Conformal Curing Oven TC V3 Maintenance Manual P/N 7211568
NOTICE This is a Nordson ASYMTEK publication, which is protected by copyright. Original copyright date 2006. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson ASYMTEK. The information contained in this publication is subject to change without notice. Manuals on the Internet For the convenience of Nordson ASYMTEK customers and field service representatives, copies of Nordson ASYMTEK manuals can be downloaded from: www.
Table of Contents 1 Introduction ...................................................................................................................................... 1-1 Overview............................................................................................................................................. 1-1 Safety First ......................................................................................................................................... 1-1 Hazardous Materials ..........
Table of Figures Figure 3-1 Torque Limiter Adjustment ..................................................................................................... 3-3 Figure 3-2 Conveyor Counter Cell Location............................................................................................. 3-4 Figure 3-3 Conveyor Chain Location ....................................................................................................... 3-5 Figure 3-4 Transmission Chain Location ...............................
1 Introduction Overview This manual covers maintenance procedures necessary for the preventive and corrective maintenance of the TC V3 Conformal Curing Oven. WARNING! Maintenance and troubleshooting procedures should only be performed by trained service technicians. Safety First Before performing any maintenance or troubleshooting procedures, it is important that you thoroughly read the TC V3 Operations Manual.
2 Safety Overview Operation of the TC V3 Conformal Curing Oven involves heat, electrical power, mechanical devices, and the use of hazardous materials. It is essential that every person servicing or operating the Cure Module fully understands all hazards, risks, and safety precautions described in this section. When properly operated and maintained, the Cure Module will be safe and reliable.
Basic Safety Precautions and Practices The following precautions and practices are recommended during Cure Module operation and maintenance. Safety of Personnel • Only trained personnel should be permitted to perform operation, maintenance, service, and troubleshooting procedures. • All personnel working on or near the Cure Module should know the location of all electrical power supply sources.
Earthquake Precautions In the event of an earthquake, the cure module must be secured to prevent movement that could cause injury to personnel and damage to the equipment and facility. Each Cure Module leveler (foot) should be anchored to the floor. to the TC V3 Operations Manual for Installation Procedures. WARNING! To prevent injury during an earthquake, all personnel should follow facility earthquake safety guidelines.
2-4 4. Reset the main circuit breaker inside the electronics enclosure if it has been tripped. 5. Turn the red EMO button clockwise until it pops back into position. 6. Remove all warning tags and locking devices. 7. Restart the Cure Module. 8. Wait at least 30 seconds then push the reset button. Failure to do so could cause problems with the motor speed controller. 9. Open the Alarm window and reset alarms on the PLC. Refer to the TC V3 Operations Manual for alarm reset procedures. 10.
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 electrical, ultraviolet, or microwave energy. Lock out and tag out electrical power before performing service or maintenance work on the Cure Module.
3 Maintenance Overview Performing the recommended maintenance and service procedures increases the life of your Cure module and ensures high quality performance for every production run. Safety First Before you proceed with TC V3 maintenance, make sure you understand the precautions in the Safety section and adhere to the precautions during the performance of maintenance procedures. CAUTION! Maintenance and service should be performed by trained personnel only.
Preventive Maintenance Table 3-1 Preventive Maintenance Recommended Frequency WEEKLY – 120 h of Production Maintenance Procedure Grease chains Instructions The chains must not become dry. For proper chain lubrication, use only PERMA SO14-type oil (high temperature oil). NOTE WEEKLY – 120 h of Production Clean ceramic glasses Using any other kind of oil or grease can damage the conveyor. Clean the ceramic glasses each week.
Maintenance Procedures CAUTION! WARNING! Maintenance procedures should only be performed by trained service technicians. Refer to the Safety section for more information. Unless otherwise specified, the Cure Module should be shut down while performing maintenance or troubleshooting procedures. Refer to “System Shutdown” in the TC V3 Operations Manual. Conveyor Torque Limiter Adjustment To adjust the conveyor torque limiter: 1. Turn the power off by moving the Main Switch to the OFF position. 2.
