Summary of Contents for PVA DeltaTherm
- Page 1 WHERE PRECISION DRIVES PRODUCTION DeltaTherm IR Cure Module Operation Manual Revision B...
- Page 2 DeltaTherm IR Cure Module This document is based on information available at the time of its publication. While efforts have been made to ensure the contents of this manual are accurate, the information contained herein does not purport to cover all specific details or variations in hardware, or to provide for every possible contingency in connection with installation, operation, or maintenance.
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Page 3: Table Of Contents
DeltaTherm IR Cure Module Table of Contents Introduction ......................5 PVA Contact Information ......................5 Document History ........................5 Safety ............................6 Theory of Operation ........................ 8 Personal Protective Equipment .................... 8 Waste Disposal .......................... 8 Hazards Due to Contact ......................8 Operating, Handling, Transportation, and Storage ......... - Page 4 DeltaTherm IR Cure Module Manual Mode ....................... 20 IR Panels ..........................20 Conveyor Speed ........................21 Conveyor Width ........................21 Conveyor Jog.......................... 22 Sensors ............................ 23 SMEMA Control ........................23 Setup Mode ......................24 IR Panels ..........................24 Conveyor Speed ........................26 Conveyor Width ........................
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Page 5: Introduction
Before you operate this system, read the operation and setup manual. This will help you to become familiar with the product and ensure successful operation. If any questions or problems arise, contact PVA’s Technical Support department. PVA Contact Information Main Office... -
Page 6: Safety
DeltaTherm IR Cure Module Safety Certain warning symbols are affixed to the machine and correspond to notations in this manual. Before operating the system, identify these warning labels and read the notices described below. Not all labels may be used on any specific system. - Page 7 DeltaTherm IR Cure Module Do not smoke near the PVA UV cure machine. Always have a fire extinguisher available for emergency use. Before performing any repairs or maintenance to the system, turn off power and lock out the power disconnect switch.
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Page 8: Theory Of Operation
DeltaTherm IR Cure Module Theory of Operation The DeltaTherm IR Cure Module is an infra-red (IR) curing machine that can handle multiple boards. Upstream and downstream ends are SMEMA (Surface Mount Equipment Manufacturers Association) rated for use in a production line. The system is designed to operate with PVA workcells. -
Page 9: Operating, Handling, Transportation, And Storage
DeltaTherm IR Cure Module Operating, Handling, Transportation, and Storage The system should have minimal vibration when handled and transported. Use an air-ride truck for roadway transport. The machine is made to operate in an industrial environment but abuse will reduce its performance. -
Page 10: Smema
DeltaTherm IR Cure Module SMEMA For manufacturing lines (multiple machines utilizing conveyor systems), it is necessary for the individual modules to communicate reliably. Make sure the SMEMA and Intermodule cables are correctly connected. Note: On the diagrams, the J# refers to the label on the machine, not the label on the cable. -
Page 11: Installation And Setup
DeltaTherm IR Cure Module Installation and Setup WARNING: The following procedures should be done by qualified persons in accordance with this manual and applicable safety regulations. A “qualified person” is defined as “a person or persons who, by possession of a recognized degree or... -
Page 12: Operating Safety
Stay away from all moving parts when the system is in operation. Safety Devices and Guarding The DeltaTherm IR Cure Module has safety features that protect the operator from hazards during normal operation of the machine. Note: Do not bypass, disable, or tamper with the safety features. Precision Valve &... -
