Download Heater Controls & Components

Introduction
1
TCA- Explosive
2
TCA252-15-360E144
Type of
Furnace
Belt Width
Number of
Heating
Zones
Clearance
Above the
Belt
Heated
Length
Cooling
Length
Explosive
Process Gas
Course Prerequisites





4
Trained in use and correct disposal of hazardous materials.
Trained in Lockout/Tagout procedures.
Trained in the correct use of PPE.
Electromechanical Skills
Understand Windows and Dos basics.
COURSE OBJECTIVES
Upon successfully completion of this course you will be able to:
1 Identify all safety features and functions of the TCA.
2 Locate major systems components and understand their theory of
operations, maintenance and troubleshooting of the components.
3 Demonstrate the ability to use the TCA Owner’s Manual and it’s
drawings to support operations and maintenance responsibilities.
5
COURSE OBJECTIVES
4. Operate WINCON software to support normal operations, (nonyearly) preventative maintenance and troubleshooting.
6 Perform (non-yearly) preventative maintenance.
6
COURSE OUTLINE
7

Introduction
~ .5 Hours

TCA - Safety
~1.5 Hours

System Documentation & Drawings
~2.0 Hours

System Operational Theory, Maintenance
and Troubleshooting
~6.0 Hours

WINCON for Operators and PM Applications
~6.0 Hours

System Operations, PM, & Testing
Applications Lab
~8.0 Hours
Topic Two
Safety
Upon successfully completion of this topic you will be
able to:
1 State all system safety features and have an
understanding of their purpose, functions and
operations.
2 Demonstrate an understanding of good safety practices
used by operators and technicians, related to the TCA.
3 Understand the MSDS for materials used in the furnace
and indicate an understanding of the hazards, the PPE
and the first aid needed to use those materials.
8
Safety Conventions - Used
Safety precautions and notes described in the manual are identified within the
text using the following four types of headers. Danger, warnings and cautions are
designated by a dark frame with a shaded background. The level of safety hazard
for each heading is described in the following example illustrations:
DANG ER
Danger indicates imminently hazardous situations where a potential hazard
or unsafe practice will cause death or serious personal injury.
W ARNI NG
Warning indicates hazardous situations where a potential hazard or unsafe
practice could cause death or personal injury.
CAUTION
Caution indicates situations where a potential hazard or unsafe practice could
cause equipment or products to be damaged or minor injury if the instructions that
follow the notice are not strictly observed.
Notes relate to additional information about a procedure but do not usually
relate to safety. They have a light frame border with no shading. An example of a
note is illustrated below:
NOTE: Note indicates any additional information about a procedure.
9
Furnace Safety Features
The model TCA furnace contains the
following safety features:
1.
2.
Emergency Stop Buttons
Over Temperature Protection
Heating Zone Over-Temperature
Cooling Section Over-Temperature
10
3.
Conveyor Protection
4.
Lockable Power Disconnect Switch
5.
System Interlocks
Emergency Stop Buttons
(EMO’s)
EMO
EMO
The Start power will be turned off, which turns off heat and will cause the zone
temperature to slowly drop. This furnace configuration also turns off, the conveyor and
gas controls, cooling system, and case cooling.
11
EMO
Over-Temperature
Protection
 WINCON Temperature Deviation Alarm
 Alarm Level
10°C
810°C
 Alert Level
5° C
805°C
Setpoint
800°C
800°C
When the FCU senses 810°C it will generate a
signal that will deenergizes the Heater Power
Contactor.
12
Recipe
Over-Temperature
Protection
Alarm LED
Indicators
OVER
TEMPERATURE
MODULE
1
CH 1
2
3
CH 2
4
5
6
7
J2
J1
9
CH 5
10
CH 6
RESET
PWR ON
J3

13
CH 7
CH 8
J4

CH 3
CH 4
8
Reset Button
(Same Function
as Heat Off/On
Switch)
T/C Input
Connecto
rs J1, J3,
and J4
CH 9
CH 10
Channels 7
through 10
are Omitted
in 6 Channel
Version.
The Overtemperature Module’s setpoints are preset at the factory (to ≃ 25°C above system software limits) and
should not be changed.
Each heated zone is monitored by an overtemperature T/C that is independent from the zone control circuitry. If
any zone exceeds the preset safe maximum temperature, the overtemp condition causes the module to shut off
all heater power and generates an alarm with the WINCON software, puts the system into a purge mode but the
Conveyor is maintained running for removal of product.
Module
Conveyor
Protection

