button labeled for that function. COOL DOWN MODE COOL DOWN MODE is selected to stop oven operation when operating in HEAT MODE. A labeled indicator at the WORK STATION indicates the ON/OFF status of this mode. At the WORK STATION display, COOL DOWN will be displayed. Selecting this mode will automatically turn the heaters off. After the oven has reached a preselected cool down time for 10 minutes. The oven's MAIN BLOWER and EXHAUST FANS will automatically switch OFF. The Work Station will operate in either F or C. Cool Down turns on the Yellow light. Page 13
START MODE START mode is selected to start main blowers and exhaust fans. The LCD display at the WORK STATION will display the statue of the CONVEYOR AND THE HEATERS. Start must be pushed prior to turning on the HEATERS. OVEN HEAT MODE OVEN HEAT mode is selected to start heating the oven up to set temperature. A labeled indicator at the WORK STATION indicates the ON/OFF status of this mode. When OVEN HEAT mode is selected, the Heaters, Main Blower and Exhaust Fans are automatically switched ON. The LCD display at the WORK STATION will display OVEN HEAT. Indicators at the WORK STATION will illuminate to indicate the HEATERS, MAIN BLOWER and EXHAUST FANS are switched to the ON status. Press COOL DOWN to switch OVEN HEAT mode OFF. HEATER SHUT DOWN MODE SHUT DOWN mode is selected to stop heating the oven. A labeled indicator at the WORK STATION indicates the ON/OFF status of this mode. When SHUT DOWN mode is selected, the Heaters are switched off, Main Blower and Exhaust Fans continue to operate. The LCD display at the WORK STATION will display SHUT DOWN. FAST CONVEYOR To utilize FAST CONVEYOR, push the MORE button. It is used to set the oven conveyor ON/OFF. The oven conveyor will run continuously when FAST CONVEYOR is ON. A labeled indicator at the WORK STATION is illuminated when FAST CONVEYOR is ON. This selection is generally used to clear the Oven of any content as quickly as possible. Note that any preselected conveyor time setting will be ignored in this conveyor run mode. Page 14
CONVEYOR CONVEYOR is used to set the oven conveyor ON/OFF. Turn Conveyor on after selecting Heat Mode. A labeled indicator at the WORK STATION is illuminated when this conveyor mode is ON. The WORK STATION LCD display will display CONVEYOR TIME XX MIN. CONVEYOR is usually selected for all panel "tack-dry" and "final cure" drying processes through the oven. When TIMED CONVEYOR is ON, the conveyor speed may be set to a desired panel process time through the oven. Conveyor speed is set in XX minutes in the heated chamber zone to equal the desired process time within the heated chamber zone. The TC-150 heated chamber zone is 3.0 meters long. To change the set time, press TIME SET The WORK STATION will display the screen below. Enter the NEW time in minutes at the WORK STATION by pushing the + and keys. The NEW time entered will now be displayed as CURRENT TIME XX MIN. at the MAIN SCREEN. Page 15
Figure 4 Main control panel screen 2 Figure 5 TC150 Oven System Page 16
CHART RECORDER A Chart Recorder located at the Operator Control Panel is available to record a "paper copy" of the TC-150 oven temperature. Oven temperature profile as controlled by the oven temperature controller may be retained for historical process monitoring by retaining chart recorded oven temperatures. Press the RECORD button on the chart recorder to start recording. The chart recorder automatically starts recording temperature on start up of the machine to switch the CHART RECORDER ON/OFF. To change chart recorder fan fold paper, open the black door of the chart recorder. Pull out the gray bar, which will pull out the recorder mechanism. Flip up the clear cover. Place the fan fold paper in the tray and feed the holes in the paper over the notches in the gray revolving bar. Close the clear cover to hold the holes over the notches. Push in the gray recorder mechanism and close the black door. Chart recorder paper can be purchased from Circuit Automation, Inc. Page 17
