In-Line Diffusion SYSTEM MANUAL
In-Line Diffusion SYSTEM MANUAL
Manual Number:
Issue Date:
TM 5259111 Rev. 0
September 26, 2007
BTU International
23 Esquire Road
N. Billerica, MA 01862 USA
Phone: 1.978.667.4111, Fax: 1.978.670.2796
BTU Europe, Limited
Unit 14 Armstrong Mall, Southwood Summit Centre
Farnborough, Hants, England GU14 ONR
Phone: 44.01252.660010, Fax: 44.01252.660011
BTU Overseas, Limited
01-116, LHK Building
701 Sims Drive
Singapore 387383
Phone: 65.741.4567, Fax: 65.841.4567
24-Hour Help
USA: 1.800.998.0666
UK: 0.800.96.8910
Ireland: 1.800.55.7687
Mexico: 1.800.547.1783
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
LIMITATION OF LIABILITY
BTU International, Inc. (BTU) believes that the information in this publication is correct as of the print
date. BTU reserves the right to make changes in specifications and information without notice. BTU is
not responsible for inadvertent errors.
The terms and conditions for use and the licensing of BTU products and BTU software are directed by
contracts that are made between BTU and its customers. Representations of products that are in this
document will not be cause for warranty by or liability to BTU.
BTU will not be liable for damages that include but are not limited to direct, indirect, incidental, special
or consequential damages (including but not limited to loss of profits) that are related to this document
in any way, even if BTU was advised or aware, or knew or should have known, about the possibility of
such damages.
Copyright 2007 BTU International, Inc. All rights reserved. Printed in the USA.
Copyright
• The products and software programs that are described in this manual are confidential information
and proprietary products of BTU or its licensers.
• No part of this document may be reproduced in any form, including by electronic retrieval systems,
without the prior written permission of BTU.
Registered Trademarks and Trademarks
• Items noted with ® are registered trademarks.
• Items noted with ™ are trademarks.
Correspondence
• Contact the address on the front cover with questions and concerns that are related to this document.
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
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TABLE OF CONTENTS
Chapter 1: INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How-to-Use Instructions ....................................................................................................................... 1-1
Technical Help ...................................................................................................................................... 1-1
Equipment Label .................................................................................................................................. 1-2
Required Tools and Consumable Items ............................................................................................... 1-3
Manual Description .............................................................................................................................. 1-4
Related Documentation ......................................................................................................................... 1-4
Symbols, Abbreviations & Terms ........................................................................................................ 1-5
Chapter 2: SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Material Safety Data Sheets ................................................................................................................. 2-2
Safety Precautions ................................................................................................................................. 2-2
Safety Identification ............................................................................................................................. 2-6
Dangers, Warnings, Cautions, and Notes ............................................................................... 2-6
Electrical Hazards ................................................................................................................... 2-6
Safety Labels........................................................................................................................... 2-7
Standard and Optional Safety Equipment ............................................................................................ 2-8
Standard Equipment................................................................................................................ 2-8
Optional Equipment ................................................................................................................ 2-8
Safety Procedures ................................................................................................................................. 2-9
Safety Interlocks ..................................................................................................................... 2-9
Lockout / Tagout Procedure ................................................................................................. 2-10
Lockout / Tagout Removal Procedure .................................................................................. 2-11
EMO (Emergency Off) ......................................................................................................... 2-13
Disposal of Equipment.......................................................................................................... 2-14
Chapter 3: SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Theory of Operation ............................................................................................................................. 3-2
Direction of Product Travel .................................................................................................... 3-2
Equipment Features / Options .............................................................................................................. 3-3
Equipment Locator and Subsystems .................................................................................................... 3-7
Frame & Panel System.......................................................................................................................... 3-8
Frame ...................................................................................................................................... 3-8
Panels ...................................................................................................................................... 3-8
Entrance Table....................................................................................................................................... 3-8
Conveyor & Drive System ................................................................................................................... 3-9
Conveyor System .................................................................................................................... 3-9
Drive System........................................................................................................................... 3-9
Electrical & Control System .............................................................................................................. 3-11
Operator Control Panel ......................................................................................................... 3-11
Light Tower .......................................................................................................................... 3-12
WINCON Furnace Control Software ................................................................................... 3-12
Intellimax Furnace Controller............................................................................................... 3-13
PID Temperature Control ..................................................................................................... 3-13
Atmosphere System ............................................................................................................................ 3-16
Atmosphere Control.............................................................................................................. 3-16
Dual Venturi Exhaust Stacks ................................................................................................ 3-16
Atmosphere Curtains ............................................................................................................ 3-17
Heating System ................................................................................................................................... 3-18
Fully Enclosed Coil (FEC) Heaters ...................................................................................... 3-18
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Shadow Walls [Option]......................................................................................................... 3-18
Temperature control .............................................................................................................. 3-19
Cooling System .................................................................................................................................. 3-20
Passive Cooling..................................................................................................................... 3-20
Active Cooling ...................................................................................................................... 3-20
Chapter 4: INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Customer Site Requirements ................................................................................................................ 4-2
Equipment Location................................................................................................................ 4-2
HVAC Requirements .............................................................................................................. 4-2
Exhaust Requirements............................................................................................................. 4-3
Site Plumbing Requirements................................................................................................... 4-3
Cooling Water Requirements.................................................................................................. 4-4
CDA and Nitrogen Requirements ........................................................................................... 4-5
Electrical Requirements .......................................................................................................... 4-6
Installation Procedures ......................................................................................................................... 4-8
Receive Equipment ................................................................................................................. 4-8
Remove Crates ........................................................................................................................ 4-9
Move the furnace .................................................................................................................. 4-10
Assemble Sections ................................................................................................................ 4-13
Installation Checklist .......................................................................................................................... 4-15
System Startup .................................................................................................................................... 4-16
Chapter 5: OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General ................................................................................................................................................. 5-2
Summarized Checklist........................................................................................................................... 5-2
Calculate Cover Gas Flow (All Furnaces)............................................................................................. 5-2
Common Measurements ......................................................................................................... 5-3
Calculate the Per-minute Volume of Cover Gas..................................................................... 5-3
English Measure (Example).................................................................................................... 5-3
Metric Measure (Example) ..................................................................................................... 5-4
Calculate Atmosphere Curtain Flow Rates ............................................................................. 5-4
Start and Operate ................................................................................................................................... 5-4
Normal Shutdown.................................................................................................................................. 5-7
Emergency Shutdown............................................................................................................................ 5-8
Idle the Furnace ..................................................................................................................................... 5-8
System Alerts and Alarms ..................................................................................................................... 5-8
Alerts....................................................................................................................................... 5-8
Alarm ...................................................................................................................................... 5-8
Respond to Interlock and Alarm Conditions......................................................................... 5-10
Recover from an Over-temperature Condition ..................................................................... 5-11
Operate Options................................................................................................................................... 5-13
Operate the Belt Cleaners ..................................................................................................... 5-13
Operate the Hand Crank [Option] ......................................................................................... 5-13
Operate the O2 Analyzer [Option] ........................................................................................ 5-13
Operate the Product Feed Conveyor [Option] ...................................................................... 5-13
Chapter 6: TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshoot the Frame and Panel System .......................................................................................... 6-2
Troubleshoot the Conveyor System ...................................................................................................... 6-2
Troubleshoot the Temperature System ................................................................................................. 6-5
Troubleshoot the Atmosphere System................................................................................................... 6-7
Troubleshoot the Exhaust System ........................................................................................................ 6-8
Troubleshoot the Furnace Controller System........................................................................................ 6-8
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Chapter 7: Preventive & Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Observing Safety Precautions .............................................................................................................. 7-2
Main Power Disconnect Switch [OPTION] ........................................................................... 7-2
Electrical Hazards ................................................................................................................... 7-3
Required Tools and Consumable Items ................................................................................................ 7-4
Removing Access Panels ...................................................................................................................... 7-4
Preventive Maintenance Schedule ....................................................................................................... 7-6
Weekly Preventative Maintenance ....................................................................................................... 7-7
Perform a Temperature Profile ............................................................................................... 7-7
Examine and Adjust Conveyor Belt Tracking ........................................................................ 7-7
Backup WINCON Files ........................................................................................................ 7-11
Monthly Preventative Maintenance ................................................................................................... 7-12
Examine Conveyor System................................................................................................... 7-12
Examine and Shorten the Conveyor Belt.............................................................................. 7-13
Examine and Adjust Pressure Pulley Tension ...................................................................... 7-15
Clean External Surfaces........................................................................................................ 7-17
Clean Conveyor System........................................................................................................ 7-17
Align Entrance and Exit Pulleys ........................................................................................... 7-19
Test Furnace Interlocks......................................................................................................... 7-20
Quarterly Preventative Maintenance .................................................................................................. 7-21
Examine and Lubricate the Drive Chain and the Drive Chain Sprockets ............................ 7-21
Examine and Adjust Drive Chain Tension ........................................................................... 7-23
Fill Drive Motor Gearbox with Oil....................................................................................... 7-24
Semi-Annual Preventative Maintenance ............................................................................................ 7-26
Replace Drive Motor Brushes............................................................................................... 7-26
Lubricate Idler Pulley Bearings ............................................................................................ 7-27
Annual Preventative Maintenance ..................................................................................................... 7-29
Verify Intellimax Calibration................................................................................................ 7-29
Clean the Exhaust Ducts ....................................................................................................... 7-29
Empty Exhaust Traps............................................................................................................ 7-30
Test Exhaust.......................................................................................................................... 7-32
As Required Maintenance .................................................................................................................. 7-33
Clean Ultrasonic Belt Cleaner Tank ..................................................................................... 7-33
Reset a Circuit Breaker ......................................................................................................... 7-34
Verify and Calibrate Conveyor Speed .................................................................................. 7-34
Calibrate Conveyor Belt Motion........................................................................................... 7-36
Replace the Air / Gas Filters................................................................................................. 7-38
Calibrate the O2 Analyzer with Calibrated Gas [Option] ..................................................... 7-38
Test Heater Current............................................................................................................... 7-39
Chapter 8: COMPONENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Conveyor System ................................................................................................................................. 8-3
Replace the Conveyor Belt ..................................................................................................... 8-3
Replace the Drive Motor Chain .............................................................................................. 8-5
Replace the Drive Motor......................................................................................................... 8-6
Replace the Drive Motor Optical Encoder ............................................................................. 8-8
Replace the Drive Motor Shear Pin ........................................................................................ 8-9
Replace Drive Return Rollers ............................................................................................... 8-11
Electrical and Control System............................................................................................................. 8-12
Replace the Belt Speed Module............................................................................................ 8-12
Replace Intellimax Controller............................................................................................... 8-13
Replace the Light Tower....................................................................................................... 8-16
Replace a Light Tower Bulb ................................................................................................. 8-17
Replace the Computer........................................................................................................... 8-18
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Replace an SSR ..................................................................................................................... 8-18
Replace the UPS [Option]..................................................................................................... 8-20
Replace the Belt Speed Module ............................................................................................ 8-21
Atmosphere System ............................................................................................................................ 8-23
Replace an Atmosphere Curtain ........................................................................................... 8-23
Replace a Gas Dispersion Tube ............................................................................................ 8-24
Replace a Flowmeter............................................................................................................. 8-25
Heating System ................................................................................................................................... 8-27
Replace Top Heaters ............................................................................................................. 8-27
Replace Bottom Heaters........................................................................................................ 8-42
Replace a Thermocouple....................................................................................................... 8-46
Cooling System ................................................................................................................................... 8-47
Muffle System ..................................................................................................................................... 8-48
Replace a Silicone Gasket..................................................................................................... 8-48
Appendix A: DRAWINGS, SPECIFICATIONS & OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Introduction .......................................................................................................................................... A-1
Engineering Diagram and Equipment Identification............................................................................ A-1
Electrical Diagram Lines and Line Codes ............................................................................. A-1
Electrical Wire Identification................................................................................................. A-2
Plumbing Identification.......................................................................................................... A-4
Specifications ......................................................................................................................... A-4
Options ................................................................................................................................... A-4
Appendix B: RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Introduction ...........................................................................................................................................B-1
Ordering Spare Parts or Warranty Parts ................................................................................................B-1
Appendix C: MATERIAL SAFETY DATA SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Appendix D: CALIBRATION SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Appendix E: VENDOR MANUALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
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IN-LINE DIFFUSION SYSTEM MANUAL
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CHAPTER 1
INTRODUCTION
TABLE OF CONTENTS
How-to-Use Instructions ....................................................................................................................... 1-1
Technical Help ...................................................................................................................................... 1-1
Equipment Label ................................................................................................................................... 1-2
Required Tools and Consumable Items ................................................................................................ 1-3
Manual Description ............................................................................................................................... 1-4
Related Documentation ......................................................................................................................... 1-4
Symbols, Abbreviations & Terms......................................................................................................... 1-5
HOW-TO-USE INSTRUCTIONS
Read this section so that you understand how to use the manual.