120 VAC
C360-TR
333-LS
C370-TR
Conveyor Spocket
As the Conveyor drive shaft
rotates the sprocket turns
moving C360-LS, which supplies
120 VAC power to either the
C360-TR or the C370-TR. These
relay are Time Delay to Make
(TDM), set for the minimum
conveyor speed. If the
conveyor stops moving or is to
slow, one of the relays will
energize and provide an alarm
to the WINCON software.
Safety Labels
!
CAUTION
EMO
EMERGENCY
STOP BUTTON
(Yellow and Black)
MECHANICAL OR PINCH POINT HAZARD
(Yellow and Black)
!
CAUTION
Hot internal surface
use caution when
opening the lid.
TEMPERATURE HAZARD
(Yellow and Black)
15
EMERGENCY OFF OR
EMERGENCY STOP
BUTTON
(Red and White)
Safety Labels
!
DANGER
!
DANGER
HIGH VOLTAGE
Hot internal surface
use caution when
opening the lid.
ELECRICAL HAZARD
(Red and Black)
TEMPERATURE HAZARD
(Yellow and Black)
ELECRICAL HAZARD
(Red and Black)
!
! DANGER
TEMPERATURE HAZARD
(Yellow and Black)
DANGER
!
our hands.
CRUSH HAZARD
(Red and Black)
16
WARNING
This equipment contains Refractory Ceramic Fibers (RCF) that have been identified by the
International Agency for Research on Cancer (IARC) as a possible human carcinogen
(Group 2B). Exposure to RCF may be hazardous to your health. Under normal operating
conditions, exposure should not occur. If maintenance is to be performed on this
equipment, or if exposure to RCF otherwise occurs, then precautions should be taken for
the handling of RCF. The necessary precautions and emergency procedures are described
in the MSDS sheets included in the technical manual supplied with this equipment. Further
information on RCF may also be obtained from: The Carborundum Company - Fibers
Division. HOTLINE NUMBER (716) 278-2183.
CRUSH HAZARD
(Yellow and Black)
VAPOR HAZARD
(Red and Black)
Lockable Power
Disconnect Switch
Tab may be pulled out
when switch is in the
OFF Position
and Locked Out
A000-DISC
System Interlocks
Burn-Off Failure
Turns off Cover Gas
Auto Purge On
Low H2 Pressure
Turns off Cover Gas
Auto Purge On
Low N2 Pressure
Turns off Cover Gas
Auto Purge On
Low AR Pressure
Turns off Cover Gas
Auto Purge On
System Alarms
(External)
Over Temp
Conveyor Belt Fail
Emergency Stop
Water Flow Fail
Water O/T
Low Hydrogen Pressure
Low Nitrogen Pressure
Low Argon Pressure
Gas Safety
Good Safety Practices
Some general safety practices are:
 Perform maintenance procedures with teams of two or more people.
 Wear safety glasses and protective clothing when working on the system.
 Whenever possible, make sure that both compressed gases and electric power are
turned off at the source prior to beginning any maintenance task.
 Do not attempt to defeat any of the interlock switches or the safety features that are
built into the system.
 Make sure that all access panels or doors are closed and latched when they are not
being used for maintenance.
20
Good Safety Practices
 Periodically check the operation of all the safety interlock in the system
 Be careful when using flammable solvents such as alcohol for cleaning. Make sure
that the electric power is off and the equipment is cool enough to prevent a fire
hazard.Observe all safety warning labels.
 Never remove a warning label from the system.
 Never operate damaged or leaking equipment.
 Make sure that the electric power to the system is turned off using the lockout/tagout
procedure before connecting or disconnecting cables.
21
Good Safety Practices
 Turn off the furnace and disconnect the power from the source before moving the
system.
 Move the furnace with care. Sudden jolt or drops can damage the equipment.
 Report any unsafe conditions or situations immediately.
22
MSDS
Material
Safety
Data
Sheet
Three questions to ask
1. What is the Hazard ?
2. How do you protect yourself ?
3. What is the First Aid ?
23
FiberFax
Topic 3
System Documentation &
Drawings
Upon successfully complete of this topic you will be able
to:
1 Demonstrate the ability to use the System Owner’s Manual to
determine but not limited to the following:
a Identification of system specifications. (Appendix A)
b Performance of preventative maintenance. (Section-5)
b Removal and replacement of system components.(Section-5)
24
System Documentation &
Drawings
2 Demonstrate the ability to use the system drawings to determine,
but not limited to the following:
a.
b.
c.
d.
e.
Layout of the system, assemblies, wiring, and plumbing.
Reference connections to other diagrams.
Source voltage information.
Component identification.
Component specification.
3 Demonstrate an ability to use the electrical systems drawing to
isolate and diagnose problems.
25
System Owner’s Manual