Page 13: Exhaust Requirements
DeltaTherm IR Cure Module Exhaust Requirements Exhaust Air Velocity at Test Air Velocity at Test Machine Duct Size Requirement Point (ft/min) Point (m/sec) DeltaTherm 4’ 300 CFM 4” (102mm) 3438 DeltaTherm > 4’ 600 CFM 6” (152mm) 3056 Note: Check machine specifications. Custom order machines and processes may require higher exhaust flow rates. -
Page 14: Operation
2. Engage the EMERGENCY STOP button. Figure 5: Emergency Stop Button 3. Turn the main power switch to ON. 4. Push the green POWER ON button on the front of the DeltaTherm module. Figure 6: Power On Button Page 14 of 41... -
Page 15: Light Tower Operation
DeltaTherm IR Cure Module 5. Enter your password as necessary, if in protected mode. 6. Operate the system as necessary. Figure 7: Enter Password Light Tower Operation Three stacked indicator lights and a buzzer are used to show the machine status. The lights are green, amber, and red. -
Page 16: Machine Safety Check
Figure 9: PVA Screen The machine safety check ensures that the DeltaTherm IR Cure Module safety devices (emergency stop, door interlocks, etc.) operate correctly. For the startup procedure, the operator must start and complete the safety check successfully. After you start the safety check, you must activate and deactivate the safety devices. -
Page 17: Cycle Stop
DeltaTherm IR Cure Module Cycle Stop Figure 10: Cycle Stop Options in Cycle Stop are: Auto Cycle, Manual, and Setup. Select “F1” or the auto cycle icon to operate the module in Auto Cycle. Select “F3” or the manual icon to operate the module in Manual mode. -
Page 18: Auto Cycle
DeltaTherm IR Cure Module Auto Cycle Auto Cycle is the normal operating mode for the DeltaTherm IR Cure Module. In Auto Cycle, the cure module can operate as part of a production line. All communication with adjacent machines is done without operator input. In Auto Cycle, the machine uses the parameters in setup mode. - Page 19 This is normal. • If the DeltaTherm IR Cure Module is the last machine in a line, the alarm will signal when a board exits. This only occurs if a downstream SMEMA signal is not present.
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Page 20: Manual Mode
DeltaTherm IR Cure Module Manual Mode IR Panels The panel temperature is shown for each zone. A zone is an area in the oven that is controlled and monitored independent of other areas. Usually an oven has four zones. Figure 12: Manual IR Panels 1. -
Page 21: Conveyor Speed
DeltaTherm IR Cure Module Conveyor Speed The Conveyor Speed can be set in Manual mode. 1. Select the Speed box to manually enter conveyor speed. The metric/standard u nit range is .03 – 15.3m/min (.1 - 50.2ft/min). • The keypad will be shown, enter the necessary value. -
Page 22: Conveyor Jog
DeltaTherm IR Cure Module The Conveyor Width can be set in Manual mode. 1. Press to manually enter the target conveyor width setpoint. • Touch the screen and a keypad will be shown. • Enter the necessary value. • Push ‘ENT’, and the zone screen will be shown again. -
Page 23: Sensors
DeltaTherm IR Cure Module Sensors The PIP Sensors can be monitored in Manual mode for correct operation. Figure 16: Sensors in Manual Mode Note: Process PIP will only show on 12 ft and 16 ft oven length systems. SMEMA Control 1. -
Page 24: Setup Mode
DeltaTherm IR Cure Module Setup Mode In Setup mode, the operator can set basic functions of the machine and Auto Cycle parameters. These parameters (depending on the machine) are the current recipe, IR panel temperatures, allowable deviations, conveyor width, and conveyor speed. Parameters are saved in the controller under the current recipe even when the module is shut down. - Page 25 DeltaTherm IR Cure Module 3. The Actual Temperature displays the current actual temperature of the heater panel. • On double-sided ovens, the upper and lower panels for each section are controlled as one zone. The display temperature is the average temperature (display temperature is filtered) of the upper and lower panel.