TECHNICAL HELP
• If you have problems when you install or operate the equipment, review the installation procedures.
• If you can not correct a problem, contact your dealer or BTU. Use the telephone numbers from the
title page. A representative will help you.
• Keep the reference manuals and serial number available when you call.
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EQUIPMENT LABEL
• The serial number of the equipment is on the manual binder and on the equipment label (located near
the electrical connections). Make sure that you know the serial number when you call for information.
• For a typical equipment label, refer to Figure 1-1.
International
N. Billerica, MA USA 01862
SERIAL
1
MODEL
2
ATMOSPHERE
VOLT
AMP
PH.
KVA
HZ.
IN RUSH
AMP
SEC.
MAX TEMPERATURE
SHIPMENT DATE
1
Serial number
2
Model number
Figure 1-1: Equipment Label (Typical)
1-2
INTRODUCTION
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REQUIRED TOOLS AND CONSUMABLE ITEMS
This section contains lists of required tools and required consumable items to perform preventative and
corrective maintenance and replacement procedures. Any special tools or consumable items not listed
here are identified in the applicable procedures.
Require Tools
Required Consumable Items
• Ammeter, clip-on
• Brush, soft-bristle applicator
• Brush, stainless-steel wire
• Grease gun
• Cleaning solution (90 percent water / 10 percent
isopropyl alcohol)
• Hammer
• Dope, nickel anti-seize pipe thread
• Multimeter, digital or analog (must be true RMS) • Grease, lubricating (EP-1)
• High-temperature RTV gasket or sealant
• Pliers, needle-nose
adhesive
• Screwdriver set (Phillips and standard)
• Identification labels
• Torque wrench, 0 – 50 in.-lb. (6.0 Nm)
• Lint-free wipes
• Torque wrench, 0 – 50 ft.-lb. (68.0 Nm)
• Oil, gear
• Vacuum cleaner (with HEPA-rated filter bag)
• Oil, gear and chain lubricating
• Allen wrench set
• Tape, thread (Teflon®)
• Wrench set, metric and SAE
• Water, distilled or purified (do not use de-ionized
• Adhesive, thread (Loctite No. 222 or equivalent)
water)
• Brush, non-metallic, firm-bristle
DANGER!
DANGEROUS SUBSTANCE!
BTU International does not recommend any specific cleaning solution to remove
production residue. Refer to your product manufacturer’s MSDS for a proper cleaning
solution.
Do not use isopropyl alcohol to clean any internal components of the furnace. Refer
to your material supplier’s documentation for all recommended safety and cleaning
procedures before you do this procedure.
CAUTION!
EXPLOSIVE SUBSTANCE!
Some procedures in this manual recommend a cleaning solution of 90 percent water
/ 10 percent isopropyl alcohol. Isopropyl alcohol is explosive in a non-diluted state
(flashpoint: 14°C (57°F)).
• Refer to the correct MSDS of any cleaning solution you may use.
• Do not make a cleaning solution on or near the furnace.
• Do not use any cleaning solution on a furnace in operation.
• Make sure there is sufficient ventilation when using cleaning solutions to clean the
furnace and its components.
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MANUAL DESCRIPTION
Refer to Table 1-1.
Table 1-1: Description of Chapters and Appendices
Section
Description
Chapter 1, INTRODUCTION
Gives instructions to use this manual and
references to technical resources that are
available from BTU.
Chapter 2, SAFETY
Gives safety related practices that are used in this
manual and dangers that are related to the use of
the equipment.
Chapter 3, SYSTEM DESCRIPTION
Gives a description of the equipment.
Chapter 4, INSTALLATION
Gives equipment install data and instructions.
Chapter 5, OPERATION
Gives procedures to operate the equipment.
Chapter 6, TROUBLESHOOTING
Gives procedures to troubleshoot equipment
operation.
Chapter 7, Preventive & Corrective
Maintenance
Gives procedures to maintain the equipment so
that problems do not occur.
Chapter 8, COMPONENT REPLACEMENT
Gives procedures to replace parts of the
equipment.
Appendix A, DRAWINGS, SPECIFICATIONS &
OPTIONS
Includes equipment-specific drawings.
Appendix B, RECOMMENDED SPARE PARTS
Includes parts that are available to support
operation and maintenance of the equipment.
Appendix C, MATERIAL SAFETY DATA
SHEETS
Includes MSDSs that may apply to hazardous
materials related to your equipment.
Appendix D, CALIBRATION SHEETS
Includes the calibration sheets from the final test of
your equipment.
Appendix E, VENDOR MANUALS
Includes vendor manuals that apply to your
equipment.
RELATED DOCUMENTATION
For other documentation that is used to operate the equipment, refer to Table 1-2.
Manual Title
WINCON Online Help
1-4
INTRODUCTION
Table 1-2: Related Documentation
Contents
Gives instructions to operate
WINCON software
Qty
1
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TM 5259111 Rev. 0
SYMBOLS, ABBREVIATIONS & TERMS
For a list of symbols, abbreviations, and terms that are used in this manual, refer to Table 1-3.
Table 1-3: Symbols, Abbreviations, and Terms
Symbol /
Abbreviation / Term
Definition
<
Less than
</=
Less than or equal
=
Equal
>
Greater than
>/=
Greater than or equal
°C
Degree Celsius
ac or AC
Alternating Current
Alarm
An alarm condition warning, generally halts the furnace operation unless it is a deviation
alarm
Alert
An alert condition, warns of an impending alarm condition (usually, a temperature or gas
condition has exceeded the alert deviation limits)
Bill of Materials
A list of all parts and assemblies that are used to build a system (also BOM)
BOM
Bill of Materials
Btu
British Thermal Units
CAP
Cooled Air Plenum
Catenary
The curve or loop that a flexible belt or chain forms when it is supported only at two
points, as with an anchor chain or the conveyor belt on your furnace
CDA
Compressed, dry air
CE
Community of Europe
Circuit Breaker
An electrical device designed to open a circuit automatically on an overcurrent to prevent
equipment damage
cm
Centimeter
cm/min
Centimeter per minute
CO
Carbon monoxide
CO2
Carbon dioxide
Control Cabinet
The housing for the control panel, whether mounted on the furnace or separately
mounted
Control Circuit
The circuit of a control apparatus or system that carries the electrical signals directing the
performance of the controller
Controller
A device or group of devices that control furnace operation or other devices (also furnace
Controller)
Cover Gas
Any process gas introduced into the process chamber to cover the product being
processed.
dc or DC
Direct Current
Dewpoint Meter
Used to measure moisture in the process atmosphere (refer to Hygrometer)
Eductor
Cooling option for enhanced convection cooling in conveyor ovens
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Symbol /
Abbreviation / Term
Definition
Emergency Stop Button
Used to stop the conveyor and shut off the heaters in an emergency while controller
circuits and safety devices continue to operate
EMO
Emergency Off (see Emergency Stop Button)
EPB
Emergency Push Button (see Emergency Stop Button)
EPO
Emergency Power Off Button (see Emergency Stop Button)
Equilibrium Zone
The zone or zones of a furnace where the temperature continues to rise until the entire
product reaches a uniform soak temperature
Explosive Gas
Any gas that will burn with explosive force when mixed with oxygen from the air or from an
oxygen-rich compound (for example, methane or hydrogen)
FEC Heater
Fully enclosed coil heaters that have a durable iron-chromium-aluminum alloy resistance
element embedded in a cast-fiber insulating plate to give clean, energy efficient
continuous processing at temperatures up to 1150°C
Forming Gas
Any mixture formed by combining two or more gases. Where a furnace uses hydrogen as
its principal process gas, the term forming gas usually refers to the mixture formed when
a large amount of inert N2 is mixed with a small amount of highly reactive hydrogen (often
in a 96 percent N2 : 4 percent hydrogen ratio). This kind of forming gas is used to displace
an all hydrogen atmosphere from a process chamber. The slight mixture of hydrogen lets
impurities in the product complete the process of binding with hydrogen, yet the new gas
is non-explosive when mixed with outside air.