OVEN TEMPERATURE CONTROLLER 1. Process Value (PV) Temperature Display 2. Set Value (SV) Temperature Display 3. Active Controller Function Indicators 4. Input Switches Page 18
OVEN TEMPERATURE CONTROLLER Oven temperature is set at and controlled by an Oven Temperature Controller located on the Operator Control Panel. Oven temperature is displayed in red numerals under the heading PV at the Temperature Controller. Directly under this value, the temperature set point will be displayed in green numerals under the heading SV. The Oven Temperature Controller can be set to either F or C. To change the oven temperature set point: Press the UP or DOWN arrow to increase or decrease the temperature set point as desired. Note: The temperature set point will be indicated at the SV display. TEMPERATURE CONTROL ALARM SET POINT The Temperature Controller initiates two alarms. Alarm 1 (AL1) is set to indicate deviation from Process Value temperature set point. Alarm 1 will initiate a blinking green indicator light to indicate oven temperature is out of range. Alarm 2 (AL2) will initiate an "Over Temperature Alarm". This alarm will: Initiate a blinking red indicator; Sound an audible alarm; Mode Button Switches off the oven heaters and exhaust fans. Press the Mode button at the temperature controller to set Alarm 2 "Over Page 19
Temperature Alarm" in conjunction with the Process Value temperature set point. Press Mode once to set or display Alarm 1 (AL1). Press Mode a second time to display Alarm 2 (AL2). When Alarm 2 (AL2) is displayed, Press the Up or Down arrow to set AL2 value. Alarm 2 is generally set 5 degrees higher than the Process Value temperature set point. Press Mode to return to temperature display. Note: Alarm 2 (AL2) must be set to a larger value than the temperature set point at SV heading, otherwise the oven will go into Over-Temperature Alarm. SYSTEM STATUS The SYSTEM STATUS indicators consist of a Green, Amber and Red indicator lights. These are located at the Operator Control Panel. The indicators display the operating or Page 20
fault status of the oven. A light "beacon" above the Operator Control Panel will also display the same indications. Below is a description of each indicators function. Flashing Green Indicates oven HEAT MODE is ON and oven temperature has not reached the temperature set point. Indicates oven HEAT MODE is ON and oven temperature has reached the temperature set point. Oven temperature Process Value (PV) must be within -2 F of Set Value (SV). Flashing Amber Indicates a Panel Rack has reached the "end of conveyor sensor" when either TIMED CONVEYOR or FAST CONVEYOR are ON. NOTE: An audible alarm will also sound when a Panel Rack reaches the "end of conveyor sensor". Indicates COOL DOWN has been selected ON and the oven is in the process of cooling to preselected values. Flashing Red Indicates one of the following faults has occurred. Note: All faults that initiate a Flashing Indicator will also sound an Audible Alarm. Page 21
Work Station Inputs The following input screen monitors the machine. Sensors and Inputs. Page 22
Machine Outputs Machine outputs are listed and the solid indicator showing active outputs. ALARMS EMERGENCY STOP An EMERGENCY STOP button has been pressed and is still ENGAGED. EMERGENCY STOP buttons must be twisted clock-wise to DISENGAGE or RESET. WARNING: Be sure any potentially unsafe conditions have been corrected prior to restarting equipment. HEATER OVER TEMPERATURE Oven temperature has exceeded the high limit set point at the Page 23
