Asymtek TC V3 Operation Manual Download Page 5

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Introduction 1

1 Introduction

This manual covers basic operations for the TC V3 Conformal Curing Oven. It is intended as a reference
for production operators, process engineers, service technicians, and persons unfamiliar with Asymtek
products.

Overview

This manual consists of the following sections:

•

Safety

•

Components

•

Installation

•

Operation

•

Software

Basic System Description

The main features of the TC V3 Cure Module are:

•

Five oven lengths (3.2, 3.8, 4.4, 5.6, and 7.4 m)

•

Top and bottom radiant panel heating system

•

Bottom extraction (TC 2400, TC 3000, TC 3600)

•

Top blowing and bottom extraction (TC 4800, TC 6600)

•

400 mm loading and unloading zone

•

Chain

conveyor

Summary of Contents for TC V3

Page 1: ...Conformal Curing Oven TC V3 Operations Manual ...

Page 2: ...d service representatives copies of Asymtek manuals can be downloaded from http www asymtek com support manuals htm Contact Us Asymtek welcomes requests for information comments and inquiries about its products Please contact us using the information below Headquarters 2762 Loker Avenue West Carlsbad CA 92010 6603 USA Toll Free 1 800 ASYMTEK 1 800 279 6835 Tel 1 760 431 1919 Fax 1 760 431 2678 E m...

Page 3: ...s 7 Conveyor System 7 Air Exhaust 8 Heating System 8 Reinforced Cooling System 9 Software 9 Light Beacon 10 Optional Accessories 13 Second Track Conveyor 13 Heavy Duty Conveyor 13 Automatic Conveyor Chain Lubrication 14 Dropped Board Detection Cell 14 Pin Chain Conveyor 3 mm 15 Board Counter Cell 15 Exit Jam Detection Cell 15 4 Installation 17 Overview 17 Safety First 17 Facility Requirements 17 U...

Page 4: ...n Menu 28 Tool Bar 28 Zone Graphic View 29 Recipe Menu 30 Recipe Management 34 Control Menu 35 Inputs Outputs 38 Conveyor Parameters Modifications 41 Set Date and Time Procedure 43 Production Scheduling 45 Tactile Screen 47 Options Parameters Modifications 48 PLC Messages 49 Counters 50 Alarms 51 Resetting the Alarms 52 ...

Page 5: ... Asymtek products Overview This manual consists of the following sections Safety Components Installation Operation Software Basic System Description The main features of the TC V3 Cure Module are Five oven lengths 3 2 3 8 4 4 5 6 and 7 4 m Top and bottom radiant panel heating system Bottom extraction TC 2400 TC 3000 TC 3600 Top blowing and bottom extraction TC 4800 TC 6600 400 mm loading and unloa...

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Page 7: ...pplied with the equipment may result in injury to persons or damage to property To further optimize safe operation maintenance and servicing of the TC V3 Cure Module precautions and recommended practices are included with the procedures throughout this manual WARNING Safety is considered a joint responsibility between the original equipment manufacturer and the end user owner Safety precautions an...

Page 8: ... cooling to meet environmental stress limits of personnel and the Cure Module Follow MSDS recommendations for the proper handling cleanup storage and disposal of hazardous materials Know the MSDS recommendations for treatment of injury resulting from exposure to hazardous materials Preventing Cure Module and Workpiece Damage Immediately push the EMO button if the Cure Module or a workpiece is in d...

Page 9: ...ure Module point out areas where personnel must use extreme caution to prevent injury or damage WARNING CAUTION Comply with all safety warning labels to prevent serious injury to personnel and or damage to the equipment Worn or damaged labels should be replaced with new labels having the same part number Emergency Shutdown The TC V3 Cure Module features an EMO button that the operator or service t...

Page 10: ...the Main Menu 11 Wait for temperature stabilization before running production NOTE The alarm will sound upon start up Lockout of Electrical Energy TC V3 Cure Module electrical components have been designed in accordance with industry wide safety standards However precautions must still be taken whenever personnel may be exposed to the unexpected power up of the equipment or release of hazardous el...