FRU
Field replaceable unit
ft.
Foot/Feet
FU
Fuse
Gas
Refers to cover gas, explosive gas, forming gas, inert gas, non-explosive gas, process
gas and purge gas
GEM
Generic Equipment Module (see Generic Equipment Module)
Generic Equipment Module
A host communication software that is used with the windows version of the controller
software
gpm
Gallons per minute
H2O
Water
HAP
Heated Air Plenum
Host
A remote supervisory computer system that uses the management software to interface
with the furnace
hp
Horsepower
Hr
Hour
HVAC
Heating, Ventilation, Air Conditioning
Hygrometer
Used to measure the amount of moisture in the process atmosphere (also Dewpoint
meter)
Hz
Hertz
ID
Inside Diameter
in.
Inch
Inconel™ 601
A high-nickel, chromium and silicon alloy selected for its resistance to corrosion and its
high heat transfer characteristics
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Symbol /
Abbreviation / Term
TM 5259111 Rev. 0
Definition
Inert gas
A gas whose chemical properties make it non-reactive. For example, nitrogen or carbon
dioxide are inert because they have no “free” electrons to form a molecular bond with
other elements or compounds
Interlock
A switch device that limits or inhibits the operation of a unit or furnace to prevent damage
or personal injury.
iph
Inch per hour
ipm
Inch per minute
ips
Inch per second
iwc
inches water column
kg
Kilogram
kPa
Kilopascal
kVa
Kilovolt-amperere
kW
Kilowatt
l
Liter
l/hr
Liter per hour
lb
Pound
LED
Light Emitting Diode
Lockout/Tagout
An OSHA safety standard (29 CFR 1910.147) procedure using locks, tags and hasps to
disable equipment before maintenance, cleaning and inspection
lph, LPH
Liter per hour
lpm, LPM
Liter per minute
M
Meter
Magnehelic
An instrument for measuring static gas pressures (also manometer)
Manometer
An instrument for measuring static gas pressures, usually in inches of water column (also
magnehelic)
Material Return Authorization
Number
An authorization number assigned by BTU that is used when you return parts for warranty
replacement (also MRA number)
MB
Megabyte
mbar
Millibar
MCP
Main Control Panel
Menu Driven
A type of software program that lets the operator make selections from a list of options or
functions on the screen
mm
Millimeters
mm/min
Millimeters per minute
MSDS
Material Safety Data Sheet
Mu
Micron
Muffle
The chamber that surrounds the product as it enters and leaves the furnace
N.m
Newton meter
N2
Nitrogen
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Symbol /
Abbreviation / Term
Definition
NFPA
National Fire Protection Agency
Non-Explosive Gas
A gas or gas mixture that is inert and non-combustible such as N2
NPT
Nominal Pipe Thread
O2
Oxygen
OD
Outside Diameter
Orifice Plate
A perforated panel that is used to distribute an even flow of air or gas from the heaters to
the process chamber (also Heated Air Panel)
OEM
Original Equipment Manufacturer; Products purchased from other manufacturers for use
in the furnace (for example, the oxygen analyzer or the UPS).
OSHA
Office of Safety and Health Administration. Regulatory body that oversees work place
safety in the U.S.
OTM
Over-temperature module
PID
Proportional Integral Derivative
PLC
Progammable Logic Controller
PN
Part Number
ppm, PPM
Parts per million
Process Gas
The gas or gas mixture used in a chemical process within a furnace
Profile
A graphic composite of the process zone temperatures over the length of the furnace as
monitored by profile thermocouples
Proportional Integral
Derivative
A mathematical algorithm used to control to a setpoint
psi, PSI
Pounds per square inch
psia, PSIA
Pounds per square inch absolute
psig, PSIG
Pounds per square inch gage
Purge gas
Any non-explosive gas or gas mixture used to displace a process gas from the furnace
process chamber. Because it is inert and relatively inexpensive, N2 is usually the purge
gas of choice.
PX
Proximity switch
qt/min
Quarts per minute
Ramp
Controlled heating process that, when graphed over time, would form a ramp-like incline
or decline
RCF
Refractory Ceramic Fiber
RCS
Retractable Center Support
Ready State
A mode of operation when the furnace has stabilized and is ready to process products
REC
Rectifier
RECP
Receptacle
Refractory Ceramic Fiber
A type of high temperature insulation used in the furnace
RES
Resistor
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Symbol /
Abbreviation / Term
TM 5259111 Rev. 0
Definition
Return Authorization Number
An authorization number assigned by BTU that is used when returning parts for paid
repair (also RA number)
scfh
Standard cubic feet per hour
scfm
Standard cubic feet per minute
SEMI S2
Semiconductor Equipment and Materials International. Makes safety standards for
electrical equipment.
SMEMA
Surface Mount Equipment Manufacturer’s Association (merged with Institute for
Interconnecting and Packaging Electronic Circuits (IPC)). IPC/SMEMA includes suppliers
to electronics assemblers. It starts and drives technical, managerial, and financial
programs to enhance work relationships and equipment compatibility within the
electronics assembly industry
SMG
System Monitor Graphic
Sparger
A device that introduces air or gas into the atmosphere surrounding product being
processed to ensure thorough gas infiltration of the product and efficient evacuation of
effluents
Spike
The high temperature or “reflow” zone of a furnace where the product is exposed to a
rapid rise in temperature, which forms a spike in a heat profile graph
SSR
Solid Switch Relay
Thermocouple
a kind of thermometer consisting of two wires of different metals that are joined at both
ends; one junction is at the temperature to be measured and the other is held at a fixed
lower temperature; the current generated in the circuit is proportional to the temperature
difference
Trim Pot
A miniature trimming potentiometer which usually has a small screw adjustment
True-RMS
The specific rating of an electrical device or instrument
Uninterruptable Power Supply A device that is used as an emergency power supply when the primary source of power to
the system is lost
UPS
Uninterruptable Power Supply
V
Volt
Vac
Volts Alternating Current
Vdc
Volts Direct Current
W
Watt
WINCON
Proprietary software that controls the operation of BTU thermal processing equipment
that uses Microsoft Windows®
September 26, 2007
INTRODUCTION 1-9
TM 5259111 Rev. 0
1-10
INTRODUCTION
IN-LINE DIFFUSION SYSTEM MANUAL
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
CHAPTER 2
SAFETY
TABLE OF CONTENTS
Material Safety Data Sheets .................................................................................................................. 2-2
Safety Precautions ................................................................................................................................. 2-2
Safety Identification .............................................................................................................................. 2-6
Dangers, Warnings, Cautions, and Notes ............................................................................... 2-6
Electrical Hazards ................................................................................................................... 2-6
Safety Labels........................................................................................................................... 2-7
Standard and Optional Safety Equipment ............................................................................................. 2-8
Standard Equipment................................................................................................................ 2-8
Optional Equipment ................................................................................................................ 2-8
Safety Procedures.................................................................................................................................. 2-9
Safety Interlocks ..................................................................................................................... 2-9
Lockout / Tagout Procedure ................................................................................................. 2-10
Lockout / Tagout Removal Procedure .................................................................................. 2-11
EMO (Emergency Off) ......................................................................................................... 2-13
Disposal of Equipment.......................................................................................................... 2-14
September 26, 2007
SAFETY
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IN-LINE DIFFUSION SYSTEM MANUAL
MATERIAL SAFETY DATA SHEETS
All potentially hazardous material provided by BTU includes a Material Safety Data Sheet (MSDS),
located in Appendix C: MATERIAL SAFETY DATA SHEETS.
Any potentially hazardous materials included in an Original Equipment Manufacturer (OEM) product,
such as the oxygen analyzer, includes a MSDS insert within the manufacturer's manual (refer to your
Vendor Manual package).
It is your responsibility to provide MSDS inserts regarding use and disposal of all chemicals and
processing materials not specified in this manual.
SAFETY PRECAUTIONS
DANGER!
DANGEROUS SUBSTANCE!
The customer must be aware of the outgasses and emissions of their process!
This furnace may use gases that pose danger from asphyxiation or suffocation. Also,
industrial processes at this site may produce toxic gases. Make sure the site is
adequately ventilated.
BTU International strongly recommends testing the exhaust periodically in reference
to facility or local regulations; otherwise, serious injury or death to personnel may
occur.
WARNING!
READ!
• Read this manual in its entirety before you install, operate, troubleshoot or
maintain the furnace.
• Read a procedure in its entirety before you perform it.
• Always note and take any safety precautions recommended in this manual and
other documentation before you perform any procedure; otherwise, severe
personal injury or equipment damage may occur.
QUALIFIED PERSONNEL!
• Procedures include working with high amperage, high voltage and moving parts.
• Procedures must be performed by fully trained, fully qualified personnel.
• Most procedures require advanced knowledge of electrical, mechanical, and
plumbing theories and issues.
• DO NOT PERFORM THE PROCEDURE IF YOU HAVE ANY DOUBTS ABOUT
HOW TO ACCOMPLISH THE TASKS INVOLVED. Contact BTU International
Customer Service; otherwise, severe personal injury or equipment damage may
occur.
