PVA DeltaTherm, Operation Manual

Page 1: ...DeltaTherm IR Cure Module Operation Manual Revision B WHERE PRECISION DRIVES PRODUCTION ...

Page 2: ...ers of this document with respect to changes subsequently made Precision Valve and Automation Inc makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply This document including the i...

Page 3: ...t 8 Operating Handling Transportation and Storage 9 Dust and Debris 9 Temperature and Humidity 9 Location 9 SMEMA 10 Installation and Setup 11 Installation 11 Operating Safety 12 Notices and Warnings 12 Safety Devices and Guarding 12 Safety Circuit 12 Doors 12 Exhaust Requirements 13 Air Velocity Test Point 13 Operation 14 Startup Procedure 14 Light Tower Operation 15 Machine Safety Check 16 Shutd...

Page 4: ...ings 29 Fault Recovery Procedure 30 Recovery from Emergency Stop or Open Door Error 30 Recovery from an Exhaust or Intake Fan Failure 30 Recovery from a Parameter Out of Range Error 30 Recovery from an Over Temperature Error 31 Recovery from an Auto Conveyor Adjust Error 31 Error Messages 32 Troubleshooting 35 Calling Technical Support 35 Fault Diagnosis 36 Maintenance 37 Notes 38 Warranty 39 PVA ...

Page 5: ...cal Support PVA Six Corporate Drive Halfmoon NY 12065 Tel 1 518 371 2684 Fax 1 518 371 2688 Website https pva net Email info pva net Tel 1 844 734 0209 Email cs pva net Document History Revision Revision Date Reason for Changes REV B January 2020 DeltaTherm Version 1 9 Release REV A December 2018 Initial Release Note All photographs and CAD model representations in this document are a general repr...

Page 6: ...th the unit Never put hands or tools in areas with this symbol when the machine is in operation A dangerous condition may exist Read and understand the manuals provided with the unit before any repairs or maintenance is done Only a qualified individual should do service Use caution when there are pressurized vessels Find and repair any leaks immediately Always wear appropriate safety equipment whe...

Page 7: ... emphasize that hazardous voltages current temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use Only qualified personnel should enter areas designated with this symbol Laser light source present Do not stare directly into the beam Do not use in the presence of highly reflective surfaces Pinch hazard from moving parts Avoid cont...

Page 8: ... operation of this machine Any uses other than those listed above could result in a dangerous condition and cannot be protected against by the safety features installed on the system Figure 1 DeltaTherm IR Cure Module Functional Block Diagram Personal Protective Equipment Operators must use eye protection Always wear gloves when handling materials and solvents Refer to MSDS sheets on the material ...

Page 9: ...ut abuse will reduce its performance Dust and Debris All enclosures and connector covers should be closed tightly Put a cover over the system if dust or other airborne debris is present in the storage area Temperature and Humidity Storage and operation should be done in an area at 40 105 F 4 41 C and low humidity Do not let the machine have condensation on it Location The machine should be install...

Page 10: ...ce Mount Equipment Manufacturers Association SMEMA Electrical Equipment Interface Standard is used to make sure the sequence of boards is correct If these connections are not in place boards cannot move from one machine to another SMEMA cables have male 14 pin amp type CPC connectors The cables are straight through so orientation does not matter On each module the wire to the J1 plug must connect ...

Page 11: ... work ref ANSI ASME B30 2 1983 Installation 1 Plug the machine into an appropriate power source as shown on the legend plate on the module The electrical service should be correctly grounded and the power source clean If high power equipment operates off the same source a line conditioner may be necessary Poor quality power can cause errors in machine operation WARNING Failure to obey electrical s...

Page 12: ... Do not bypass disable or tamper with the safety features Precision Valve Automation Inc is not responsible for any damages incurred mechanical or human because of changes or destruction of any safety features Safety Circuit The main power to the machine is monitored and controlled by the safety circuit The safety circuit has a control relay and one or more safety devices The tripping contact of t...

Page 13: ...st Point ft min Air Velocity at Test 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 Air Velocity Test Point Measure the velocity at the inlet to the factory supplied duct Figure 4 Air Velocity Test Point ...

Page 14: ... for all machines ON OFF options are displayed by showing black background with white lettering for ON and white background with black lettering for OFF Startup Procedure 1 Close all doors 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 15: ...all other times The amber light is on when the machine is in Auto Cycle but the specified parameters have not been reached It is off at all other times The red light is on steady when the machine is not in Auto Cycle due to operator intervention It flashes when the machine is in cycle but the cycle is stopped because of a machine problem It is off at all other times The buzzer cycles when the red ...