Page 11: ...tion Standard Module Components Conveyor System The Conveyor System moves items PCBs substrates etc through the oven for thermal cycle processing Figure 3 1 It is adjustable by a hand crank see Figure 5 5 in the Operation section Maximum product weight is 2 Km per meter CAUTION The correct operation of the conveyor is not guaranteed if the product weight is heavier than 2kg per meter For heavier w...

Page 12: ...Figure 3 2 Air Exhaust Heating System The Heating System provides for the thermal cycle inside the oven It includes six to ten zones depending on the oven length that can be set to the determined thermal cycle The heating mode is composed of 70 radiation and 30 convection The heating system provides medium long infrared radiation above and below the load The heating tunnel is made up of resistors ...

Page 13: ...lied waste air exhaust Figure 3 3 Cooling System Software The Software control of the equipment is ensured by a complete SIEMENS PACKAGE Figure 3 4 that has the following characteristics Industrial PLC SIEMENS CPU IM 151 315 2DP SIEMENS 5 7 TFT Display Industrial SIEMENS Modem Option Auto diagnostic On line help Alarm log historical log capability Instruction and alarm management Storage capacity ...

Page 14: ...alarm capability to alert the operator of routine and urgent tasks that require attention NOTE The alarm will sound automatically for certain conditions with action required for the red light alarm Table 3 1 Light Beacon Colors Color Condition Green Equipment running okay Orange Oven is below defined temperature or conveyor speed needs stabilization Red At least one alarm has been detected Heat ca...

Page 15: ...mperature is outside of the authorized band defined in the recipe Heat and conveyor on Oven ready signal off Orange tower light on When the measured temperature is inside the defined band Reset the alarm Thermocouple Short Cut Alarm There is not 10 C of temperature elevation on one zone while more then 80 of the power is applied Conveyor on Heat off Oven ready signal off Red tower light on Alarm s...

Page 16: ...lay defined in option parameters menu Heat and conveyor on Oven ready signal off Red tower light on Alarm sounds When the sensor is not activated Reset alarm Input Transfer Alarm option The delay between the Send PCB signal from the upstream machine and input board sensor on the oven is longer than the time defined in the option parameters menu Oven ready signal off Red tower light on Alarm sounds...

Page 17: ...ble width is identical for both conveyors Minimum 2 x 50 mm Maximum 2 x 200 mm Figure 3 6 Second Track Conveyor Heavy Duty Conveyor The Heavy Duty Conveyor option is recommended for PCB or carrier weights over 2kg m Figure 3 7 Features include a special rail shape and a dual chain to transport PCBs or carriers Figure 3 7 Heavy Duty Conveyor ...

Page 18: ...and ensure chain lubrication by a drip mode The lubrication cycle frequency and quantity is controlled by PLC When the tank is nearing empty a standard low level alarm will display Dropped Board Detection Cell The Dropped Board Detection Cell is an optical cell that crosses the cure module from the input to the output of the conveyor Figure 3 9 If a dropped board is detected the heat will automati...

Page 19: ...the number of boards conveyed through the oven and to count total PCB production Figure 3 11 Counter cells are located at the input and output of the oven Figure 3 11 Board Counter Cell Exit Jam Detection Cell The Exit Jam Detection Cell is an optical fiber detection cell located at the output of the oven to detect potential board jams This cell monitors the correct transition operation between th...

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Page 21: ...possible covered with a non flammable floor covering See Leveling the Cure Module in this section Adequate space must be provided around the Cure Module in order to facilitate maintenance operations Unpacking and Placing the Cure Module To unpack and place the Cure Module 1 If the Cure Module was shipped in a wooden crate use a flat bar and hammer to remove the lid and sides of the crate WARNING C...

Page 22: ...y include UV lamps power supplies power cords tool and maintenance kits and equipment manuals They may be in a crate plastic wrapped on a skid or secured to the Cure Module To Unpack the Accessories 1 Locate the shipping list and place it in a safe location 2 If the accessories were shipped in a wooden crate use a flat bar and hammer to remove the crate lid 3 As you uncrate or unwrap each item ide...