• If you do not obey all the safety precautions listed in this manual and any other
associated documents, you risk the occurrence of death or serious injury to
personnel and a cancelled manufacturer's warranty.
This equipment has high electrical voltages, high temperatures, high gas pressures and moving parts.
Obey the instructions in this and other manuals when you install, operate and maintain the equipment.
This reduces risk of personal injury.
For precautions that relate to the equipment, refer to Tables 2-1 through 2-7.
2-2
SAFETY
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Table 2-1: General Precautions
Precaution
General
Description
Do use only trained personnel to install, operate and do maintenance.
Do obey all DANGER, WARNING and CAUTION labels.
Do obey all procedures written in this manual (this will protect you from dangers
that other methods can not prevent).
Do give instructions to all personnel in electrical, mechanical, compressed gas,
chemical and other types of safeties that are related to operation and
maintenance.
Do use teams of two or more persons to do maintenance. One person must
monitor the controls and indicators, and one person must monitor the system
operation.
Do wear safety glasses and protective clothing when you do maintenance on
the system.
Do turn off compressed gases and electric power at the source before you do
maintenance on the system, when possible.
Do turn off electric power to the system, in accordance with the lockout/tagout
procedure, before you connect or disconnect cables.
Do close and latch all access panels or doors when you are not doing
maintenance.
Do periodic checks of the operation of all safety interlocks.
Do be extremely careful when you use 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.
Do turn off the system and disconnect the power source before you move the
system.
Do move equipment carefully. Jolts or drops can damage the equipment.
Do not remove warning labels from the system.
Do not operate damaged or leaking equipment.
Do not operate without cooling fluid available to the system (if applicable).
Do not wear watches and/or jewelry when you work on electrical equipment.
Do not override safety interlocks (if a procedure requires work while the power is
on, obey the procedure).
Table 2-2: Chemical Precautions
Precaution
Chemical
September 26, 2007
Description
Dangerous materials are used for processes and maintenance procedures.
Cleaning solvents, lubricants, adhesives and other chemicals are recommended
in this manual. Refer to MSDSs and to all local, state and federal regulations,
when you use chemicals, rags and brushes to operate and do maintenance. For
hazardous items that are not identified in this manual, the end user must keep
MSDSs.
SAFETY
2-3
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IN-LINE DIFFUSION SYSTEM MANUAL
Table 2-3: Electrical Precautions
Precaution
Description
DANGER!
High voltage is used to operate the equipment. Death or serious injury can
occur if you touch high-voltage connections.
Electrical
In the U.S., give instruction in electrical handling procedures as specified in the
National Fire Protection Association standard NFPA 70E, Standards for
Electrical Safety Requirements for Employee Workplaces, 1988 edition.
In countries other than the U.S., give instruction in the equivalent safety
standards of your country.
Do use all precautions to prevent contact with live circuits when you install and
do maintenance (do not rely on the indicator lamps, since they may have burned
out).
Do be careful when any internal parts or wiring are exposed.
Do de-energize, lockout and tagout the main power disconnect to prevent
unauthorized use (if applicable).
Table 2-4: Exhaust Precautions
Precaution
Exhaust
Description
The exhaust system must comply with all local, federal and state codes. This
prevents toxic gas from entering the area or polluting the environment. Do not
operate the system if the exhaust system does not comply with these codes.
Do have an exhaust system that is sufficient to remove all effluents from the
equipment.
DANGER!
DANGEROUS SUBSTANCE!
The customer must be aware of the outgasses and emissions of their process!
This furnace may use gases that pose danger from asphyxiation or suffocation. Also,
industrial processes at this site may produce toxic gases. Make sure the site is
adequately ventilated.
BTU International strongly recommends testing the exhaust periodically in reference
to facility or local regulations; otherwise, serious injury or death to personnel may
occur.
Table 2-5: Heat and Burns Precautions
Precaution
Heat and Burns
2-4
SAFETY
Description
Do not touch hot parts (for example, product that exits the equipment). Let the
system cool before you do maintenance. Wear heat protective gloves as
necessary.
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Table 2-6: Gas Precautions
Precaution
Description
DANGER!
Nitrogen may be used as a process gas. Nitrogen is inert and makes up 80
percent of the air we breathe, but will cause death without sufficient oxygen.
Make sure that workspaces where nitrogen is used are vented.
This equipment may use hydrogen. Hydrogen is explosive when mixed with air.
Make sure that the nitrogen to the plenums is more than the hydrogen (cover
gas) flow rate into the exhaust.
Do be careful when you handle inert gases, like nitrogen. Inert gases can cause
you to suffocate because of the lack of oxygen.
Gas
Do give instruction to correctly handle pressurized gases.
Do have sufficient fresh air to compensate for the nitrogen and exhaust system
requirements.
Do have all related medical information available to personnel.
Do obey all local codes for gas plumbing and gas handling.
Do install gas supply systems in accordance with local fire and building codes,
NFPA and the Compressed Gas Association.
Do install automatic shutout devices on all gases.
Do weld plumbing lines and do not use fittings (for high gas concentrations).
Do install flow-regulating devices at the gas source.
Do keep compressed gas in cabinets that have vents and sprinklers, and that
meet safety codes.
Do make sure that all supply lines are clearly marked every 2 ft., with both
contents and use.
Table 2-7: Insulation, Moving Parts, Noise, and Plumbing Precautions
Precaution
Description
Insulation
Insulation may contain RCF insulation that can irritate your skin. You should not
become exposed to RCF. If you do, do not breathe the fibers. Use a protective
dust mask, clothing and gloves. Refer to the MSDS.
Moving Parts
Be careful when you do maintenance procedures. When possible, use the
lockout/tagout procedure to de-energize the system before you do work on any
moving part.
Noise
OSHA set the maximum safe operating noise level at 70 db. Depending on the
equipment features, the usual acoustic noise level may exceed the maximum
safe noise level. Ear protection is recommended.
Plumbing
Plumbing lines have labels with the contents and direction of flow (labels have a
green background with white lettering). When you do maintenance, obey the
labels. Use the lockout/tagout procedure on gas lines when you do maintenance
on the gas system.
September 26, 2007
SAFETY
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TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
SAFETY IDENTIFICATION
Dangers, Warnings, Cautions, and Notes
Procedural safety precautions and notes used in this manual are identified by one of four levels. Each
level of safety precaution is described below:
DANGER!
Shows that an event or an unsafe practice may occur that will cause death to
personnel.
WARNING!
Shows that an event or an unsafe practice may occur that will cause serious injury
to personnel.
CAUTION!
Shows that an event or an unsafe practice may cause minor injury to personnel
and/or damage to equipment.
NOTE: Gives any additional, but not safety related, information about a procedure.
Electrical Hazards
The type of electrical hazard is identified at the beginning of maintenance procedures that include
electrical work (Table 2-8).
Table 2-8: Electrical Hazards
SEMI Category
Type 1
Description
Equipment is fully de-energized (electrically cold).
Follow lockout / tagout procedures.
2-6
SAFETY
Type 2
Equipment is energized. Live circuits are covered or insulated. Work is performed
at a remote location to preclude accidental shock.
Type 3
Equipment is energized. Live circuits are exposed and accidental contact is
possible. Potential exposures are less than 30 volts RMS [or DC], 42.2 volts peak,
240 volt-amps and 20 Joules. (See NFPA 79-14.3, IEC 204, UL 1950 & 1262, IEC
950.)
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
SEMI Category
Type 4
Description
Equipment is energized. Live circuits are exposed and accidental contact is
possible. Voltage potentials are greater than 30 volts RMS [or DC], 42.2 volts
peak, 240 volt-amps, 20 Joules, or radio frequency (rf) is present.
Safety Labels
Safety labels are used in various locations on the equipment and in the manual to warn of potential
hazards when installing, operating or maintaining the equipment. Figure 2-1 shows a few examples of
the most commonly used safety labels on BTU furnaces. Safety labels conforming to SEMI S2
standards indicate the level of hazard by the background color of the label (Table 2-9).
Table 2-9: SEMI S2 Safety Labels Background Colors
Color
Level of Hazard
Red
Danger
Orange
Warning
Yellow
Caution
EN C Y -
O
U
S
RG
NOT - A
ENCE
G
ER
FF
EM
NOTE: High voltage labels are on all access panels of electrical cabinets that contain voltages of more
than 110 VAC.
ARRET D’U
Burn Hazard
Electrical Hazard
Electrical Hazard, UPS
Emergency Off
Hand Crush, Side
Hand Crush, Top
Hand Entanglement
Vapor Hazard, Fumes
VOLT
120
AMP
1 MAX
Consult Service Manual
Wear Eye Protection
Wear Safety Gloves
High Voltage
Figure 2-1: Safety Labels
September 26, 2007
SAFETY
2-7
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
STANDARD AND OPTIONAL SAFETY EQUIPMENT
Standard Equipment
Refer to Table 2-10.
Table 2-10: Safety Features
Device
Description
EMO
EMOs stop equipment operation in an emergency.
Interlocks
Interlocks de-energize power and prevent part damage. Interlocks are installed on doors, access
panels, exhaust ducts, lids and gas supply lines.
Temperature alarms,
temperature switches
Temperature deviation alarms, over-temperature thermal switches and thermocouples in each
heated zone, protect the system from over-temperature. Alarms are set in the recipe through the
furnace controller.
Belt stop alarm
The belt stop alarm is an electro-mechanical alarm that indicates when operation is stopped or
moving too slowly.
Main disconnect switch
[Option]
Lockable switch that lets you energize and de-energize the furnace. It also provides over-current
protection that can be reset.
DANGER!
The UPS remains energized when the main power disconnect switch is set to
OFF.
The main power switch can be locked in the off position to prevent unapproved use. The red tab
on the switch handle can be pulled out (off position) and locked with a padlock. If the furnace has
a UPS, the backup power is disabled when the main power disconnect switch is in the off
position.
Optional Equipment
NOTE: You (the customer) are responsible for approving, procuring, installing, operating and
performing maintenance of safety items that are used at your (the customer) facility.
