TABLE of CONTENTS 1. INTRODUCTION ..........................6 1.1. Manual Contents Organization....................6 1.2. Installation Requirements ......................6 1.2.1. Unpacking ........................6 1.2.2. Machine Placement ......................1 1.2.3. Machine Inspection ......................7 1.2.4. Providing Power ......................7 1.2.5. Providing Gas and Air ....................7 1.2.6.
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TABLE of CONTENTS 3.5. Recipe Setup ..........................14 3.5.1. Setpoint Modification (Levels 2 and 3) ............... 14 3.5.2. Power Distribution (Levels 2 and 3) ................14 3.5.3. PID Zone Tuning (Levels 2 and 3) ................15 3.5.4. Transport Speed (Levels 2 and 3) ................16 3.6.
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TABLE of CONTENTS 6. PRODUCT SPECIFICATION ......................38 7. OPTIONS ............................39 7.1. Temperature Profile - Profile Menu (Option) ................39 7.2. Element Monitor (Option) ......................39 7.3. Moisture and Oxygen Analyzer System (Option) ..............41 7.3.1. Introduction ........................41 7.3.2.
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TABLE of CONTENTS FIGURES Figure 3.1.2.1 Control Panel ........................11 Figure 3.2.6.1 Security Window, Log-on ....................13 Figure 3.2.8.1 Gas Flow Window ......................14 Figure 3.2.9.1 Process Control Window ....................11 Figure 3.3.1.1 Recipe Window ....................... 13 Figure 3.8.1.1 Event Logging ......................... 17 Figure 4.1.3.1 Scheduled Maintenance Window ..................
TABLE of CONTENTS Section 1 INTRODUCTION and INSTALLATION REQUIREMENTS 1. INTRODUCTION 1.1. Manual Contents Organization This manual is intended for users of the Radiant Technology infrared furnace system. The manual will help in understanding the machine's capabilities, uses, routine maintenance, and basic design features.
machine at the approximate locations shown on the installation drawing (see Documentation Section), and slide the shipment skid out from under the machine. Do not attempt to lift the machine at one point or at points other than recommended; failure to follow these instructions invites frame damage and will void the warranty.
1.2.6. Process Exhaust Requirements In most applications, process exhaust and heat should be vented to the outside atmosphere. It is the customer's responsibility to review the process, local laws, and facility in deciding on an exhaust system. Insulated exhaust tubing and a collector hood with a 4 inch inside diameter, or larger, is routinely used.
The screws which secure these brackets to the frame must be removed before bringing the furnace up to operating temperature. WARNING: Failure to remove slide restraint screws invites structural damage and will void the warranty. 1.2.9. Radiant Technology Customer Service Startup (Optional) It is the customer's responsibility to accomplish the tasks described in 1.2.1 through 1.2.8, prior to scheduling a visit by a Radiant Technology Customer Service technician.
2.3. Normal Good Laboratory Practice Normal good laboratory practices apply to the operation of RTC furnaces. Do not use the space above the furnace as storage. Do not block the cabinet doors preventing the cooling of the electronic equipment inside. Do not operate with side covers off as this will prevent normal cooling of the electronic equipment thus voiding the warranty.
Section 3 EQUIPMENT OPERATION 3. OPERATING INSTRUCTIONS 3.1. Power Controls and Indicators 3.1.1. Power Status Indicators 3.1.1.1.MAIN (Red Indicator) This lamp burns continuously whenever power is available to the furnace and the main circuit breaker (optional) is turned on. 3.1.1.2.ON (Green Indicator) This lamp burns continuously when the control circuits are energized, and indicates that power is available to actuate the control circuits.
3.1.2.1.POWER ON Pressing this switch causes the furnace to go through its power up sequence, providing the MAIN lamp is lit and the EPOs (Emergency Power Off switches) and interlocks located in the doors are released. The ON indicator, described in 2.1.1.2, will illuminate. 3.1.2.2.POWER OFF Before pressing POWER OFF, the furnace must be in cooldown mode.
3.2.6. Security and User Information This window allows the operator to select access level, log-on or log-off, add or delete users, and modify password and access codes. NOTE: Before turning off system, you must “Log-Off” through Security screen. 3.2.6.1.Access Level Select Access Level by clicking on the User List, then log-on with the appropriate password.
(Initial password is set to “2”.) Access Level 3 is restricted to RTC personnel only. 3.2.7. Screen Menu (Located at bottom of screen) Allows operator to select the desired screen by moving the cursor and clicking on the chosen screen.