Page 23: ...level from side to side 3 If necessary adjust the Levelers feet as follows Figure 4 1 Loosen the locking nut Turn the Adjusting Nut in the desired direction until the level s bubble is centered indicating that the system is level from side to side Figure 4 1 Leveler Height Adjustment 4 Check for all around stability by putting your hands on top of the Cure Module in one corner and pressing down If...

Page 24: ...etween each anchor bolt and the floor must be able to withstand at least 220 lbs 100 kg of pullout force Figure 4 2 Anchoring the Cure Module Connections Connecting Power The power supply line should be connected directly to the main circuit breaker located inside the electrical panel Connecting Exhaust Connect the exhaust contact between Terminal 6C and 6A of the connector block XC1 inside the el...

Page 25: ...d Before starting up the Cure Module check the following Electrical network is compatible with the cure module design Main circuit breaker is in the neutral position Correspondence of phases for first use Exhaust connections NOTE When first operating the Cure Module check the proper rotation of the oven blower exhaust blower and hood blowers To start the Cure Module 1 Connect the Cure Module s mai...

Page 26: ...the Main Switch to the ON position When the Cure Module power is turned on the programmable logic controller PLC initializes without any operator intervention When the PLC has initialized the control software automatically starts The Main Menu appears 8 Press the Reset button at the output of the oven Figure 5 1 Figure 5 1 EMO Button Reset Button EMO Button Reset Button ...

Page 27: ...oduction run is complete the conveyor has stopped and there are no PCBs remaining in the oven before turning the equipment off Check the PCB Counter that there are no PCBs left in the oven From the Main Menu click on the Stop button to stop the heat and conveyor movement Figure 5 2 Figure 5 2 Main Menu WARNING If the equipment will be turned off for an extended period of time more than one month m...

Page 28: ...cking Bar Figure 5 4 When opening the Hood a Safety Locking Bar must be placed between the frame and the hood A photoelectric sensor detects the presence of the safety bar If the bar is not in place the alarm will keep sounding until it is installed Twenty seconds is allowed to put the bar in place or to remove it when closing the Hood Figure 5 4 Hood Safety Locking Bar WARNING Before performing a...

Page 29: ...front of the Cure Module Figure 5 5 Verify that the crank is placed in the opening labeled CONVEYOR Turn the crank to move the adjustable rail to modify the rail width Figure 5 5 Hand Crank WARNING Make sure that the oven is clear of all PCBs before adjusting conveyor width Failure to do so could cause damage to the equipment or workpieces NOTE For nitrogen based systems the Cure Module is equippe...

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Page 31: ...ware operation for the TC V3 Conformal Curing Oven Topics included are Software Architecture Control Menu Main Menu Alarms Recipe Menu Software Architecture The following graphic Figure 6 1 represents the software architecture Figure 6 1 Software Architecture ...

Page 32: ...ure 6 3 Tool Bar Recipe Menu Main Menu Current User Level Reset Alarm Log On Password Alarm Page Menu Control Menu Temperature Zone Setpoint SMEMA Signals options Zone Regulation Bar Graph 0 100 Recipe Name Start Stop Button Current Temperature Zone Open Zone Graphic View for each zone Speed Setpoint Speed Measurement ...

Page 33: ...n of the current zone temperature the regulation percent and the setpoint temperature Figure 6 5 Figure 6 4 Main Menu Zone Name Location Figure 6 5 Zone Settings Process Value Graphical Representation of Zone Temperature Setpoint Temperature PID Loop Parameters Previous Zone Next Zone Regulation Percent Date Time Display Zone Names ...

Page 34: ...6 Main Menu 2 The Access Level Selection screen appears Click on the Operator Mode button Figure 6 7 Figure 6 7 Access Level Section NOTE Operator Mode Access Level 1 download recipe to PLC only Supervisor Mode Access Level 2 download change recipe value create or delete a recipe Recipe Menu Button Operator Mode Access Level 1 ...