You (the customer) must protect your equipment and employees. The safety equipment that is
listed does not protect equipment or employees from all dangers.
You must have the following safety equipment available:
• Fire protection equipment
• Self-contained breathing device
• Safety glasses
• Heat-resistant gloves
• Protective clothing
• Dust mask
• Ear protection
2-8
SAFETY
DANGER!
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
SAFETY PROCEDURES
Safety Interlocks
Safety interlocks shut down heat, gas and blower motors. The system identifies a tripped interlock with
a visual alarm on the light tower and in WINCON.
N
WARNING!
EQUIPMENT SAFETY!
Make sure only an authorized technician overrides the hood lift interlock; otherwise,
severe personal injury may occur.
Never keep equipment unattended with any interlock defeated.
1
2
1
1
1
EMO
Top View
2
1
TFQ1009
Main Disconnect Switch [Option]
Figure 2-2: EMO and Main Disconnect Switch Locations (Typical)
NOTE: The above illustration is a typical example. Your furnace may be different.
September 26, 2007
SAFETY
2-9
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Lockout / Tagout Procedure
Procedure Category:
Type 1
Special Tools:
• Lockout / Tagout signs
• Padlock
• Voltmeter
Related Documents:
WINCON Online Help
Exit Criteria:
The furnace has been de-energized, all applicable components and
associated equipment has been locked with a padlock, and lockout tags
have been hung on all applicable and associated equipment.
For safety purposes, the main power disconnect switch can be locked off to prevent unauthorized use.
The main power disconnect switch is normally located on the furnace near the power input cable.
NOTE: Energy isolation and lockout / tagout are to be applied only by trained employees that are
authorized to perform service or maintenance. Before lockout / tagout is applied, all employees
who work in the affected area must be notified. This procedure does not override your facility’s
lockout / tagout procedure.
To perform a Lockout / Tagout procedure:
1
Notify all appropriate personnel that a lockout / tagout is being performed.
2
In WINCON, run a cooldown recipe. Refer to WINCON Online Help.
WARNING!
BURN HAZARD!
You will be severely burned if you touch hot equipment!
Wait until the internal temperature of the furnace is at or less than 60°C before
performing the lockout / tagout procedure. Make sure the furnace and its components are cool to the touch before performing any maintenance procedure.
3
Examine the internal furnace temperature in WINCON. Wait until the temperature is 60°C or less.
4
Shut down WINCON. Refer to WINCON Online Help.
5
De-energize the personal computer. Refer to the applicable vendor manual.
6
If applicable, de-energize the UPS. Refer to the applicable vendor manual.
7
If applicable, disconnect all wires from the UPS. Lock all wires with a plug-locking device.
8
Set the main power disconnect switch (1) to OFF.
9
Using a padlock, lockout the main power disconnect switch.
10 Hang a lockout / tagout sign on the main power disconnect switch.
2-10
SAFETY
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
DANGER!
CHECK FOR RESIDUAL VOLTAGE!
Residual high-voltage electricity may electrocute personnel!
Always use a voltmeter to detect any residual voltage in the electrical system before
performing any maintenance or replacement procedure,
11 Using a voltmeter, examine the electrical system for any residual voltage.
12 Shut off all liquid and gas supplies. Put a lockout / tagout sign on the shutoff valves.
Lockout / Tagout Removal Procedure
Procedure Category:
Type 2
Special Tools:
None
Related Documents:
WINCON Online Help
To remove a Lockout / Tagout:
1
Make sure the equipment is fully assembled and safe to operate.
2
Remove all tools from the work area.
3
Notify all appropriate personnel that a lockout / tagout is being removed.
4
Remove all lockout / tagout devices.
5
Turn on all liquid and gas supplies.
6
Set the main power disconnect switch to ON.
7
Energize the UPS (unlock and connect cables, if applicable) and the personal computer. Refer to
the appropriate vendor manual.
8
Press START / RESET on the main control panel.
9
Start WINCON and run the correct recipe. Refer to WINCON Online Help.
10 Operate the furnace.
September 26, 2007
SAFETY
2-11
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
1
2
3
4
ON
ON
TRIPPED
TRIPPED
RESET
OFF
RESET
OFF
BELT1013_0
1
3
ON (I) position, unlocked
2
OFF (O) position, locked with padlock
ON (I) position, unlocked
4
OFF (O) position, locked with padlock
Figure 2-3: Main Power Disconnect Switch
2-12
SAFETY
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
EMO (Emergency Off)
Procedure Category:
Type 2
Special Tools:
None
Related Documents:
WINCON Online Help
In an emergency, press an EMO at one of the following locations:
NOTE: In a typical setup, there are two EMOs at the entrance end, two at the middle, and two at the
exit end. Your particular furnace may have more, depending upon the options ordered. Refer to
the Installation Drawing for the specific EMO locations on your furnace.
When you press an EMO the following items de-energize: heaters, conveyor system, 6-kVA power
transformer and all subsystems except the 24V control circuits.
When you press an EMO, the following items stay energized: Intellimax, personal computer and the
1.5-kVA instrument transformer.
NOTE: Power stays OFF until you disengage all activated EMOs.
To energize the furnace after an emergency:
1
Turn the EMO 1/8-turn counterclockwise. The EMO extends.
NOTE: If possible, remove product to prevent heat damage.
2
Press START/RESET on the main control panel to energize the conveyor system and heaters.
3
Restart the product recipe and clear the EMO alarm in WINCON.
4
When the furnace is READY, load product.
September 26, 2007
SAFETY
2-13
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IN-LINE DIFFUSION SYSTEM MANUAL
Disposal of Equipment
Procedure Category:
Type 2
Special Tools:
• Lifting equipment
• Common hand tools
Related Documents:
WINCON Online Help
Environmentally Responsible Recycling of Equipment
BTU believes in environmentally responsible recycling of equipment. If the equipment is no longer
needed, consider the following:
• Can you extend the life of the equipment?
• Can you upgrade the equipment to your present requirements?
• Can you use the equipment elsewhere in your facility or company?
• Can you sell the equipment for further use?
End-of-Life Decommissioning
NOTE: Disassemble and sort the parts by material type (i.e., steel, stainless steel, aluminum,
insulation, etc.).
1
Disassemble the Equipment.
2
Sort parts by material type.
CAUTION!
In normal operation, the only parts that are exposed to process chemicals are
internal areas of the process chamber and the exhaust stacks.
3
Remove process materials from parts, if applicable.
4
Dispose of hazardous and non-hazardous materials in an environmentally responsible manner.
• For information about hazardous materials related to maintenance and operation of your
equipment, refer to Appendix C: MATERIAL SAFETY DATA SHEETS or the standard practice
of your facility.
• Hazardous maintenance materials include lithium batteries, contaminated rags, etc.
• Dispose of hazardous materials in accordance with local, state, and federal regulations.
2-14
SAFETY
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
CHAPTER 3
SYSTEM DESCRIPTION
TABLE OF CONTENTS
Theory of Operation .............................................................................................................................. 3-2
Direction of Product Travel .................................................................................................... 3-2
Equipment Features / Options ............................................................................................................... 3-3
Equipment Locator and Subsystems ..................................................................................................... 3-7
Frame & Panel System.......................................................................................................................... 3-8
Frame ...................................................................................................................................... 3-8
Panels ...................................................................................................................................... 3-8
Entrance Table....................................................................................................................................... 3-8
Conveyor & Drive System .................................................................................................................... 3-9
Conveyor System .................................................................................................................... 3-9
Drive System........................................................................................................................... 3-9
Electrical & Control System ............................................................................................................... 3-11
Operator Control Panel ......................................................................................................... 3-11
Light Tower .......................................................................................................................... 3-12
WINCON Furnace Control Software ................................................................................... 3-12
Intellimax Furnace Controller............................................................................................... 3-13
PID Temperature Control ..................................................................................................... 3-13
Atmosphere System............................................................................................................................. 3-16
Atmosphere Control.............................................................................................................. 3-16
Dual Venturi Exhaust Stacks ................................................................................................ 3-16
Atmosphere Curtains ............................................................................................................ 3-17
Heating System ................................................................................................................................... 3-18
Fully Enclosed Coil (FEC) Heaters ...................................................................................... 3-18
Shadow Walls [Option] ........................................................................................................ 3-18
Temperature control.............................................................................................................. 3-19
Cooling System ................................................................................................................................... 3-20
Passive Cooling..................................................................................................................... 3-20
Active Cooling ...................................................................................................................... 3-20
September 26, 2007
DESCRIPTION
3-1
TM 5259111 Rev. 0
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THEORY OF OPERATION
Product is loaded onto the conveyor belt at the entrance end of the furnace. The product enters the process chamber through an atmospheric barrier called an atmosphere curtain, which keeps processing
atmosphere within the furnace, and ambient atmosphere out. As the conveyor belt moves through the
process chamber, product is carried through a series of individually controlled heated zones, in reference to a thermal profile.
A typical thermal profile first begins with a rapid temperature increase, also known as “ramping up.”
Ramping up typically occurs in the first few heated zones. Ramping up brings the product to processing
temperature within a controlled state.
Once the first designated temperature of the profile has been obtained, the other heated zones (called
“soak zones”) are typically programmed to produce a uniform temperature so that the entire product stabilizes at the same temperature.
After the heated process chamber, the product is then carried through the cooling section, which is
designed to slowly cool the product so that it is not susceptible to thermal shock as it exits the furnace.
The cooling section is controlled by adjusting the flow of water through the water jackets.
After cooling, product is carried through another atmospheric barrier onto the exit end of the furnace for
unloading.
As the product is carried through the furnace, the processing atmosphere flows counter to the product
direction of travel. This flow is known as a “counter flow.” The counter flow helps remove impurities
from the product and the processing chamber so that product is always being carried through a progressively cleaner atmosphere.
Direction of Product Travel
To accommodate various production facilities, conveyor furnaces can be configured at purchase for
either left-to-right or right-to-left direction of product travel:
• Left-to-right: The operator controls are on the right-hand side (exit end) of the furnace as you
face the furnace from the front.