Section 1
Safety

Section 2
System Overview

Section 3
System Operations

Section 4
System Troubleshooting

Section 5
System Maintenance

Section 6
Spare Parts

Section 7
System Drawings

Section 8
Appendices
 Appendix A System Specifications
 Appendix B Glossary of Terms
 Appendix C Reference Manuals
 Appendix D MSDS

Index
System Drawings
Installation Drawing
TCA252-15-360E144
Heater Current Data Drawing
W/D FCU 3615 Controller Drawing
FCU to PC Connecting Cable
Program Data Sheets
Electrical Circuits Drawings
Ground Layout Drawing
Terminal Block Layout
Operator Panel Assembly & Layout Drawings
Calibration Procedure for Drive Controllers
Calibration Procedure for Temperature Sensor Inputs
Plumbing Schematics
Line Numbering
Line Numbering
Electrical drawings have line numbers drawn along the
left side. Each line number contains both a letter and a
number.
 The letter designates a circuit group.
 The number locates a position on the drawing.
Circuit groups may be designated differently from one
BTU product to another, depending on the types of
circuits included.
This table shows an EXAMPLE of a circuit group set
contained in a typical BTU oven or furnace
A
Input Power/ Heaters
B
Instrument Control
C
Drive Control
D
Gas Control
E
Controller
E
Alarms
G – Z Optional Equipment
The Circuit Groups for your BTU product are listed
next.
Reference Connections
to
Other Diagrams














 Ladder Logic Designation
A000 – A650 Input/Heaters440-480V TCA252-15-360
B000 – B130 Instrument Power w/ UPS 120V
B300 – B430 Instrument Power
B900 – B990 Profile T/C
C000 - C130 MC95/(2) OT/2 FCU’s/2 Contactors
C300 - C430 Belt Speed/ (2) OT/ ENCDR/ Honeywell OT
C600 - C730 Computer
D000 - D120 3615 Alarm Inputs
G000 - G120 Case Cooling
H000 - H250 ACS
H260 - H380 Atmosphere Control System H2/N2/AR
H390 - H510 Gas Miser
J000 - J110 Hygrometer
K000 - K130 Water Jacket Sensor Inputs
Reference Connections
Reference pointer with line numbers
Reference pointers direct you to the next drawing or to drawings
for other circuits. The line number with each pointer identifies
• The circuit group of the next drawing (D or L in the example).
• The position of the connection on the next drawing (150, 430, 010).
Reference pointer line numbers may also be enclosed in a box as
shown in the following example.
You match the drawings on the right has reference pointers.
The example on the top left shows it’s reference pointer exiting
on the bottom of the drawing, as you would normally hold it, but the
example on the bottom has it’s reference pointer pointing to the
right, both are outputs.
The top right drawing section has a reference pointer coming in from
the top, this indicates an input and shows where the input is coming from.
Source Voltage
Information
Electrical diagrams which have voltages originating from other electrical diagrams are marked with the
voltage level, voltage type (AC or DC) and the wire size and insulation type. A description may be
included to describe the general origination of the source voltage (I.e. from input power circuits). This
general description, if used, is immediately below the voltage level/type information.
Source Voltage & Information
Source Location
Wire Information
Wire Numbers
Wire Color Codes
COLOR
Black
Red
CIRCUIT AND CONDUCTORS
Line, load, and control circuits at line voltage
AC control circuits at less than line voltage
White
Grounded circuit conductor (neutral)
Blue
DC control circuits
Gray
Grounded circuit conductor for UPS control circuits
Yellow
Green/Yellow
Interlock control circuits supplied from and external power
source
Equipment grounding conductor
Exceptions:
Multi-conductor cables present an exception to the above standard color codes.
Light Blue is used for the Neutral for equipment shipped to Europe (European Community).
Customer specified color codes are used as required.
32
Device Codes and Types
CODE
TYPE OF DEVICE
CODE
TYPE OF DEVICE
AH
Alarm Horn or Audible
Alarm
PB
Push Button
CB
Circuit Breaker
PL
Plug
CR
Control Relay
POT
Potentiometer
CON
Contactor
PS
Pressure Switch
CT
Current Transformer
PWRS
Power Supply
DISC
Disconnect Switch
PRX
Proximity Switch
ENCO
Optical Encoder
RES
Resistor
EPB
Emergency Push
Button
RECP
Receptacle
FS
Flow Switch
SOL
Solenoid
FU
Fuse
SS
Selector Switch
GND
Ground
SSR
Solid State Relay
HTR
Heater
T
Transformer
INST
Instrument
TAS
Temperature Actuated
Switch
LS
Limit Switch
TB
Terminal Block
LT
Pilot Light
T/C
Thermocouple
MTR
Motor
TR
Timing Relay
OL
Overload
UPS
Uninterruptable Power
Supply
SST - Solid State Timer Set for 30 Min
33
Component
Specifications
Details of component ratings etc. are shown adjacent to the symbol to add supplementary data
for the component. This supplementary data indicates applicable values such as amperage, voltage,
or KVA rating and the like.
The following lists the minimum supplementary data for different types of components:
Component