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Page 26: Conveyor Speed
DeltaTherm IR Cure Module Conveyor Speed Figure 19: Conveyor Options 1. To change the conveyor speed while in Auto Cycle, select the Speed box. The keypad will be shown. • Enter the necessary value. The minimum speed is 0 feet per minute or 0 meters per minute, the maximum speed is 60 feet per minute or 19 meters per minute. -
Page 27: Conveyor Width
DeltaTherm IR Cure Module Conveyor Width This is an optional setting. Not all modules will have this option. • Use the arrows on the screen or the “F1” and “ESC” button to scroll to the Setup- Conveyor Adjust screen. •... -
Page 28: Rename Recipe
DeltaTherm IR Cure Module Rename Recipe • Use the arrows on the screen or the “F1” and “ESC” button to scroll to the Setup- Settings screen. Figure 21: Setup - Rename Profile • Use the + - Page icons or the F2 and F4 keys to scroll through the recipe names. -
Page 29: Global Settings
DeltaTherm IR Cure Module Global Settings Figure 22: Global Settings 1. Press Unit Selection to toggle between Metric and Standard. 2. Press Process Timeout to enable or disable board process timeout in Auto Cycle. 3. Press Clear Board to enable or disable the clear board check when entering Auto Cycle. -
Page 30: Fault Recovery Procedure
DeltaTherm IR Cure Module Fault Recovery Procedure Several errors can cause a fault condition. They are: • The EMERGENCY STOP is engaged or there is an open door • There is an exhaust or intake fan failure • The parameters are out of range •... -
Page 31: Recovery From An Over-Temperature Error
DeltaTherm IR Cure Module Recovery from an Over-Temperature Error 1. Select “Silence Horn” to stop the alarm or “Clear Fault” to clear the fault. 2. Let the module temperature decrease. 3. Operate the module in manual mode or restart Auto Cycle. Look for the parameter that causes the error. -
Page 32: Error Messages
DeltaTherm IR Cure Module Error Messages The following are all the possible error messages generated by the PLC program. Msg Number DeltaTherm Fault Messages Zone 1/2 Overtemp Monitor Fault Zone 3/4 Overtemp Monitor Fault Zone 5/6 Overtemp Monitor Fault Zone 7/8 Overtemp Monitor Fault Exhaust Fan Low Pressure. - Page 33 DeltaTherm IR Cure Module Panel 6B Overtemp >285C Panel 7A Overtemp >285C Panel 7B Overtemp >285C Panel 8A Overtemp >285C Panel 8B Overtemp >285C Zone 1A Intensity Fault Panel Never Reached Setpoint Zone 1B Intensity Fault Panel Never Reached Setpoint...
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Page 34: Figure 23: Error Messages
DeltaTherm IR Cure Module Zone 6A Deviation Fault Zone 6B Deviation Fault Zone 7A Deviation Fault Zone 7B Deviation Fault Zone 8A Deviation Fault Zone 8B Deviation Fault Master Conveyor Transfer (CAN3) Drive Mapping Fault Master Conveyor Width (CAN4) Drive Mapping Fault... -
Page 35: Troubleshooting
DeltaTherm IR Cure Module Troubleshooting If Something Goes Wrong . . . Some problems are easy to identify and solve, others may require more extensive help. This troubleshooting section is designed to assist an operator in solving many problems before seeking additional help. -
Page 36: Fault Diagnosis
DeltaTherm IR Cure Module Fault Diagnosis Operation Other Symptoms Possible Cause Corrective Action The machine is ON. Cables are loose or not Examine the cable connections And the operator connected Correct any loose connections interface does not have power The electrical... -
Page 37: Maintenance
DeltaTherm IR Cure Module Maintenance Service Area Weekly Monthly Conveyor System Examine the sensors Apply a small amount of high temperature chain for material and dust lubricant, such as Darmex 773ND or equivalent to buildup the chains. Conveyor System Rails: Clean and lubricate with Mobil DTE-24 or equivalent. -
Page 38: Notes
DeltaTherm IR Cure Module Notes Page 38 of 41 Revision B February 2020... -
Page 39: Warranty
Unauthorized repair or modification of the enclosed product, and/or the use of spare parts not directly obtained from PVA (or from factory authorized dealers) will void all warranties. -
Page 40: Appendix A - Definitions
PLC – Programmable Logic Controller. Type of controller used to program industrial machinery. See also SLC. PVA –Precision Valve & Automation, Inc. Setup – Machine state where the Auto Cycle parameters are determined. Mutually exclusive with Auto Cycle and Manual. -
Page 41: Table Of Figures
DeltaTherm IR Cure Module Table of Figures Figure 1: DeltaTherm IR Cure Module Functional Block Diagram ..........8 Figure 2: SMEMA Process Flow ......................10 Figure 3: Power Switch "On" ........................11 Figure 4: Air Velocity Test Point ......................13 Figure 5: Emergency Stop Button .......................
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