• Right-to-left: The operator controls are on the left-hand side (exit end) of the furnace as you face
the furnace from the front.
To determine the configuration of your furnace, refer to the Installation Drawing in Appendix A,
DRAWINGS, SPECIFICATIONS & OPTIONS.
3-2
DESCRIPTION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
EQUIPMENT FEATURES / OPTIONS
NOTE: Your equipment may not have all the listed features and options.
Table 3-1: Overall Furnace
Item
Air / N2
CE Certification
O
Entrance Section
S
Exit Section
S
Extended Onload and
Offload Table
O
Separation Joint
O
Spare Parts Kit
Special Color
O
O
Description
Certifies the furnace meets safety standards for the Community of Europe (CE).
Safety labels and other European safety features are included.
The entrance section consists of an entrance load table and an entrance muffle
section. Product is placed on the entrance conveyor for processing. The entrance
muffle immediately follows the entrance table and isolates the internal and external
atmosphere.
The exit section consists of the exit muffle and the exit off-load table. The exit muffle
follows the cooling section and isolates the internal and external atmosphere. The
exit table follows the exit muffle and is where processed product is retrived from the
conveyor.
Increases the onload and offload area. More area may be necessary if the
equipment operates at high throughput, or if manual product handling is required
upon entering or exiting. Sections start with a 12 in. length and can be extended in
12 in. increments. Legs can be included to maintain a horizontal conveyer.
A separation joint in the entrance or exit muffle or in the process chamber lets the
equipment be broken down into separate sections for shipment.
Furnace specific recommended spare parts.
Choice of colors (external panels only)
O = Option, S = Standard
Table 3-2: Conveyor System
Item
Air / N2
Belt Speed Module
S
Belts
S
Brush Belt Cleaner
O
Conveyor Belt and Idler
Pulley
S
Drive System
S
Hand Crank
O
Description
The belt speed module receives the speed signal from the Intellimax and gives the
correct voltage and power to drive the conveyor drive motor.
29 or 36-in. Nichrome V.
The brush cleaner consists of rotating brushes that physically scrub the conveyor belt
or loose debris. The belt continuously passes through a motor-driven set of top /
bottom rotating brushes.The rotary brush cleaner is software-controlled via WINCON
recipe. For more information, refer to WINCON Online Help.
The conveyor belt is supported on a large idler pulley. Next to the pulley is a proximity
switch which measures the rotation of the belt.
The drive motor and gear reducer box, drive chain, pulley, shear pin assembly, and
pressure pulley assembly are at the exit end of the furnace. Your system may be
different. The drive unit is covered to keep it free of contamination and to ensure
operator safety.
Used to manually advance the conveyor to remove product from the process
chamber in the event of a power failure or a drive shear pin failure.
The ultrasonic belt cleaner efficiently cleans irregular conveyor belt surfaces by using
sound to agitate a tank of deionized (DI) water through which the belt passes.
An air rake removes excess water by spraying compressed air on the belt as it exits
the tank. The air is sprayed through a perforated metal cylinder that is horizontal to
the furnace floor.
Ultrasonic Belt Cleaner
S
The standard ultrasonic belt cleaner is equipped with a multi-frequency generator and
an immersible transducer. The system includes a double- walled, stainless steel tank
with a solenoid-operated water inlet valve, a float switch, and a solenoid-operated
valve on the drain.
Use the ultrasonic belt cleaner on a maintenance schedule at sufficient intervals to
ensure an acceptable level of cleanliness for the specific product process. Do not use
the ultrasonic belt cleaner during product processing. otherwise, the moisture from
Ultrasonic Belt Cleaner will increase dew point levels and affect product process.
The ultrasonic belt cleaner is software-controlled via WINCON recipe. Refer to
WINCON Online Help for operating information and to the Vendor Manual located in
Appendix E: Vendor Manuals.
O = Option, S = Standard
September 26, 2007
DESCRIPTION
3-3
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Table 3-3: Electrical and Control System
Item
Air / N2
Circuit Breakers
S
EMOs
(Emergency Off
Switch)
S
Intellimax Controller
S
Multi-language
WINCON
Dual Monitor, Keyboard
and Mouse
Light Tower
S
Description
Circuit breakers or fuses protect specific electrical circuits. For more information, refer
to Appendix A: DRAWINGS, SPECIFICATIONS & OPTIONS.
EMOs de-energize the conveyor system and heaters. Depending on the
configuration, some equipment may de-energize all power. The EMOs are located at
the entrance and exit sections. Optionally, the door panels may be equipped with
interlock switches to de-energize power.
The Intellimax controller works with WINCON software to continuously monitor and
control the furnace.
O
S
Over-temperature
Protection
Lights indicate system status.
Provides equipment over temperature protection by utilizing two features: zone
specific temperature deviation alarm settings stored in WINCON recipes, and a
separate OverTemperature Unit.
S
Computer, Keyboard,
and Monitor
S
Dual thermocouples, located in each heated zone, monitor the temperature of that
zone. If an over-temperature condition exists, an audio/visual alarm occurs, and all
heater power is removed. The conveyor continues to run to allow safe removal of the
product from the furnace.
A dedicated computer-based control system interface includes hardware and
software that are used to perform specific tasks including recipe programming,
product processing, status reporting, system setup, system maintenance and
adjustments.
Dual Monitor, Keyboard
and Mouse
O
Profiling System
(Thermocouple Ports)
S
Thermocouple Reel
O
Remote Diagnostics
O
SSRs
S
Temperature Deviation
Alarm Settings
S
Temperature Alerts
S
UPS
O
Thermocouples, used to profile the furnace, can be connected to the profile jack panel
under the entrance table and used with profiling software to capture, display, print out,
and store profiling data. The computer has high resolution capability to display
dynamic left center-right temperature profiles with minimum and maximum
temperatures.
The thermocouple reel assembly consisting of a stand, a reel and a mounting clamp
is used to anchor and control a profile thermocouple as it is fed through the furnace.
Provides remote access to the control system through modem or ethernet
networking. Can be used by BTU field service to reduce downtime by remotely
diagnosing problems. Includes modem and software required to operate the furnace
from a remote location.
SSRs control power to heaters and other components. For more information, refer to
Appendix A: DRAWINGS, SPECIFICATIONS & OPTIONS.
Temperature deviation protection is provided by alarm settings stored in WINCON
recipes. The limits can be programmed through the Recipe Edit pages in WINCON.
Temperature deviation alarm settings are used to set the acceptable upper and lower
temperature limits that can be reached before activating an alarm. Temperature
deviation alarm settings are zone specific.
When a thermocouple detects a temperature that exceeds the zone’s programmed
setpoint values (plus or minus the high or low alarm values), WINCON initiates an
alarm. (For example, if a zone's temperature setpoint is 200°C, and the high and low
temperature alarm values are 10, the temperature deviation alarm will occur when the
temperature registers above 210°C or below 190°C).
Alert limits warn the operator that a deviation is occurring and may be approaching
alarm conditions.
The UPS protects equipment from blackouts, brownouts, surges, spikes, and
interference conditions. The UPS automatically converts to battery/inverter on 3phase power fault and provides power for approximately 30 minutes. (Actual time
varies, depending on power needs.) The system automatically synchronizes and
transfers on 3-phase power recovery.
When the UPS is active, normal operation continues for the following items: the
computer, microprocessor controller, overtemperature system, conveyor speed
control, printer, and optional host communication system.
Voltage: 380/220V, 50/
60 Hz, 3 Phase, 4 Wire
Voltage: 400/230V, 50/
60 Hz, 3 Phase, 4 Wire
Voltage: 415/240V, 50/
60 Hz, 3 Phase, 4 Wire
3-4
DESCRIPTION
O
O
O
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
Item
Voltage: 440/460/480
Transformer
Air / N2
TM 5259111 Rev. 0
Description
O
O = Option, S = Standard
Table 3-4: Atmosphere System
Item
Air / N2
Dewpoint Analyzer
(Panametric)
O
Dual Venturi Exhaust
with Gate
O
Exhaust Stack
Monitoring System
O
Dual Venturi Exhaust
S
Flowmeters
S
Gas Pressure Alarms
S
Mass Flow Controllers
O
O2 Analyzer (Zirconium
Oxide)
O
O2 Analyzer (Delta F)
O
Description
This option measures the moisture concentration of the process atmosphere within a
certain temperature range, and displays a visual readout for the operator. The
dewpoint analyzer is mounted in the furnace control panel, and is connected to
WINCON for monitoring alarms and data collection. For more information, refer to
the vendor manual in Appendix E: Vendor Manuals.
The dual exhaust venturi with gate is used for processes that require an atmosphere
separation and separate exhaust controls for adjacent areas.
Atmosphere is drawn to a single location with individual control of gases from the
entrance and exit ends of the furnace without concern for the atmosphere crossing
this point. This separation is assured by the gate being lowered to very near the
traveling product, thereby preventing the atmosphere from flowing through. A
separate control valve and two N2 flowmeters are required, one for the venturi
exhaust on each side of the gate.
This option records data regarding the measurable parameters (pressure and
temperature of each local exhaust stack) within the exhaust system.
• Includes a thermocouple, a 1 to 5 volt negative pressure transmitter, and two loops
of analog circuitry to monitor each exhaust stack in the furnace for pressure and
temperature.
• Using the furnace controller, values of deviation can be assigned to report any
changes and to set alarm conditions.
Dual venturi exhaust stacks located towards the entrance are standard. The exhaust
system includes heaters, effluent traps, and venturis for effective exhaust removal.
Regulate gas flow to the gas dispersion tubes and the venturi-controlled exhaust
stacks. Located on the flowmeter panel. For locations, refer to Appendix A:
DRAWINGS, SPECIFICATIONS & OPTIONS.
Gas safety devices include low gas flow alarms that sense a low compressed gas or
nitrogen supply.
With this option, recipe setpoints are controlled by the Intellimax. The MFC sends an
analog flow signal to the microprocessor so that the alarm monitoring system can
initiate either an alert or alarm condition for an out-of-range value. With two master
flow controllers, gases can be mixed in any proportion.