Transformers (T)
Circuit Breakers (CB)
Motor (M)
Fuse (FU)
Overload (OL)
Disconnect Switch (DISC)
Data
KVA, Primary & Secondary Voltage
Amperage Rating
HP, Full Load Amperage (FLA)
Amperage and Type
Trip Point and Range (if available)
Voltage Rating, Amperage Rating
Electronic
Controls & Components
 Solid State Relays
 Fuses and Circuit Breakers
 Control Relays & Contactors
Timing Relays
35
Solid State Relays
1
1
2
Heater SSR
3
1
SSR
4
3
2
Control SSR
3
2
4
+ 5VDC
FCU
4
E020-INST
36
Fuses & Circuit Breakers
FU
Fuse Symbol
CB’s
Circuit Breaker Symbol
1-Pole
37
2-Pole w/Thermal
3-Pole w/Magnetic
Overload device
Overload device
Control Relays & Contactors
2
7
(Coil)

N.O.
Contact
N.C.
Contact
Control Relay Types
 VOLTAGES - 24, 120, & 240 VAC
24 VDC
 # OF Pins - 5 Pin - 1 Control Legs/Contacts
8 Pin - 2 Control Legs/Contacts
11 Pin - 3 Control Legs/Contacts

38
Contactors - Used for High Voltage and High Current Needs
usually at or above 120 VAC, dependent upon
system needs. Additional contacts may be added.
Timing Relays
TDM
A1
Control Voltage
A2
Return/Neutral
A3
May be Assumed
(Coil)
A1
TDB
(N.O.)
(N.C.)
Return/Neutral
A2
Control Voltage
A3
Never Assumed
(Coil)
39
(N.O.)
(N.C.)
Topic Four Objectives
System Operational Theory,
Maintenance
and
Troubleshooting
1 Understand the system theory and operation of the Paragon to include:
A Oven Description
B Furnace Sections
1
2
3
4
Entrance Section
Process Chamber Sections
Cooling Section
Exit Section
C Sequence of Operation
2.Understand system components and their operations, to support
maintenance and troubleshooting efforts, to include:
A System Features
B System Controls
C System Optional Equipment & Features
40
FURNACE
SPECIFICATIONS
 Maximum Temperature
 Normal Operating Temperature
 Number of Controlled Heating Zones
 Working Dimensions
 Heated Length
 Belt Height Above Floor
 Furnace Atmosphere
41
1160°C
200-1130°C
15 Zones (Top &
Bottom L,C,R)
25” Belt
2” Clearance above belt
360”
36.0”
N2/H2/AR
Furnace Description
TCA
Case Cooling
Exhaust Stacks
Atmosphere Curtain
Cooling Section
with Optional
Eductors
H2 Burn-Off
Atmosphere Curtain
H2 Burn-Off
Exit Section
Entrance Section
Process Chamber
Section
42
MC-95 & ACS
Furnace Sections
P150 LAYOUT
 System dimensions
 Loading Table
 Entrance w/ Baffle Assembly, N2 Fiberglass
Curtain and Ignitor Burnoff
 Entrance Vestibule
 Zones # 1 through # 15 (24” each)
 Exit Vestibule
 Hearth Plate Cooling
 Water Cooling # 1
 Water Cooling # 2 w/ Cross Flow Eductors
 Water Cooling # 3 w/ Dual Parallel Eductors
 Exit w/ Baffle Assembly, N2 Fiberglass
Curtains and Ignitor Burnoff
 Frame Allowance
 Unloading Table
 Approximate System Working Length
 Approximate System Total Length
43
Inches
24.0”
43.0”
18.0”
360.0”
20.0”
24.0”
24.0”