HI-Limit board. This temperature is generally set at a maximum temperature of 400 F. The HI-LIMIT temperature sensor must be reset after cooling the oven temperature below the maximum temperature set point. Switch SYSTEM ON/OFF (item 8 in Diagram A) to the OFF and back to ON position to reset the HI-LIMIT sensor board. NOTE: If oven temperature exceeds set temperature and HI- LIMIT set point, the heater control fault should be corrected before restarting oven. Shutter system out of range Should the difference temperature reading from the entrance to the exit end exceed 30 degrees F, then an alarm will trigger. This will indicate a fault in the shutter system or thermal couples. SHUTTER SYSTEM Fuse F26 protects the Shutter Motor (M3) has failed. Fault with Shutter Motor and/or shutter drive mechanism must be corrected. Replace fuse F26. Page 24
The Shutter and Temperature screen on the MMI indicates the position and direction of the shutter, the temperature at each end, and the speed of adjustment of the baffle system. Air adjusting Shutters Page 25
TC-150 OVEN OPERATION OVEN START-UP PROCEDURE 1) Move DISCONNECT SWITCH lever to ON position. 2) Turn SYSTEM switch to ON position. 3) Set oven temperature at TEMPERATURE CONTROL. 4) Press RECORD button at the CHART RECORDER. This selection is optional. 5) Press OVEN START mode at WORK STATION. 6) Press CONVEYOR then HEATER at WORK STATION. A Green Indicator at SYSTEM STATUS will blink until the oven has reached set temperature. After oven temperature has reached temperature set point, the green indicator will be illuminated continuously. Boards can now be loaded into the oven. TC-150 OVEN OPERATION (continued) Page 26
SHUTDOWN PROCEDURE 1) Press COOL DOWN mode switch at the WORK STATION. The Amber indicator at SYSTEM STATUS will blink indicating the oven is in COOL DOWN mode. COOL DOWN mode will remain ON for three minutes or until the oven temperature is below 200 F. 2) Press CONVEYOR switches the oven conveyor OFF. 3) Press CHART RECORDER to switch the CHART RECORDER OFF. This selection is optional, as the CHART RECORDER does not have to be used during a tack-dry or final cure process. 4) Set SYSTEM switch to the OFF position. 5) Set Disconnect switch to the OFF position. TC-150 OVEN OPERATION Racks Page 27
TC series ovens can be equipped with a variety of racks. The different racking systems allow for a variety of types of panels that can be dried utilizing this system. Figure 6 Standard Rack 6-3169 The Standard TC rack is a 27 slot rack with two adjustable sides with alternating slot widths of.90 and.125. PCMICA Rack Optional special sides attach to a Standard rack bottom to allow the Page 28
racks to accommodate thinner panels. The PCMCIA sides are 25 slots and are suited for 0.018 thick panels. Figure 7 PCMCIA Rack Back Panel Racks Racks to accommodate various combinations of thicker panels have been designed and produced. The different racks accommodate both lengthwise and widthwise loading of the oven. Several are pictured here, we have do date produced over 8 different versions of these racks for specific applications. Page 29
Figure 8 11-3665 Widthwise Page 30
Figure 9 11-1020 Lengthwise TC-150 Oven Fuse List 380 Volt Page 31
380-415 V 50 Hz Version Part # Fuse # System AMPS Type EC156 F12-2 Exhaust 2 CER. Slo-blo EC156 F12-3 Exhaust 2 CER. Slo-blo EC156 F12-4 Exhaust 2 CER. Slo-blo EC75 F13 Temp. Control 1.25 FAST EC75 F14 Hi Limit 1.25 FAST EC3401 F15 Infeed 10 CER. Slo-blo EC75 F16 Works 1.25 FAST EC64 F17 Fan 1 CER. Slo-blo EC257 F18 Trans 32ma FAST EC3401 F19 Utility 10 CER. Slo-blo EC75 F20 Cht. Recorder 1.25 FAST EC156 F21 24VDC 2 CER. Slo-blo EC156 F22 24VDC 2 CER. Slo-blo EC75 F23 CPU 1.25 FAST EC75 F24 Hour 1.25 FAST EC202 F25 SCR 100 A70-P100 EC64 F26 Shutter 1 CER. Slo-blo EC202 F27 SCR 100 A70-P100MFFM EC202 F28 SCR 100 A70-P100 EC257 F29 Trans 32ma FAST EC257 F30 Trans 32ma FAST EC64 F31 24VDC 1 CER. Slo-blo EC156 F32 24VDC 2 CER. Slo-blo TC-150 Oven Fuse List Page 32