Page 35: ...e the green light and the oven ready signal switch on Speed Set Point cm min This value is the requested conveyor speed in cm min AL1 Speed Low Alarm cm min This value is the lower limit of the conveyor speed below this alarm the red light turns on and the alarm sounds see Alarms in the Software section of this manual for further information AL2 Speed Band Setpoint cm min This value represents the...

Page 36: ...hat the correct Recipe has been downloaded to the PLC Figure 6 9 6 Click the Start button to activate the heat and conveyor Figure 6 9 Main Menu Start 7 After you click on the Start button check the Main Menu to confirm that the heat and conveyor are running Figure 6 10 Figure 6 10 Main Menu Check Temperature and Speed Recipe Name ...

Page 37: ...zone temperatures are inside the AL2 alarm band the temperature stabilization timer will start to run Figure 6 11 Figure 6 11 Main Menu Temperature Stabilization 9 When the timer has stopped the Oven Ready signal will display green The oven is ready for production Figure 6 12 Figure 6 12 Main Menu Oven Ready Oven Ready Signal Temperature Stabilization Timer ...

Page 38: ...on the Supervisor Mode button Figure 6 13 Figure 6 13 Access Levels 2 The Recipe Parameters screen appears Enter or change the Recipe Values Figure 6 14 Figure 6 14 Recipe Parameters Supervisor Mode Access Level 2 Save As Download to PLC Recipe Name Recipe Parameters Delete Save Create New Recipe Recipe Record Number PLC Message ...

Page 39: ...ons is only available at password level 2 Supervisor or above To change the password level follow the instructions under Password Management 2 The Control Menu appears Figure 6 16 Figure 6 16 Control Menu Control Menu Button Conveyor Close Loop Speed Parameters Automatic Oven Start and Stop Tactile Screen Maintenance Passwords Management Oven Parameters Modification PLC I O Test and Check PLC Diag...

Page 40: ...access the Password Management screen Figure 6 17 Figure 6 17 Control Menu Password Management Screen 2 The Password Management screen appears Click on user name password or access level to make changes Figure 6 18 Password Management Screen Password Management Button User Name Password Access Level ...

Page 41: ...e necessary changes Use the Backspace Key to make any corrections Figure 6 19 Virtual Keyboard 4 Click on the Return Key Check that the access level is correct on the Main Menu Figure 6 20 Figure 6 20 Main Menu Access Level Access Level Return Key Backspace Key ...

Page 42: ...of the PLC from the Control Menu click on the Inputs Outputs PLC button Figure 6 21 Figure 6 21 Control Menu Inputs Outputs PLC 2 The Inputs Outputs Selection screen will appear Click on Inputs Figure 6 22 Figure 6 22 Inputs Selection Screen Inputs Outputs PLC Button ...

Page 43: ...ndicates inputs are not activated You cannot change the input status View Outputs 1 To view the Output Status of the PLC click the Inputs Outputs PLC button on the Control Menu See Figure 6 21 The Input Output Selection screen appears Figure 6 24 Click on the Outputs button Figure 6 24 Outputs Selection Screen Green Input Activated Gray Input Not Activated ...

Page 44: ...uts Activate Test screen Figure 6 27 Figure 6 25 Outputs Activate Test Screen 3 A warning message will display to check the oven production Figure 6 26 Figure 6 26 Activate Test Warning Message WARNING Activating the Outputs Test will stop the oven Check to see if the oven is in production Activate Test Button Carefull ...

Page 45: ...een Conveyor Parameters Modifications 1 To adjust the close loop conveyor speed parameters click on the Conveyor Parameters Modification button from the Control Menu Figure 6 28 Figure 6 28 Control Menu Conveyor Parameters Modification Button De activate Test Mode Next Page Button Activate Output Conveyor Parameters Modification Button ...

Page 46: ...ment Screen NOTE Forcing the conveyor will stop the oven be careful if the oven is in production 3 When the measurement is finished check the real speed against the measured speed Figure 6 30 If the real speed is different from the measured speed enter the Real Speed of the conveyor Next click on the Adjustment Real Speed Measured Speed button The PLC will automatically correct the calculation of ...