36.0”
54.0”
36.0”
9.0”
24.0”
52’ 0”
56’ 0”
Furnace Layout
Cover Gas Inlets
Ent/Exit (2 Inputs each)
Fiberglass
Curtain
Assembly
Gas Sample Lines
Zones 1,4,12,15
Water Cooling # 1
Water Cooling # 3
w/ Dual Eductor
Fiberglass
Curtain
Assembly
Gas Sample Line
Cooler Section
15 Heating Zones
Water Cooling # 2 w/
Cross Eductor
44
Sequence of Operation
Standard Features
 Fully Enclosed IR Heaters
(Top & Bottom - L, C, R)
 Cover Gas Recirculation
 Gas Tight
 Redundant Overtemp Protection
 3 Profile Thermocouple Ports
 Windows Based Operating
Software
45
 Redundant Conveyor Protections
 Emergency Off Push-Buttons
Product Transport System
Components and Specifications
 Belt type material……………Inconel 601 GC (B36-10-10) Mesh Belt
 Belt Type Width……………………………………………………..25”
 Speed, Nominal…………………………………………….….……14 IPM
 Speed, Range…………………………………………….……….…4-24 IPM
 Speed Control Accuracy…………………………..……...……..± 0.1 IPM
 Belt Loading…………………………..……………………...……..0.9 lb/ft2
46
Transport
Conveyor
Controls and Components
Brushes
Minimum ware is
.2 Inches
A1
MTR
L1
L2
-
BSM
0-90VDC
Sig
Max
Sig
Min
Max
Min
IR
Torque Comp
+
A2
0-6.72VDC
+5VDC
C6-9
0-5VDC
Square Wave
ENCO
C1-3
C1-2
FCU
GND
Light Emitting Diode
30 Counts per Revolution
C6-10
GND
C6-10
C1-1
Feedback
Isolation Resistor
47
5182385
560 Ω
Operation
BSM Potentiometers
A1
L1
L2
-
BSM
+
Sig
Max
SIGNAL ADJ Min/Max
Set for a 0-90 VDC
output at A1 and A2
Sig
Min
Min
Max
Torque
IR
Comp
IR COMP
Set to 2 O’Clock
A2
TORGUE
Set to 9 O’Clock
MIN
Set
Fully Counter Clockwise
(CCW)
MAX
Set Fully Clockwise (CW)
48
Transport
Ends
Heater Controls & Components
Control Signal
FCU
Controller
Thermocouple Input
(Zone Temperature)
Solid State
Relay
AC
Power Input
49
Zone
Heater
Heater Controls & Components
Control Signal
FCU
Controller
Thermocouple Input
(Zone Temperature)
Solid State
Relay
AC
Power Input
50
Zone
Heater
TC
Heater Controls & Components
T/C Troubleshooting
1. Open T/C
2. Shorted within the Zone
3. Shorted outside the Zone
+
51
-
4. Reversed Wiring
T/C Issues
Heater Controls & Components
Electrical Connections
Protection Tube
T/C Tips
52
Heater Controls & Components
Control Signal
FCU
Controller
PID
Thermocouple Input
(Zone Temperature)
Solid State
Relay
AC
Power Input
53
Zone
Heater
PID Algorithm
P = Proportional Band (Pro-bands)
54
 I = Intergral
(Reset)
 D = Derivative
(Rate)
Control Coefficients
PID Algorithm
TEMP
PRO BAND
HIGH
PB Power
+ Reset Power + Rate Power
Pro Band, Reset and Rate
Pro Band Only
Pro Band and Reset
SP
PRO BAND
LOW
SYSTEM CALLS FOR
100 % POWER
TIME
55
Heater Controls & Components
Control Signal
PWM
FCU
Controller
Thermocouple Input
(Zone Temperature)
Solid State
Relay
AC
Power Input
56
Zone
Heater
Pulse Width Modulation
ZONE
57
FCU
INPUT
Z1T
1
Z1B
2
Z2T
3
Z2B
4
Z3T
5