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3.2.8.1. Default Settings Verify flowmeter settings are per recipe requirements. See Section 2.6. NOTE: If operating on hydrogen, understand the appropriate features before attempting operation. 3.2.8.2.Optional Mass Flow Controller(S) Flowmeters labeled as MFC provide control to mass flow controllers. Use the vertical Slide switch or numeric dialog box on the appropriated Mass Flow Controller to set the desired flow rate.
3.2.9. Furnace Startup (Process Screen) Figure 3.2.9.1 Process Control Window 3.2.9.1.Check for no active alarms or alerts. If appropriate, move cursor to and click on “Acknowledge Events” to clear or silence an alarm/alert in order to proceed with furnace operation. If alarm/alert does not clear, see Troubleshooting Section 3.2.
While the machine is heating, check for alarms and listen for the alarm buzzer. In particular, check for any exhaust fan failure alarms. Element failure alarms (if element monitor option is selected) usually occur in the "warmup" mode. The effect of an element failure is generally minimal unless two failed elements are adjacent to each other.
Press the POWER OFF button. The ON power indicator will turn off. Once the temperature falls below 100°C, all functions will automatically shut down. 3.2.15. Gas Shut Off Turn the supply gas off. The functional checkout is now complete. 3.3. Software Operation 3.3.1.
3.3.1.2.Delete Recipe (Levels 2 and 3) 3.3.1.3.Edit Stored Recipe, Save Stored Recipe (Levels 2 and 3) NOTE: Do not use this feature on the current recipe while in ready mode and while processing parts. Process Monitor Screen 3.4. This displays the setpoint temperature, the current recipe, process state and status, transport speed, and other information such as percentage of power to elements and edge heaters.
The maximum power is typically set at 1.5 times the actual percentage of power used when the furnace is in the “Ready” mode. 3.5.2.2.Edge Heaters (Levels 2 and 3) The edge heaters are located at the outer edges of the belt and run the entire length of the heated chamber.
3.5.4. Transport Speed (Levels 2 and 3) On the Process window, place the cursor on the transport speed field, click, type in the new value and press enter from the keyboard. NOTE: Transport speed is displayed in inches per minute. 3.6.
Section 4 SERVICE INFORMATION 4. SERVICE INSTRUCTIONS 4.1. Routine Maintenance 4.1.1. Daily Maintenance Daily maintenance consists of a simple series of functional checks that will alert maintenance personnel to any signs of developing problems. The importance of regularly checking the machine cannot be over stressed to prevent not only damage to the machine, but also loss of productive time and product.
4.1.3. Other Scheduled Maintenance 4.1.3.1. See Preventive Maintenance Screen Figure 4.1.3.1 for Reference Figure 4.1.3.1 Scheduled Maintenance Window The Remaining Time Status Bar on the Maintenance Window will provide a graphical representation of the time remaining before maintenance is required. When any Maintenance Item has timed out/reached the maintenance required date, the MAINT status box on the Process Window will Flash.
To Enter the Item Field, Click on the desired row in the column titled “Item”. The following dialog box will appear. Figure 4.1.3.2 User Selectable Maintenance Description Enter the description of the new maintenance item. To Enter the new item’s maintenance frequency, to the right of the recently added maintenance description field, Click on #days box.
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Note: Refer to the mass flow controller schematic diagram for the output test point wiring detail. 4.1.3.5.Inspect all system cooling fans and flow switches, for freedom of movement and proper operation, every 6 months. 4.1.3.6.If the system has a belt brush, the unit should be inspected every 6 months to establish a maintenance cycle.
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The chain drive system is contained in the motor enclosure at the exit end of the oven. The chains should be lubricated every 6 months with RTC P/N 100523 chain lubricant or an equivalent all-purpose chain lubricant. The chain tensioner is equipped with a grease fitting for lubrication. The chain tensioner should be lubricated every 6 months with a general multipurpose bearing grease.
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The belt should be checked periodically to make sure that it is tracking through the center of the oven. Belt tracking can be checked visually at the entrance and exit ends of the oven. The belt should be centered between the belt guides at the entrance and exit ends of the oven. If the belt tracks off-center this problem can be rectified by realigning the belt shafts.
4.1.3.19.Chamber, Self Clean The chamber should require no maintenance. If a problem with the chamber is suspected, an RTC field service engineer should be consulted. Because the process gas is forced through the insulation, the gas flow away from the insulation prevents contamination from building up on the chamber walls.
B) Check K3 and K6 relays (located in safety enclosure) to be sure they are operational. If not, check interlock switches (located on pedestal doors) to be sure they are engaged. (Ref: Power Control Schematic in Documentation Section.) Check K4 relay (located on OPTO22 panel. (Ref: Channel Assignment Sheet) Check for illuminated LED, indicating an active...