This option uses a portable analyzer with a built-in pump to extract sample gas for
periodic testing of O2 levels. It does not contain any electrolyte fluid. Range of
operation is 0 PPM to percent O2 scaling or equivalent. A Zirconium Oxide analyzer
is preferred for fast response. When ordered as a standalone option, this option must
include a flexible sample line to connect to furnace gas sampling ports. This analyzer
operates well with an optional air / N2 mixing system or auto sampling system.
This oxygen analyzer allows for periodic testing of O2 levels. It includes an electrolyte
fluid cell and a built-in pump for extracting sample gas. The range of operation is 0 to
1000 PPM scaling or equivalent. When used with the automatic gas sampling
system, the analyzer is connected to the gas sampling ports making feedback to the
furnace controller possible. The O2 Analyzer connects to WINCON for monitoring,
alarms, and data collection. For directions on how to use the O2 Analyzer, refer to the
instruction manual in Appendix E: Vendor Manuals.
O = Option, S = Standard
Table 3-5: Heating System
Item
Air / N2
Description
Heating Section
S
Heater Contactor
S
The heating section is divided into zones. Each zone has heaters that are monitored
by thermocouples.
Heater contactors de-energize zone heaters when EMOs are activated or the
computer detects a zone temperature that exceeds a certain temperature over the
preset value.
Quartz Liner
S
O = Option, S = Standard
September 26, 2007
DESCRIPTION
3-5
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Table 3-6: Cooling System
Item
Air / N2
Case Cooling
S
Cooling System Drip
Tray
S
Product Cooling Fan
Module
O
Cooling, Water
S
Water Flow Switch
S
Water Valves
O
Thermocouples
S
Description
Case cooling prevents heat buildup within the case and the electrical cabinet. The
case cooling design uses a blower in the case exhaust duct to evacuate case heat.
The case cooling exhaust port connection is located at the top of the process
chamber. This duct can be connected to the facility exhaust system, thus decreasing
the load on the room air conditioning. If you make this kind of connection, make sure
the exhaust blower has enough power to handle this extra load.
Drip trays collect water from cooling system leaks and condensation. Drip trays drain
to floor of frame.
The offload table can be equipped with a cooling fan module to give more product
cooling after product exits. This module is mounted over the exit table. An optional
fan speed control is also available for this cooler.
The product cooling fan module may include an optional dial that adjusts the speed
of the cooling fans.
Includes copper tubes on the outside of the metal muffle. The water cooling tubes are
attached to the muffles with high conductivity aluminum heat sinks. This system has
a better rate of heat transfer per unit under identical water flow rates and heat load
compared to other designs.
Inside the access panel opposite the operator control panel is a water flow switch,
which verifies a continuous water flow. The switch is connected to the main outflow
pipe inside the cooling section. Lack of water flow generates a WINCON alarm.
Water valves in the cooling section have fixed orifices so that they do not fully close
and so that they collect steam.
Equipment with water-cooled muffles [option] have a temperature-actuated valve in
the water supply line. A temperature probe opens the valve automatically as the
temperature increases, and closes it as the temperature increases.
Thermocouples for each zone are connected to the computer.
O = Option, S = Standard
3-6
DESCRIPTION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
EQUIPMENT LOCATOR AND SUBSYSTEMS
1
Top View
2
2
4
3
6
5
2
9
7
10
8
In-Line 1011
1
Main Disconnect Switch [Option]
5
Case Cooling Exhaust
9
2
EMO Buttons
6
Gas Flowmeters Panel
10 Master Control Panel
Profile Thermocouple Ports
3
Entrance Table
7
Keyboard and Monitor
4
Venturi Exhaust Stacks
8
Exit Table
Figure 3-1: In-Line Diffusion Furnace Major Components (Typical)
The In-Line Diffusion furnace contains the following subsystems:
• Frame & Panel System
• Entrance Table
• Conveyor & Drive System
• Electrical & Control System
• Atmosphere System
• Heating System
• Cooling System
September 26, 2007
DESCRIPTION
3-7
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
FRAME & PANEL SYSTEM
Frame
The modular frame is made from heavy gauge steel. The frame houses the electrical wiring, plumbing,
controls, conveyor system, and process chamber. The electrical cabinet is integral with the bottom half
of the furnace framework, and is accessible after you remove the front and rear panels. The Intellimax
controller and associated components are located in the electrical cabinet. Adjustable legs support the
frame 102 to 152 mm (4 to 6 in.) above the facility floor, enabling you to level the furnace on an uneven
surface. This raised position allows air to flow upward from floor level, supplying the required ventilation.
Panels
The outer surface of the furnace consists of removable access panels, which provide access to the subsystems within. The access panels protect personnel from contact with potential electrical hazards and
hot surfaces, and delicate components from dirt or damage. The top covers are typically perforated. The
side covers are insulated to protect personnel from hot components. For operator safety, access panels
are designed to keep the external surfaces of the furnace to temperatures less than 38°C (100°F).
ENTRANCE TABLE
The stainless steel entrance table is bolted to the furnace frame and can be separated for shipping or
moving. An extended entrance table is offered as an option.
The entrance table contains the following components:
• Belt return idler pulley
• Belt motion alarm sensor
• Profile thermocouple ports
3-8
DESCRIPTION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
CONVEYOR & DRIVE SYSTEM
Conveyor System
Product is placed on and carried by a steel-mesh conveyor belt through the process chamber. Standard
belts are available in a variety of widths. The conveyor belt height is typically 965 mm (38 in.) above
the floor, but can vary. Conveyor belt specifications for your furnace can be found in Appendix A,
DRAWINGS, SPECIFICATIONS & OPTIONS.
Conveyor Control
The conveyor system is controlled by WINCON, the Intellimax controller, and the belt speed module.
WINCON software along with the Intellimax controller provide tight, closed loop speed control of the
conveyor belt, including:
• belt speed setpoint
• actual belt speed
• belt motion alarm
• belt stretched alarm
• high and low deviation alarms
For instructions on using WINCON, refer to WINCON Online Help.
Belt Speed Deviation Alarm
On the entrance table, the conveyor belt is supported by the idler pulley. Next to the idler pulley is a
proximity switch that measures conveyor speed as part of a closed-loop control system. If the idler pulley speed does not match the drive motor speed, a belt motion alarm is generated in WINCON. For
more information, refer to page 5-8, System Alerts and Alarms.
Drive System
The drive system is designed to move the belt at the speed required to maintain the recipe controlled
process parameters. The drive system operates by moving the conveyor belt over a series of parallel
quartz tubes.The quartz tubes have a low coefficient of friction and enable smooth belt travel.
The drive system (Figure 3-2), located on the exit table, consists of the following components:
• DC drive motor
• Drive chain
• Drive pulley and shaft
• Gear reducer assembly
• Pressure-pulley assembly
• Motor shaft speed encoder
• Shear pin assembly or torque limiter
• Drive sprocket
September 26, 2007
DESCRIPTION
3-9
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Shear Pin Assembly
If equipped, a shear pin assembly is located on the drive shaft (Figure 3-2) and is designed to break if an
excessive load is applied to the conveyor belt. The breaking shear pin prevents extensive damage from
occurring if the conveyor jams. In the event of a shear pin failure, a WINCON alarm is generated. Spare
shear pins are provided with your furnace.
Torque Limiter
If equipped, the torque limiter is a detente-type, oil-filled slip clutch that will disengage the conveyor
belt from the drive system if an excessive load is applied to the conveyor belt.
4
5
A
6
DOT
1
2
A
DOT
3
13
7
8
15
12
14
11
9
10
16
18
17
BELT1003R1
1
Splice Wire
7
Drive Motor & Speed Encoder
13 Belt Motion Sensor
2
Return Rollers
8
Belt Catenary
14 Pressure Pulley & Shaft
3
Conveyor Belt
9
Ultrasonic Belt Cleaner [Option]
4
Shear Pin
10 Drive Pulley
16 Tension Spring Adjustment Locknuts
5
Drive Sprocket
11 Belt Tracking Locknuts
17 Belt Tracking Adjustment Nuts
6
Drive Chain
12 Adjustable Mounting Bracket
18 Fixed Bracket
15 Pressure Pulley Tension Sprint
Figure 3-2: Drive Assembly
3-10
DESCRIPTION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
ELECTRICAL & CONTROL SYSTEM
The electrical and control systems consists of the following components:
• Operator Control Panel
• Light Tower
• WINCON Furnace Control Software
• Intellimax Furnace Controller
• PID Temperature Control
• Emergency Off Switches (Refer to page 2-13, EMO (Emergency Off).)
• Main Power Disconnect Switch (Refer to Table 2-10 and Figure 2-3.)
Operator Control Panel
The operator control panel is typically located on the front of the furnace close to the exit end. The controls and indicators on the operator control panel include the following (Figure 3-4):
• START/RESET: a green push button, which energizes the conveyor and heating systems. When
these systems are energized, the START/RESET indicator comes on. You must press START/
RESET to reset the system after an emergency stop and other fault conditions.
• Alarm chime: an audible alarm that sounds during alarm conditions; a black dial adjusts the
volume of audible alarm.
• E-stop: a red push button, which de-energizes the heat and conveyor systems in the event of an
emergency.
GENCY-ST
ER
O
M
P
E
START / RESET
D'
NOT-AU
S
ARRET
U
1
2
RG
ENCE
3
BELT1012_1
1
START/RESET push button
2
Alarm chime dial
3
E-stop push button
Figure 3-3: Operator Control Panel
September 26, 2007
DESCRIPTION
3-11
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Light Tower
The light tower is used as a visual indicator of the status of the furnace. The standard configuration for
the light tower is described below. If the light tower is customized, refer to Appendix A, DRAWINGS,
SPECIFICATIONS & OPTIONS.