Z3B
6
Z4T
7
Z4B
8
Z5T
9
Z5B 10
Z6T 11
Z6B 12
Z7T 13
Z7B 14
PWM
CYCLE
1
2
3
4
1
2
3
4
1
2
3
4
1
2
2 Second Time Period
PWM Time period is 1/2 of a second
Pulse Width Modulation
ZONE
58
FCU
INPUT
Z1T
1
Z1B
2
Z2T
3
Z2B
4
Z3T
5
Z3B
6
Z4T
7
Z4B
8
Z5T
9
Z5B 10
Z6T 11
Z6B 12
Z7T 13
Z7B 14
PWM
CYCLE
1
2
3
4
1
2
3
4
1
2
3
4
1
2
2 Second Time Period
The #1 PWM’s turns
on the SSR for 1/2 of a
second @ 100 %
Power.
Pulse Width Modulation
ZONE
59
FCU
INPUT
Z1T
1
Z1B
2
Z2T
3
Z2B
4
Z3T
5
Z3B
6
Z4T
7
Z4B
8
Z5T
9
Z5B 10
Z6T 11
Z6B 12
Z7T 13
Z7B 14
PWM
CYCLE
1
2
3
4
1
2
3
4
1
2
3
4
1
2
2 Second Time Period
The #2 PWM’s turns
on the SSR for 1/2 of a
second @ 100 %
Power.
Pulse Width Modulation
ZONE
60
FCU
INPUT
Z1T
1
Z1B
2
Z2T
3
Z2B
4
Z3T
5
Z3B
6
Z4T
7
Z4B
8
Z5T
9
Z5B 10
Z6T 11
Z6B 12
Z7T 13
Z7B 14
PWM
CYCLE
1
2
3
4
1
2
3
4
1
2
3
4
1
2
1 Second Time Period
The #3 PWM’s @ 100
% Power turns on the
SSR for 1/2 of a
second
Pulse Width Modulation
ZONE
61
FCU
INPUT
Z1T
1
Z1B
2
Z2T
3
Z2B
4
Z3T
5
Z3B
6
Z4T
7
Z4B
8
Z5T
9
Z5B 10
Z6T 11
Z6B 12
Z7T 13
Z7B 14
PWM
CYCLE
1
2
3
4
1
2
3
4
1
2
3
4
1
2
2 Second Time Period
The #4 PWM’s turns
on the SSR for 1/2 of a
second @ 100 %
Power.
Pulse Width Modulation
ZONE
62
FCU
INPUT
Z1T
1
Z1B
2
Z2T
3
Z2B
4
Z3T
5
Z3B
6
Z4T
7
Z4B
8
Z5T
9
Z5B 10
Z6T 11
Z6B 12
Z7T 13
Z7B 14
PWM
CYCLE
1
2
100 %
3
4
1
2
3
4
1
2
3
4
1
2
2 Second Time Period
75 %
50 %
25 %
Heater Controls & Components
Control Signal
FCU
Controller
Thermocouple Input
(Zone Temperature)
Solid State
Relay
AC
Power Input
63
Zone
Heater
HEATERS
Heater Controls & Components
Top Heaters
Power KW at
109.3 / 218.5 / 109.3
Line Voltage
Heater Current
Ohms (HOT)
Watts / SQ. Inch
Plate Length
Plate Width
Plate Thickness
Wire Gage
Material 0.750 Dia
Grooves_Wire
Groove Space
Total Groove Length
Close Wound Coil
Stretch
Lead Gage
Ohms Cold Total
Ohms Cold Min.
Ohms Cold Max.
Parallel Windings
R
64
R
L
C
R
1.6
3.2
220
14.6
14.9
4.9
24.00
33.00
2.5
10
KA-1
10
1.50
220.0
102.9
2.8
5
14.4
13.7
15.1
No
1.6
7.5
5
1.50
110.0
51.4
7.2
6.8
7.5
No
C
C
L
7.5
5
1.50
110.0
51.4
7.2
6.8
17.5
No
L
Heater Controls & Components
Bottom Heaters
Power KW at
54.6 / 109.3 / 54.6V
Line Voltage
Heater Current
Ohms (HOT)
Watts / SQ. Inch
Plate Length
Plate Width
Plate Thickness
Wire Gage
Material 0.750 Dia
Grooves_Wire
Groove Space
Total Groove Length
Close Wound Coil
Stretch
Lead Gage
Ohms Cold Total
Ohms Cold Min.
Ohms Cold Max.
Parallel Windings
65
L
C
R
1.20
2.40
220
22.0
5.0
7.7
11.00
31.00
2.00
9
KA-1
10
1.50
100.0
49.2
2.0
5
4.8
4.6
5.0
No
1.20
2.5
5
1.50
50.0
24.6
2.4
2.3
2.5
No
2.5
5
1.50
50.0
24.6
2.4
2.3
2.5
No
Heater Layout
66
Over-Temperature
Protection
Alarm LED
Indicators
OVER
TEMPERATURE
MODULE
1
CH 1
2
3
CH 2
4
5
6
7
J2
J1
9
CH 5
10
CH 6
RESET
PWR ON
J3
67
CH 7
CH 8
J4