Page 16: ...k successfully After you start the safety check you must activate and deactivate the safety devices Some safety checks are timed and will cause a failure if the action is not done in the set time Shutdown Procedure Do the following procedure to shut down the cure module 1 Wait for all boards to clear the cure module 2 Press Auto Stop on the OIT Wait for the PVA screen to appear 3 Wait one minute f...

Page 17: ...ycle 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 Select ESC or the settings icon to go to Setup mode and view or change the operating parameters of the module Select the Home icon or F3 from any mode to return to Cycle Stop ...

Page 18: ...erature setpoint of the heater panel 3 The At Temperature indicator will light up when the panel temperature is within the allowable setpoint deviation value 4 The Current Recipe Name will display at the top of the screen 5 The Board Counter displays the number of boards in the oven In the event of an incorrect value PIP flashing press and hold for 5 seconds to reset this to zero 6 The Autocycle M...

Page 19: ...due to absorption of energy from the lower panels 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 When the conveyors stop for a board to be removed the cure module will maintain the parameters The module will not time out if a board is not removed In Auto Cycle the PL...

Page 20: ...e the target set points for each zone and heater panel To change the target Setpoint press the designated box A new screen will be shown The left side box in the Zone Control area is the target temperature display temperature is filtered for each zone and the deviation point for that zone Touch the screen and a keypad will be shown Enter the necessary value Push ENT and the zone screen will be sho...

Page 21: ...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 Select ENT to save 2 Press the red X icon or green checkmark icon to toggle the conveyor between on and off Figure 13 Conveyor Control in Manual Mode Conveyor Width Figure 14 Conveyor Width in Manual Mode ...

Page 22: ...ain 2 Press to move the current target conveyor width setpoint Note Prior to the move the machine will check for any boards 3 Press to rehome the conveyor width Note Prior to the move the machine will check for any boards Conveyor Jog Figure 15 Conveyor Jog in Manual Mode 1 This screen displays the current conveyor width 2 Press to adjust the conveyor width This will jog the conveyor width in a po...

Page 23: ... in Manual Mode Note Process PIP will only show on 12 ft and 16 ft oven length systems SMEMA Control 1 The SMEMA inputs Upstream Board Available and Downstream Ready can be monitored for correct operation through the SMEMA screen in Manual mode 2 Select the necessary output Machine Ready and Board Available to toggle it on or off Figure 17 SMEMA in Manual Mode ...

Page 24: ...n to cycle stop IR Panels Figure 18 Setup Zone 1 Panels 1 The Heater Panel Recipe Switch can disable or enable the use of a zone s upper or lower heater panel in Autocycle If enabled the panel will display a green checkmark If disabled the panel will display a red X Note IR panels cannot activate unless the exhaust fan is on 2 The Setpoint box is the target temperature display temperature is filte...

Page 25: ... The Max Deviation is the max allowable deviation from the target setpoint for the specified zone and heater panel Each enabled zone s panels must reach and maintain a temperature within the set deviations to run the product in Auto Cycle Touch the Max Deviation box and a keypad will be shown Enter the desired value Press ENT to save the value and close the keyboard 5 The Apply to All button will ...

Page 26: ...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 Press ENT to save the value and close the keypad Select the arrow button to toggle the oven between left to right or right to left conveyor direction ...

Page 27: ...idth value is known press the value to manually enter the width setpoint A keypad will be shown Enter the necessary value The metric unit range is from 50 500 mm 1 97 19 69 in Select Save to keep and use the new value 2 If the width value is unknown press the arrows to use the Auto Adjust Conveyor Width This will jog the conveyor in a negative or positive direction 3 Once the target recipe width i...

Page 28: ...e Setup Settings screen Figure 21 Setup Rename Profile Use the Page icons or the F2 and F4 keys to scroll through the recipe names You can have a maximum of 30 profiles Select the name you want to change in the text box The keyboard will be shown type the new name and select enter The new name will be saved Recipe names are limited to 15 characters ...

Page 29: ...o Cycle If disabled upon entering Auto Cycle boards in the oven will not move downstream until the oven is at temperature and ready to process boards 4 Press Auto Idle Timeout to enable or disable the idle timeout in Auto Cycle When enabled if no boards are being processed in the specified timeout a silent timeout fault will occur and the oven will exit Auto Cycle turning the heater panels off 5 P...