Page 47: ...Updated Message Set Date and Time Procedure On the Main Menu if the date hour is flashing red you will need to reset the date and time before programming any production scheduling 1 From the Main Menu click on the Control Menu button To set the time and date click on the Set Date and Time button Figure 6 32 Figure 6 32 Control Menu Set Date and Time Set Date and Time Button ...

Page 48: ... Screen Clock Button 3 The following screen appears to enter the correct date and time Figure 6 34 Enter the correct Time and click Enter Follow the same procedure to set the date To download the new parameters to the PLC click on the Clock button Figure 6 34 Enter Date and Time Clock Button Time Entry Date Entry Clock Button ...

Page 49: ...duction Scheduling 2 The Production Scheduling screen appears Figure 6 36 Enter and activate the Start Time and Stop Time Activate the Production Scheduling by clicking on the Activate button Figure 6 36 Production Scheduling Enter Stop Start Time Production Scheduling Button Enter Start Time Activate Start Time Activate Production Scheduling Activate Stop Time Enter Stop Time ...

Page 50: ...e the scheduling by clicking on the Activate button before returning to the Main Menu 3 When automatic production is activated the following message will appear on the Main Menu Figure 6 37 Figure 6 37 Main Menu Automatic Production Activated ...

Page 51: ...ile Screen Parameters screen appears Figure 6 39 Click on the Cleaning button to disable the Tactile Screen for 30 seconds to clean Click on the Sensitivity button to adjust the Tactile Screen sensitivity Click on the Contrast buttons to increase or decrease the screen contrast Figure 6 39 Tactile Screen Parameters Screen Tactile Screen Button Cleaning Button Sensitivity Button Contrast Buttons ...

Page 52: ...nu Options Parameters Modification Button 2 The Options Parameters Modification screen appears Figure 6 41 Options can be adjusted on this screen Figure 6 41 Options Parameters Modification Screen NOTE The Options Parameters Modification screen will vary according to options present on the equipment The PCB counters can be checked on the Main Menu Options Parameters Modification Button ...

Page 53: ...e messages from the PLC from the Control Menu select the PLC Messages button Figure 6 42 Figure 6 42 Control Menu PLC Messages 2 The PLC Message screen appears with any messages Figure 6 43 Figure 6 43 PLC Message Screen PLC Messages Button ...

Page 54: ...he Control Menu click on the Counters button Figure 6 44 Figure 6 44 Control Menu Counters Button 2 The following screen appears displaying the counter values Figure 6 45 NOTE Counter values cannot be changed Figure 6 45 Oven Production Counters Screen Counters Button ...

Page 55: ... yellow with an orange beacon light Figure 6 46 or red with a red beacon light Figure 6 47 To access the Alarm Page screen from the Main Menu click on the Reset Alarms button Figure 6 48 Figure 6 46 Green Yellow Alarm Figure 6 47 Red Alarm Green Yellow Alarm Button Red Alarm Button ...

Page 56: ...d the alarms will need to be reset 1 On the Banner screen select the language you prefer by clicking on the French or English flag Figure 6 49 Next click on the M button to display the Main Menu Figure 6 49 Banner Screen Main Menu Button Language Selection Buttons Reset Alarms Button Help Button ...

Page 57: ... on the Alarm Page button Figure 6 50 Figure 6 50 Main Menu Alarm Page Button 3 The Alarm Page screen is displayed Reset all alarms by clicking on the Reset Alarm button Figure 6 51 Figure 6 51 Alarm Page Screen Alarm Page Button Reset Alarm Button ...

Page 58: ...assword Login Box 5 When the alarms are reset the alarm button stops flashing and OK appears at the top right corner of the screen Figure 6 53 Figure 6 53 Alarm Indicator 6 Return to the Main Menu by clicking on the M button CAUTION It is necessary to reset the date time each time you shut down the power of the Cure Module Refer to Set Date and Time Procedure TIP Click on the Help button for addit...

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Page 60: ...P N 7211567 Revision A 2006 Asymtek Headquarters 2762 Loker Avenue West Carlsbad CA 92010 6603 USA Tel 760 431 1919 1 800 ASYMTEK 1 800 279 6835 ...

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