Conveyor Incremental Encoder Adjustment The Conveyor Incremental Encoder returns an accurate measurement of conveyor speed to the PLC. In the TC oven, the encoder uses a close loop control to ensure the accuracy of the conveyor speed. Replace the encoder if it is damaged or the speed measurement is inaccurate. Various conveyor speeds can be used depending on the encoder installed. Table 3-2 lists the available encoder options.
Conveyor Chain Tension Adjustment To adjust the tension of the conveyor chains: 1. Turn the power off by moving the Main Switch to the OFF position. 2. Remove the access cover at the input of the conveyor and set aside. 3. Using an adjustable wrench, adjust the tension of the spring by turning the adjustment nut (Figure 3-3). 4. Make the same adjustment on the other side of the conveyor. Adjustment Nut Conveyor Chain Spring Figure 3-3 Conveyor Chain Location 5.
Transmission Chain Tension Adjustment To adjust the tension of the transmission chain: 1. Turn the power off by moving the Main Switch to the OFF position. 2. Remove the access cover at the output of the conveyor and set aside. 3. Adjust the tension of the transmission chain by turning the chain tightener with a wrench (Figure 3-4). Chain Tightener Transmission Chain Figure 3-4 Transmission Chain Location 3-6 4. Turn the power on by moving the Main Switch to the ON position. 5.
Adjustment of the Rail Parallelism If a printed circuit board (PCB) falls down into the oven, the conveyor rail needs adjustment. To adjust the conveyor rail parallelism: 1. Turn the power off by moving the Main Switch to the OFF position. Wait for the temperature to decrease to cool. WARNING! 2. Before performing this procedure, it is critical that you wait for the temperature to decrease to cool. Failure to do so could result in serious injury. Lift the hood to access the conveyor rails. CAUTION! 3.
5. If the input and output measurements are not equal, remove the access cover located under the crank to access the transmission gear. Unscrew the two locking screws (Figure 3-7). Insert one of the screws in the third hole to free the gear’s hub and tighten. Make necessary adjustments and replace the locking screws. 6. Replace the access cover. Locking Screw Hub Gear Insert screw here to free hub Locking Screw 7.
E Figure 3-10 Output Rail 8. If the three measurements are not equal, remove the screws from the rail fixation and adjust the position of the rails. See Figure 3-11. Screws Figure 3-11 Conveyor Rail Screws 9. While the oven is still cold, check that the PCB can slide freely from one side of the oven to the other. 10. Turn the power on by moving the Main Switch to the ON position. 11. When the oven is hot, check that the PCB can slide freely from one side of the oven to the other.
Thermocouple Replacement To replace a thermocouple: 1. Turn the power off by moving the Main Switch to the OFF position. 2. Open the top rear access cover. 3. Disconnect the defective thermocouple from the connector (Figure 3-12). 4. 5. Unscrew the pressure screw. Remove the old thermocouple. 6. Replace with the new thermocouple. 7. Tighten the pressure screw. 8. Reconnect the thermocouple to the connector. Connector Thermocouple Pressure Screw Figure 3-12 Thermocouple 9.
Resistor Replacement To replace the top resistor: CAUTION! Before performing this procedure, make sure the machine power is off. Failure to do so could result in serious injury and damage to the equipment 1. Turn the power off by moving the Main Switch to the OFF position. 2. Open the hood to access the resistor. 3. Open the top access cover of the oven. CAUTION! You will need to open the hood to make this measurement.
6. Unscrew the retaining nut on the cable. Figure 3-15 Stuffing Box Figure 3-16 Joint 7. Unscrew the nut on the stuffing box and remove the joint. 8. Replace the resistor. Resistor Cable Stuffing Box Collars Figure 3-17 Remount Joint 9. Remount joint in the stuffing box and tighten the screw.
13. Replace the top access cover. 14. Close the hood using proper procedures described in “Hood Opening/Closing Operation” of the TC V3 Operations Manual. To replace the bottom resistor: 1. Turn the power off by moving the Main Switch to the OFF position. 2. Open the hood to access the resistor. 3. Open the bottom access cover of the oven. 4. To remove the vitro-ceramic glass, on the inside of the oven unscrew the screw and remove the clips from the maintenance part.
11. Re-attach the clips on the maintenance part. 12. Check to make sure the new resistor is positioned in line with the glass. 13. Check the profile and auto-tune if necessary. Refer to the Auto-Tune Procedure. 14. Replace the bottom access cover. 15. Close the hood using procedures described in the Operations Manual.