Page 30: ... following procedure to return the machine to the cycle stop state WARNING If the Emergency Stop was engaged because of system failure do not disengage the Emergency Stop Shutdown the system and have qualified personnel repair the machine 1 Disengage the Emergency Stop button or close all doors 2 Select Clear Fault Recovery from an Exhaust or Intake Fan Failure 1 Select Clear Fault to stop the ala...

Page 31: ...y Stop button 2 Open the left cabinet and find fuse number 70 3 Release the fuse and disengage the Emergency Stop button This will move the conveyor toward the sensor 4 When the conveyor passes the sensor engage the Emergency Stop button again 5 Examine the integrity and the wiring of the sensor 6 Install fuse number 70 and home the conveyor again Error 2 The conveyor passes the software limit and...

Page 32: ... Panel 3A Overtemp 285C 110 Panel 3B Overtemp 285C 111 Panel 4A Overtemp 285C 112 Panel 4B Overtemp 285C 113 Master Conveyor Width CAN4 Drive Homing Timeout 114 Slave Conveyor Width CAN6 Drive Homing Timeout 115 Data Table Error Values Not Downloaded 118 System Options Changed Reboot Required 131 Control Power Timeout Fault 132 Autocycle Idle Timeout 141 Master Conveyor Transfer CAN3 Communication...

Page 33: ...int 163 Zone 4B Intensity Fault Panel Never Reached Setpoint 164 Zone 5A Intensity Fault Panel Never Reached Setpoint 165 Zone 5B Intensity Fault Panel Never Reached Setpoint 166 Zone 6A Intensity Fault Panel Never Reached Setpoint 167 Zone 6B Intensity Fault Panel Never Reached Setpoint 168 Zone 7A Intensity Fault Panel Never Reached Setpoint 169 Zone 7B Intensity Fault Panel Never Reached Setpoi...

Page 34: ...ult Ready to Switch On State Failed 305 Conveyor Width CAN4 Drive Enable Fault Ready to Switch On State Failed 306 Conveyor Transfer CAN5 Drive Enable Fault Ready to Switch On State Failed 307 Conveyor Width CAN6 Drive Enable Fault Ready to Switch On State Failed 308 Conveyor Transfer CAN3 Drive Enable Fault Switch On State Failed 309 Conveyor Width CAN4 Drive Enable Fault Switch On State Failed 3...

Page 35: ... mechanical or electrical problem occurs before you call Technical Support Calling Technical Support The Technical Support staff is available to help solve any problems The phone number is 1 518 371 2684 Have the following information when you call for help All the information on the OIT when the error occurred The operation in progress when the machine developed trouble when did it have problems ...

Page 36: ...place if necessary The bulb is blown Examine the bulb and replace A door is open Close all doors The emergency stop is engaged Disengage the emergency stop Board does not transfer to or from adjacent station The SMEMA connection is broken Examine the cable connections Correct any loose connections A module in the system is turned off Turn on the inactive module IR Panels do not operate or they fai...

Page 37: ...System Examine the sensors for material and dust buildup Apply a small amount of high temperature chain lubricant such as Darmex 773ND or equivalent to the chains Conveyor System Rails Clean and lubricate with Mobil DTE 24 or equivalent You can also use a thin film of the conveyor grease Darmex 773ND or equivalent ...

Page 38: ...DeltaTherm IR Cure Module Revision B February 2020 Page 38 of 41 Notes ...

Page 39: ...rom PVA or from factory authorized dealers will void all warranties All PVA warranties extend only to the original purchaser Third party warranty claims will not be honored at any time Prior to returning a product for a warranty claim a return authorization must be obtained from PVA s customer service department Authorization will be issued either via the telephone facsimile or in writing upon you...

Page 40: ... used to indicate the status of the machine Manual Machine state that permits the operator to control all the operations of the machine Mutually exclusive with Auto Cycle and Setup OIT Operator Interface Terminal Screen and or keys used to control the machine PIP Part in place sensor Designation for the sensors that sense parts Numbered incrementally along the process flow Press Press and release ...

Page 41: ...ight Tower Buzzer Status 15 Figure 9 PVA Screen 16 Figure 10 Cycle Stop 17 Figure 11 Auto Cycle 18 Figure 12 Manual IR Panels 20 Figure 13 Conveyor Control in Manual Mode 21 Figure 14 Conveyor Width in Manual Mode 21 Figure 15 Conveyor Jog in Manual Mode 22 Figure 16 Sensors in Manual Mode 23 Figure 17 SMEMA in Manual Mode 23 Figure 18 Setup Zone 1 Panels 24 Figure 19 Conveyor Options 26 Figure 20...