480 Volt Sold by Circuit Automation, Inc. Part # Fuse # System AMPS Type EC156 F12-2 Exhaust 2 CER. Slo-blo EC156 F12-3 Exhaust 2 CER. Slo-blo EC156 F12-4 Exhaust 2 CER. Slo-blo EC75 F13 Temp. Control 1.25 FAST EC75 F14 Hi Limit 1.25 FAST EC3401 F15 Infeed 10 CER. Slo-blo optional EC75 F16 Works 1.25 FAST EC64 F17 Fan 1 CER. Slo-blo EC257 F18 Trans 32ma FAST EC3401 F19 Utility 10 CER. Slo-blo EC75 F20 Cht. Recorder 1.25 FAST EC156 F21 24VDC 2 CER. Slo-blo EC156 F22 24VDC 2 CER. Slo-blo EC75 F23 CPU 1.25 FAST EC75 F24 Hour 1.25 FAST EC202 F25 SCR 100 A70-P100 EC64 F26 Shutter 1 CER. Slo-blo EC202 F27 SCR 100 A70-P100MFFM EC202 F28 SCR 100 A70-P100 EC257 F29 Trans 32ma FAST EC257 F30 Trans 32ma FAST EC64 F31 24VDC 1 CER. Slo-blo EC156 F32 24VDC 2 CER. Slo-blo EC3490 F34 Transformer 5 Amp trap EC3490 F35 Transformer 5 Amp trap PREVENTATIVE MAINTENANCE Page 33
Once a Day Entrance and Exit Cabinets Once a day, wipe down the entrance end and exit end of the oven cabinets including the top hoods with an approved cleaning agent for LPI soldermask. This prevents polymer build up, which may build up over a few months. If wiped when still warm every day, preventative cleaning is made easy. Chart Recorder Once a day, check that the chart recorder has an ample amount of paper and ink in the pin. Once a Week Exhaust Fans Once a week, check that the exhaust fans are clean of any condensed polymers. Wipe down with an approved cleaning agent for LPI soldermask if needed. Exhaust Condensation Traps Once a week, check that the exhaust traps are not clogging with condensed monomers. Scrape or vacuum the monomers out and clean if required. Page 34
Condensation Trap Figure 10 Condensation Trap Shutters Once a week, check that the shutters move back and forth freely. The shutters direct the hot air to the end of the oven, which is at lowest temperature to balance the temperature. Be sure that the fuse to the shutter motor has not blown. Be sure that the thermocouples reading temperatures for the shutter movements are working properly. To check that the shutters are working, you can use a heat source and place it near the thermocouple in the top hood at one end of the oven. Be careful not to use something dangerous such as a flame. A hair dryer is a safe example. Once the thermocouple receives higher temperature readings, you should she the shutters move to direct the air to the other side of the oven. Once the heat source is removed, the shutters should move back to the original position. Page 35
Figure 11 Shutter System Page 36
Once every Three Months Filter Screens Once every six months, check the filter screens under the conveyor. These two screens when placed end to end protect the bottom of the oven underneath the conveyor from polymer build up. To clean these screens: 1. Remove the filter and filter bracket from underneath the entrance end of the oven. 2. Remove the motor behind the filter bracket. 1 R EMOVE AIR F ILTE R SCREEN 2 REMOVE MOTOR 5 PULLOUT PER-FORATED SCREEN 3 REMOVE SIX (6) SCREWS AND REMOVE OUTERENDWALLPANEL 4 REMOVE FOUR(4) SCREWS AND REMOVEINNER PANEL SIDE VIEW END VIEW 3. Remove the access panel from underneath the entrance end of the oven. 4. Remove the sheet metal cover from behind the access panel, which will reveal the bottom chamber of the oven. 5. Pull out the two perforated screens for cleaning. Page 37
Pillow Block Bearings. Lube the bearings on the main shaft of the blower every 3 months. Lube bearings Two places Replace Yearly Replace Fan Belts yearly MF06 Belt Page 38