CH 3
CH 4
8
Reset Button
(Same Function
as Heat Off/On
Switch)
T/C Input
Connecto
rs J1, J3,
and J4
CH 9
CH 10
Channels 7
through 10
are Omitted
in 6 Channel
Version.
The Overtemperature Module’s setpoints are preset at the factory (to 315°C) and should not be changed.
Each heated zone is monitored by an overtemperature T/C that is independent from the zone control circuitry. If
any zone exceeds the preset safe maximum temperature, the overtemp condition causes the module to shut off
all heater power (C060-CON) and generates an alarm with the WINCON software. Conveyor is maintained
running.
Over-Temperature
Protection
Module
System Gas Feed
Flowmeters
Gas Feed
Flowmeters
70
Entrance Curtain Bottom/Top (N2)
2 Flowmeters
Entrance Venturi (N2)
1 Flowmeter
Argon Cover Gas (AR)
1 Flowmeter
Nitrogen Cover Gas (N2)
1 Flowmeter
Hydrogen Cover Gas (H2)
1 Flowmeter
Nitrogen Purge Gas (N2)
1 Flowmeter
Exit Venturi (N2)
1 Flowmeter
Exit Curtains (N2)
1 Flowmeter
Eductor Criss Cross Cooling Section (H2)
2 Regulator
Eductor Dual Feed Cooling Section (N2 or AR)
2 Regulators
Gas Plumbing
Entrance
Curtain
Bottom
Entrance
Curtain
Top
Muffle
Cover Gas
Entrance
Venturi
Exit
Venturi
FA
Exit
Curtains
Eductor
Criss Cross
FA
FA
1-FM
N2
2-FM
N2
3-FM
N2
4-FM
AR
5-FM
N2
6-FM
H2
7-FM
Purge
3-SOL
Notes:
1. All H2 Flowmeters are to be 100 % Inspected.
3-PS
Sample
8-FM
N2
2-SOL
1-SOL
5-SOL
7-FM
N2
4-SOL
2-PS
Sample
Gas Miser
1-PS
Sample
2. Customer to supply 10 Micron Filter for H2 Gas.
3. H2 Gas must be free of oil.
4. Set all pressure switches at 9 PSIG.
5. N2 May mix on power failure.
AR
H2
N2
10-20 PSIG
10-20 PSIG
10-20 PSIG
Eductor
Dual Feed
Gas Modes
Mode
1-SOL 2-SOL 3-SOL 4-SOL 5-SOL
Purge
OFF
OFF
OFF
OFF
OFF
N2/H2
ON
ON
ON
OFF
OFF
GAS MISER
OFF
OFF
OFF
ON
OFF
AR/H2
ON
OFF
ON
OFF
ON
Muffle Cover Gas
Staggered Hole Orientation
+/- 30 degrees
Internal Gas Flow
Burn-Offs
Burn-Off Coil
Cooling Sections
Cooling Sections
Eductors
Cooling Monitoring
77
Furnace Controls
 WINCON / 3615 FCU Controller
 System Software
 OPERATOR Controls
78
WINCON / 3615 FCU Controller
Minimum recommended
computer requirements:
 IBM compatible with MS-DOS and
WINDOWS
8MB main memory and battery
backup clock
120MB hard drive and one 3-1/2”
high density floppy drive
 One parallel printer port, and two
RS-232 serial ports
 14” VGA color graphics monitor
 Keyboard (mouse or trackball
optional)
79
5057631 RS232-3615
WINCON Software
Operating Software
80
 Windows TM
Platform
 GEM Available
 Extensive Security
Features
 Extensive data
Collection Capability
 Flexible Time and
Sequence
Scheduling
Operator Control Panel
81
Atmosphere Control
Panel
ATMOSPHERE CONTROL SYSTEM
BURNOFF
FAILURE
ON/OFF
1
TIMED
2
3
4
5
PURGE
PURGE
RESET
FAILURE
PURGE
1
2
OPERATING
MODE
PURGE
TIMED PURGE
COVER GAS
3
4
6
PURGE
TIME
HEATER
POWER OFF
SAFE
EXTERNAL FAIL
READY
Gas Miser
4-SOL
Gas Sampling
84
Topic 5
WINCON
Upon successfully complete of this topic you will be able
to:
1 Given a PC Loaded with WINCON software, log on, change
recipes, view alarms, open System Monitor Pages, monitor system
performance and log off the system.
2 Given a PC Loaded with WINCON software, acknowledge, silence
and clear alarms, perform preventative maintenance on the PC and
perform (non-yearly) system calibrations.
85
Furnace Control Unit (FCU) Board
FCU description:
The Furnace Control Unit (FCU) is an independent Z80 based Microprocessor controller
board. The board will operate with only a 15 volt DC power supply. No other external
connections and apparatus are need for it to operate. The FCU is normally connected to a IBM
compatible PC, to simplify programming and for storage of information. A PC with WINCON®
software operating an a RS-232 (COM) port interface with the FCU.
The FCU is equipped with 31 analog inputs and 36 analog output, they are generally
used as closed looped controlled I/Os. These ports are used to control heated zones, static
pressure in a close loop configurations. The analog inputs can be used without outputs to
monitor activities like O2 or dew point. The analog outputs can also used independent of inputs.
Equipment with cooling fan control operate this way, to allow the FCU to control fan RPM.
We utilize 16 digital output to control external options like Gas flow. Sixteen digital inputs,
monitor external events and alarm condition such as Low Pressure switches.
There is Lithium battery pack on every FCU board to maintain data time and
configurations for a ten year period. This allows the FCU board to maintain information on how
long it has been on or off and all calibration values.
86
Tool Bar Status Indicator
Display Status
Button
INIT
Description
This is your furnace’s state when first turned on (i.e., initializing). In this state,
communication between the PC and the FCU are established, but the FCU has not
completed its initialization. The initialization process may take several seconds.
(Displayed in black text with a yellow background).
The furnace is in the idle state when the heater power contactor has not been
turned on yet. (Shown in black text on a yellow background).
IDLE
SETUP
READY
After changing the recipe, the furnace stays in the SETUP state until the
temperature reaches the alert band and remains within this band during the preready dwell time with no alarms. (Black text, yellow background).
Furnace has stabilized and is ready to process (shown in black text with a green
background). The READY state occurs after the time-out of the pre-ready dwell
period if no alert or alarm conditions exist. In addition, the following conditions must
also be met:

Temperature is within the alert/alarm band

Conveyor speed is within the alert/alarm band

Edge conveyor chain is at the correct width
Other conditions may exist depending on options
HOLD
87
Power has been off longer than the power down time limit (shown with black text
on a yellow background). In the HOLD state, the controller maintains the
temperature levels that existed in the furnace when power was restored
Tool Bar Status Indicator
Alarm States
Display Status
Button
Description
Indicates the presence of alert conditions (shown in flashing black text on a
yellow background). You must correct the problem to clear the alert
ALERT
ALARM
88
Indicates the presence of alarm conditions (shown in flashing white text on
a red background). You can silence the audible alarm by acknowledging it in
the Status/Alarms screen. You must correct the problem to clear the alarm.
Recipe Windows and Tables
Recipe Window
Setpoints Recipe Window
Included Tables
Temperature Zone Setpoint Table
Conveyor Fields Setpoint Table
Equipment Options Setpoint Table
Pressure Zone Setpoint Table
Product Line Setpoint Table
Mass Flow Setpoint Table
PID/Trim Recipe Window
Temperature Zone PID/Trim Settings Table
Pressure Zone PID/Trim Settings Table
Atmosphere Control Table
Alarms Recipe Window
Temperature Setpoint Alarms Table
Conveyor Belt Speed Alarms Table
Pressure Zone Setpoint Alarms Table
Mass Flow Alarms Table
Atmosphere Monitoring Thresholds Table
Atmosphere Control Alarms Table
Temperature Output Alarms Table
Mass Flow Output Alarms Table
Pressure Zone Output Alarms Table
89
Topic 6
Preventative
Maintenance
Applications
90