1. • out of memory, switching to low scan mode; there is insufficient memory to run the software. Contact RTC for additional memory. • Incompatible gml file date/time; the source code has been changed, contact RTC.
If you have communication, but some variables appear as “###”, this means the controller does not know what this particular variable is. Check the Event Log viewer for more details. 4.3.2. Process Problems 4.3.2.1.Belt speed Measure the belt speed with a stopwatch. If it differs from the value on the process screen by more than 5% (1 IPM off for each 20 IPM of belt speed), re-calibrate the belt speed.
The analog inputs cannot be checked visually. 4.3.4. Remote control setup To setup the remote control on the furnace for troubleshooting by RTC at the factory, start PcAnywhere, click on “Be a Host” and “Wait for Call”. computer should be connected to an ANALOG phone line.
Now set the Integral to the period of previous oscillations (usually between 5 and 15 seconds). Round up to the nearest integer. The temperature will slowly drift to a new value. Reduce the Integral term for faster convergence. At that point, the system may start oscillating again. Decrease the Gain by an additional 10% until stable.
4.4.1.4.Remove the element and old packing material in both ceramic ends. 4.4.1.5.Before attempting to install a new element, it is absolutely imperative that two new pieces of insulating material (RTC P/N...
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NOTE: Failure to do so will cause a severe air leak and resulting profile deterioration. 4.4.1.6.Before installing the lamp, verify that the ceramic (RTC P/N 15499) is intact and the red silicone sealant is holding the ceramic. G.E. RTV, type 106 is used here. This is also essential to prevent air leaks.
4.4.1.13.The ceramic standoff mounting the connecting stud is intentionally loose. Do not tighten it or it will fracture. Again, use two wrenches, one below and one above the lead, and tighten. 4.4.1.14.Cut off the excess element lead wire. 4.4.1.15.Recheck to be certain that the insulation is not covering either terminal.
Figure 4.4.2.2 Belt Installation 4.4.2.4.Continue pulling the belt through the drive system using the wire, and then by hand, until the belt path is complete. 4.4.2.5.Splice the belt, as shown below. Figure 4.4.2.3 Inserting Belt Splice 4.5. Element Test Procedure This procedure is to be used to test for open heating elements.
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Remove all power from the furnace, and if an UPS or EPS is installed, locate and shut off the unit. Remove all side covers, completely exposing all lamp terminations. Using the schematic as a reference, locate the bus bars linking the elements in each zone.
TABLE of CONTENTS Section 5 THERMAL PROCESS 5. THEORY OF OPERATION - PROCESSING 5.1. Energy Source The radiation source in the Radiant Technology near-infrared furnaces is a filament of tungsten or nickel chromium alloy, electrically heated to a temperature substantially above chamber or product temperature.
5.4.1. Profile For most thick film processes in the RTC furnaces, the rate of temperature rise in the product can be made as fast as needed, the volatilization and sublimation of organic binders being completed long before polymerization or fusion temperatures are attained.
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Generally, maintaining as large as possible temperature differential between the heating zone(s) and the spike zone, enables the furnace to generate the high intensity spike. Dummy loading ahead of the systems being processed, to bring the furnace to a stable condition, is most desirable and is also determined by trial and error.
Application, press and hold down the ALT key, and then press TAB repeatedly. When the title “WINKIC Windows Application” appears, release ALT. The WINKIC Application appears in the foreground. Repeat the procedure to return RTC Furnace Operations to the active window.
Digital I/O modules PLC (P/N 322-092202-02) are utilized to collect element status information from Element Monitor Board (P/N 370-101831-01). Each Element Monitor Board has four monitoring circuits. Each circuit utilized a transformer coil and rectifier network to pickup and convert the element status to a low voltage output signal. This output signal is received by a digital I/O module.
Monitor Window will display all failed element legs including multiple failures within the same zone. Note: Applied power levels of less than 10% are below the threshold of the sensor circuit. Element legs operating in this range are reported as OK. Figure 5.5.1.3 Element Monitor Status Window 7.3.
7.3.2. Description The analyzer system typically uses four (4) sample lines. All but one of these lines sample process atmosphere at various parts of the furnace. The last line samples the source gas. The sample lines connect to a manifold. A series of computer controlled solenoid valves are used to switch from one sample line to another.