Adjustment of the Dropped Board Detection Cell (optional) To adjust the dropped board detection cell: Emitter Cell (conveyor input) 1. Turn the power on by moving the Main Switch to the ON position. Adjustment Screw Figure 3-25 Emitter Cell Receiver Cell (conveyor output) Figure 3-26 Receiver Cell NOTES The emitter cell (Figure 3-16) is at the input of the conveyor, it has only one red LED. This red LED should always be switched on and represents the status “under voltage”.
Auto-Tune Procedure The purpose of the auto-tune is to set PID parameters of temperature control loops. This function is used only if the regulation of a zone is not stable. Example: setpoint 120 and measure move from 110 to 130°C. PID are adjusted in factory before departure of the oven. WARNING! Never perform the auto-tune if not necessary. WARNING! Before activating the auto-tune, read through the complete procedure. IMPROPER HANDLING COULD DAMAGE THE OVEN.
3. Click on a graphical visualization of a zone (Figure 3-29). Figure 3-29 Graphic Visualization of a Zone 4. Apply the values below according to the type of regulator (PI or PID) you want (Table 3-3). Table 3-3 Regulator Regulator PI Regulator PID Gain : 1 Gain : 1 TI : 0 s TI : 0 s TD : 0 s TD : 9999 s ZR : 0 °C ZR : 0°C 5. Enter the temperature set point (150 °C max). 6. Wait for stability of the oven. 7. Click on Auto Tune. 8. Click on Start. 9.
4 Troubleshooting Overview Troubleshooting helps you identify common problems that you may experience with your cure module and offer suggestions for correcting them. Safety First Before you proceed with TC V3 troubleshooting, make sure you understand the precautions in the Safety section and adhere to the precautions during the performance of troubleshooting procedures. CAUTION! WARNING! Troubleshooting should only be performed by a trained service technician.
Alarms / Trouble Alarm Conveyor 2 – Speed Band Alarm High Temperature Alarm (AL1) Temperature Band Alarm (AL2) Thermocouple Short Cut Alarm Thermocouple Broken Alarm Security Bar Alarm Open Hood Alarm Exhaust Alarm Possible Causes Verifications and Actions Speed Sensor defective Check the sensor position and compare to the pinion teeth. Check the wiring. AL2 too low Increase the value of the alarm band. Bad calibration Recalibrate the conveyor (Refer to the TC V3 Operations Manual).
Alarms / Trouble Possible Causes Verifications and Actions Photo cell defective Adjust the sensor (refer to the Conveyor Counter Cell Adjustment procedure) Check the wiring. Board Jam Alarm Improper alignment of the oven with the downstream machine Check and adjust the position of the downstream machine if necessary. Photo cell defective Adjust the sensor (refer to the Conveyor Counter Cell Adjustment procedure) Check the wiring.
5 Parts List This section contains parts ordering information for the TC V3 Conformal Curing Oven. Part number information is also available on Nordson ASYMTEK’s Find-A-Part web page: http://webstore.asymtek.com/awweblive/apps/findapart_index.asp WARNING! Parts replacement should only be performed by trained service technicians. Nordson ASYMTEK assumes no liability for personal injury or property damage that may occur as a result of spare parts being replaced by other than trained technicians.
Level 3 - Long Lead-Time Parts Figure 5-3 Parts with a long procurement lead-time or for software update. Designation Reference Manufacturer 24 VDC power supply 2.5A 627-46962 VIT Cooling fan 640-15814 VIT Safety relay (2NO 24Vdc) SIEMENS Tactile screen TP170B 620-40537 SIEMENS Siemens PLC power module 620-40528 SIEMENS SIEMENS PLC ET200S/IM151-CPU 620-40526 SIEMENS Siemens PLC 4 digital input ET200S/MOD 4DI/24VCC 620-40530 SIEMENS Siemens PLC 4 digital output ET200S/MOD 4DO 24VCC/0.
Nordson ASYMTEK Headquarters 2762 Loker Avenue West Carlsbad, CA 92010-6603 USA Tel: (760) 431-1919 1-800-ASYMTEK (1-800-279-6835) P/N 7211568 Revision C ©2010