Figure 7.3.3.1 O Analyzer Sampling Window Optional Oxygen Level Alerts and Setting Oxygen Level 7.3.3.2.2. Alert Limits (H Mode Only) The oxygen analyzer may give a high oxygen level alert during startup. The alert will continue until the process gas lines and the furnace chamber have operated in a nitrogen mode long enough to remove excessive oxygen.
furnace will automatically enter cooldown/combustible gas purge cycle in twenty seconds. A time remaining count is displayed. The operator has the option to click the “Purge” button to immediately start furnace cooldown/purge or the “Reset” button to restart the twenty second timer. The operator cannot delay the automatic cooldown/purge cycle for more than a total of sixty seconds.
H2/FORMING GAS SEQUENTIAL OPERATION 7.4.2. Description FORMING The hydrogen operation system uses existing furnace plumbing and an additional flow control system introduce hydrogen into WARM UP the furnace chamber. hydrogen introduced into furnace by allowing it to permeate through the porous ceramic fiber...
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7.4.2.1.Control System The hydrogen control system is designed to prevent the possibility of introducing a combustible mixture of hydrogen into the furnace chamber. This is accomplished through logic which requires that nitrogen be run continuously in the exhaust venturis, entrance/exit baffles, furnace chamber, and in the transition tunnel/cooling muffle, if so equipped.
Gas flow control is accomplished manually with flowmeters. section 2.12.4 for operating instructions. 7.4.3. Installation Requirements Hydrogen is a flammable gas and, under certain conditions, it can be explosive. The user of this equipment must take adequate precautions to prevent the escape of hydrogen into the room air and to eliminate possible sources of ignition from the working environment.
It is further recommended that a trace oxygen analyzer and helium detector be made available for the checkout. RTC has taken precautions to design the furnace so that it can be safely and reliably operated on hydrogen. However, if the gas flows are not properly set, air can be drawn into the machine, or the furnace atmosphere can be discharged out the entrance or exit, causing a fire hazard.
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RTC recommends, as a minimum, a trace oxygen analyzer and combustible gas monitor be used to guide final process settings. Furnace System Functional Check 7.4.6.1. First perform the recommended furnace system functional checkout. Correct any malfunctions, as necessary, before proceeding.
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7.4.6.7.Nitrogen/Hydrogen Mixing Selecting the nitrogen/hydrogen atmosphere, with the furnace in the hydrogen mode will unbalance the ratio of input to exhaust gas. This happens because nitrogen is introduced in addition to the volume of hydrogen that is already flowing into the furnace. Before pressing nitrogen/hydrogen mixing, perform the following: Calculate the volume of helium flowing into the furnace when the machine is running in a...
Propane (C 1.56-1.99 Sodium Dioxide (SO 2.2-2.26 Butane-N Butane-ISO 1.99 Modem/PcAnywhere (Option) 7.5. In order to allow for remote examination of in-process furnace operations, a modem with communication software is provided. The remote operator, in conjunction with on-site personnel, can simultaneously view the Process screen and have access to input and control features.
Figure 7.6. Product Viewing Area 7.6. Product Viewing Area (Option) This option is only available on furnaces with separate drying and furnace areas. The viewing area is set between these two sections and it has an opening panel that allows access to the product inside.
line voltage and adjusts the power according to this voltage. Fluctuations are adjusted for +15% around the nominal voltage. Beyond those values, no adjustments are made. Since the user takes control of the system, the machine automatically goes into process ready.
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To define a unique product-unit length click the recipe button on the process screen. Once in the recipe screen, shown in Figure 0.2, double click the product length box. A pop-up window labeled “Send Value” will appear (). Define the product-unit length in the product length window, and click OK.
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Figure 0.2 Recipe Screen showing Product Length Box Figure 0.3 Send Value Window To view the product tracking window, return to the recipe screen shown in Figure 0.1 and click the view button. Figure 0.4 shows the product tracking window labeled “Product”. Rectangular representations of the defined product-unit length will scroll this screen at the set belt speed.
Appendix A DOCUMENTATION PACKAGE DOCUMENTATION • Channel Assignment Sheet • Bill of Materials and Schematics Listing for Electrical/Electronics • Bill of Materials for Mechanical • Electrical Schematics Power Control Schematic Frame Wiring Schematic Signal Control Schematic Options Schematics Element Wiring Schematic •...
You can now start the MMI software by double clicking on the Furnace icon. From now on, startup will be automatic. You should see the correct date and day in the bottom left corner. If not, go to the troubleshooting section. Check the log in dialog box for the 3 proposed users: operator, tech and rtc.
Appendix C Engineering Specifications 00025 Procedure for Jumpering Analog, I/O and Expansion Cards for OPTO 22 00028 SCR Power Control PCB Calibration, OPTO 22 Control System 00034 Calibration Procedure for Motor Speed Controller Board and Conveyor Belt (OPTO 22) 00042 Ethernet Installation and Troubleshooting...
ENGINEERING ES NO: 00025 SPECIFICATION radiant technology corporation A E.O. REVISIO 4906 8. APPROV Adams PROCEDURE FOR JUMPERING ANALOG, I/O AND EXPANSION CARDS FOR OPTO 22 1.0 Scope This document is intended to describe the procedure for jumpering an addressing all cards in the OPTO 22 control system.
2.3 LOOP BACK JUMPERS: Install loop back jumpers on last card (brick) only. JP 3 3.0 ANALOG CARD (BRICK) EXPANSION: Analog card (brick) which has an associated Expansion card (brick) must have the expansion cable attached to the brain card. NOTE: No jumpers required.
FIGURE 6 PAGE 12. ORIGINATOR: ALEX 13. DATE: 7/29/96 ISSUED: DATE: ENGINEERING ES NO: 00028 SPECIFICATION radiant technology corporation REVISIONS 13.1. A 13.2. B 09/16/96 05/26/99 14. APPROVAL SCR POWER CONTROL PCB CALIBRATION, OPTO22 CONTROL SYSTEM 1. SCOPE This procedure covers the zero crossing and span adjustment for 50Hz or 60Hz SCR power control PCB.
3. PROCEDURE 3.1 For windows 3.1 you must be in “Warm-Up” state. For Windows 95 you must be in “Cool-Down” state. 3.2 Click on icon “MAINT” 3.3 Click on “CALIBRATE SCR” 3.4 Click on “START”. Make sure the lamp power is on. (Indicator light must be green;...
3.10 Set the applied power in the appropriate zone for 50% power and go to “Warm- Up” state. Adjust the span potentionmeter to 50% of the line voltage using the following formula: 50% = INPUT VOLTAGE √2 NOTE: Due to some interaction between controls, it may be necessary to repeat adjustments 3.0 through 3.10 PAGE...
2.0 The motor speed controller board has a horsepower select switch on the main control board (see figure 1 for switch location on board). The proper DIP switch settings for various Bodine motor types can be set using the following procedure. Determine the first four digits of the motor’s type from the motor nameplate.
REVISIONS 25.1. 25.2. Alex Rey 26. APPROVAL CONTROL CIRCUIT BOARD DETAIL FIGURE 4 CONTROL CIRCUIT BOARD DETAIL ISSUED: DATE: 3 of 3 1. INTRODUCTION ..........................6 2. GENERAL SAFETY GUIDELINES ....................10 3. OPERATING INSTRUCTIONS......................11...
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4. SERVICE INSTRUCTIONS ......................23 5. THEORY OF OPERATION - PROCESSING .................. 40 6. PRODUCT SPECIFICATION ......................43 7. OPTIONS ............................44 8. APPROVAL ............................65 9. ORIGINATOR: ALEX REY ......................66 DATE: 7/29/96 ......................... 66 APPROVAL ..........................66 ORIGINATOR: ALEX REY ....................67 DATE: 7/29/96 .........................
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27.2.1. Select “Add” from the “Configuration” Dialog box. 27.2.2. Select “Client” from the “Select Network Component Type” Dialog box, then “ADD” from the “Select Network Client? Dialog box. In the Data window, select “Microsoft/Client for Microsoft Networks”, then select the “OK” pushbutton. 27.2.3.
28.Reset and Assign an IP Address to the LCM4 Controller’s Ethernet Card. 28.1. Remove the M4Senet-100 Opto Ethernet card from the controller chassis. Note: Follow standard anti-static dissipative procedures when removing and handling the card. 28.1.1. Remove Ethernet and RS-232 connectors Release (4) front panel set screws and (2) covers 28.1.2.
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28.4.1. Wait for the STD LED on the M4SENET Card to stop blinking, and then turn remove power from the system. Note: This procedure resets the Opto22 Ethernet Card to its factory default settings. 28.5. After removing power from the system, again remove the M4SENET card and restore the J7 Jumper to its normal position as shown below...
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Select and highlight the “TCP/IP -> … Ethernet …” protocol in the menu. 29.7. 29.8. Click the “Properties” button. 29.9. Click on the “IP Address” tab Check to make sure the “Specify an IP address:” selector switch is marked. 29.10. 29.11.
30.Verify that the external Opto22 SNAP-LCM4 controller’s jumpers are configured correctly Jumper the following AUTO Figure 30-1 LCM4 External Jumpers...
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