Table 3-7: Standard Light Tower Indicators
Color
Condition
3-Color
4-Color
Description
User Response
Red
Alarm
X
X
An alarm condition exists
Acknowledge the alarm, correct the
alarm condition and restart
Yellow
Alert
X
X
An alert condition exists
Correct the alert condition and restart
Green
Ready
X
X
The furnace is operating within the None
parameters specified in the recipe
currently being run in WINCON
WINCON Furnace Control Software
All furnace functions (system setup, calibration. programming, scheduling, operating, and monitoring
functions) are controlled via WINCON software. WINCON software is pre-loaded and menu-driven. A
backup of WINCON software is included with the equipment.
Software functions can be accessed from WINCON’s Main Temperature Screen, which is displayed
when the system is first powered-up. For a brief overview of WINCON’s Main Temperature Screen,
refer to Table 3-8. All instructions for using WINCON software are contained in WINCON Online Help.
A separate WINCON Quick Guide is located in the back of this binder.
Table 3-8: Software (System Power-up and Main Temperature Screen)
Item
Displays
Uses
Options Include
Alarms
Alarm Status Screen
View, silence, and clear
alarms, and view Intellimax
communication status
--
Temperatures
Temperature Screens
(several)
View temperature data,
mass flow controllers, and
belt speed data
--
Profile
Profile Menu
--
Setup (start) View, Stop
Logging
Logging Menu
--
Demand Log and Setup
Recipe
Recipe Menu
--
Edit Displayed, Edit Active,
Edit Stored, Run Stored,
Make Schedule, and Change
Directory
System
System Menu
--
Authorization, Time Limits
and Delays, Setup,
Communication, Belt
Calibration, Input Calibration,
Discrete Input/Output,
Printer Setup, and Test)
Exit
Returns to the computer operating system.
3-12
DESCRIPTION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Intellimax Furnace Controller
The furnace is controlled by the Intellimax controller which is mounted on the inside of the furnace
enclosure. The Intellimax is connected to a personal computer, at the exit panel of the furnace enclosure
and uses a RS 232 port which is capable of GEM compatible host communications. The PC interfaces to
the operator using a window based operating system program called WINCON. The following is a partial list of the features and options which the Intellimax controls.
• Flexible password and operator level furnace control
• Data collection and reporting with alarm trending
• Control of the furnace drive system
• Product profiling
• Recipe scheduling and sequencing
• Help file for operation of the furnace
• Windows based multitasking
• Testing of inputs and outputs from the PC
• Control and or display of mass flow controllers
• Control and or display of O2 analyzer
• Control and or display of dewpoint monitor
• Control and or display of various furnace sensors
PID Temperature Control
Temperature setpoints are programmed in WINCON software, and maintained by the Intellimax controller using PID temperature control loops. The temperature of each heated zone is regulated by three
control co-efficients. Control co-efficients are mathematical variables used to calculate the electrical
power required to maintain temperature setpoints.
The adjustable PID temperature coefficients include the following:
• Proportional Band is a temperature range (displayed in °C) for each zone, using the temperature
setpoint as the median.
• Integral adds or subtracts increments of electrical power to the existing proportional band to
bring the temperature deviation to zero.
• Derivative calculates the expected temperature change and attempts to prevent or decrease
overshooting or undershooting the temperature setpoint by adding or subtracting increments of
electrical power.
For more information on PID temperature control, refer to WINCON Online Help. Figure 3-4 shows a
signal-flow diagram of a basic temperature control loop for one zone. Figure 3-5 shows a signal-flow
diagram of a basic temperature control loop for a furnace that has separate top and bottom zones.
September 26, 2007
DESCRIPTION
3-13
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
CONTROL SIGNAL
INTELLIMAX
WINCON
USER / INTERFACE
SETPOINT
THERMOCOUPLE INPUT
(ZONE TEMPERATURE)
AC POWER
INPUT
SOLID-STATE RELAY
(SSR)
Modulates heater power
(+/-)
HEATER
BELT1014_1
Figure 3-4: Basic Temperature Control Loop
CONTROL SIGNAL (TOP)
CONTROLLER
THERMOCOUPLE INPUT
(ZONE TEMPERATURE)
AC POWER INPUT
SOLID-STATE RELAY
(SSR)
TOP ZONE HEATER
AC POWER
RETURN
CONTROL SIGNAL (BOTTOM)
AC POWER INPUT
SOLID-STATE RELAY
(SSR)
BOTTOM ZONE
HEATER
AC POWER
RETURN
BELT1015_0
Figure 3-5: Temperature Control Loop with Separate Top and Bottom Zones
The desired temperature setpoint for each zone is programmed in the applicable WINCON recipe. The
Intellimax receives actual temperature indications from thermocouples in each zone and compares each
temperature indication with the temperature setpoint. If necessary, the Intellimax has the applicable
solid-state relays (SSRs) apply the required amount of power to each heater to maintain the temperature
setpoint.
Left-Center-Right Bias Trim
Each heated zone may be equipped with three bottom heaters, and where applicable, three top heaters as
well (Figure 3-6). The three heaters are identified as left, center, and right (as viewed from the furnace
entrance). This heater arrangement provides more precise and uniform temperature control across the
width of the conveyor belt. For your specific heater configuration, refer to Appendix A, DRAWINGS,
SPECIFICATIONS & OPTIONS.
3-14
DESCRIPTION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Figure 3-6: Left-Center-Right Heater Configuration as Viewed from Entrance End
September 26, 2007
DESCRIPTION
3-15
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
ATMOSPHERE SYSTEM
Atmosphere Control
Various features are used in conjunction with each other to process product in a controlled atmosphere.
A typical process chamber layout is illustrated in Figure 3-7.
Figure 3-7: Atmosphere Control
Dual Venturi Exhaust Stacks
Dual venturi exhaust stacks (Figure 3-8) remove process chamber exhaust from the process chamber,
and maintain a slightly positive pressure within the furnace. Flowmeters regulate the exhaust flow rate.
CAUTION!
POSITIVE PRESSURE!
Always maintain a slightly positive pressure within the process chamber! Negative
pressure could pull in outside air containing oxygen and contaminants, which could
negatively affect your process and product.
Excessive venturi exhaust flow will decrease the pressure inside the process chamber to an insufficient
level. Insufficient pressure uses more gas and degrades the process atmosphere.
Venturi exhaust stacks work by introducing nitrogen through a gas inlet on the side of the exhaust stack.
This introduction of nitrogen creates a negative pressure in the lower portion of the stack, which
removes exhausted gases from the process chamber. The venturi stack operates at approximately a 10to-1 efficiency; in other words, for every 1 LPM of gas introduced by the venturi gas inlet, 10 LPM is
removed by the exhaust stack.
As exhaust leaves the process chamber, it is heated to ensure it does not condensate and fall back into
the process chamber. As the heated exhaust enters the exhaust stack, cooling nitrogen is circulated
around the stack and exhausted into the facility duct. The resulting condensation traps some exhaust
effluents which fall into a trap fitted to the lower section of the exhaust stack.
3-16
DESCRIPTION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
3
1
4
2
6
5
TFQ EXHAUST
1
Heated exhaust assembly
3
Exhaust stack
5
Effluent trap
2
Gas supply line to venturi
4
Cooling N2 exhaust tube
6
Cooling N2 pressure gauge
Figure 3-8: Venturi-controlled Exhaust Stack
Atmosphere Curtains
Located on the entrance and exit modules, the atmosphere curtains:
• Prevent ambient atmosphere from entering the process chamber
• Remove ambient atmosphere from the incoming product
• Prevent process atmosphere from exiting the process chamber
Each atmosphere curtain assembly consists of a series of hinged, light-weight curtains, and gas-feed
plenums, located at the top or at both the top and bottom of the assembly. A flowmeter lets you manually control the gas flow to the plenum(s). The curtains provide a physical barrier, and the plenums provide a gaseous barrier between the baffle curtains. The gas typically used is nitrogen. Longer curtain
assemblies and fabric curtains are available as options.
CAUTION!
EQUIPMENT PERFORMANCE!
Do not trim or modify the atmosphere curtains.Trimming the curtains reduces the
effectiveness of this atmosphere barrier, which increases gas consumption.
If you are having issues with product clearance, call BTU Customer Service.
September 26, 2007
DESCRIPTION
3-17
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
HEATING SYSTEM
The process chamber is divided into separately controlled heated zones. Each zone has upper and lower
sections named in reference to their position, e.g., T1 indicates that the section is the top of zone 1; B1
indicates that the section is the bottom of zone 1. Individually controlled heaters are located at the top
and bottom of each zone, and some furnaces may have additional side heaters.
Product heating is done by radiation. The locations of heating elements were chosen for optimum temperature control and energy efficiency. Depending upon the configuration of your furnace, it may take
between 2 and 18 hours to heat and stabilize the process chamber. Other factors include the following:
• the size and type of muffle
• the size and type of conveyor belt
• the amount and type of insulation used
• the operating temperature range
• facility power available
Fully Enclosed Coil (FEC) Heaters
Your furnace is equipped with fully enclosed coil (FEC) heaters, which are manufactured by BTU International. These heaters consist of a iron-chromium-aluminum alloy heating element made into a resistance wire coil that is embedded in a ceramic fiber plate. The FEC heaters provide clean, continuous,
energy-efficient operation at temperatures up to 1150°C (2102°F). Heaters are located on the top and
bottom of the process chamber. Refer to Figure 3-9.
Figure 3-9: Process Chamber
Shadow Walls [Option]
Some furnaces may include optional shadow walls. Shadow walls are one-inch ceramic walls that create
a thermal barrier between heated zones and help maintain the independent thermal control in each zone
3-18
DESCRIPTION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Temperature control
Using WINCON recipes and the Intellimax controller, the temperatures within each zone are controlled
to expose product to the appropriate thermal process as it moves through the process chamber.
The specific requirements of your product will determine the temperatures required. You can set zone
temperatures to create the following “environments” within the process chamber:
• Preheat/Burnout Environment: Binder and other impurities are burned off as product is brought
to temperature in the preheat zone(s).
• Equilibrium Environment: Product temperature continues to increase in the equilibrium zones
until the entire product gets to a uniform temperature.
• Firing Environment: After the preheat and equilibrium environments, product is further heated
in a clean environment.
The necessary temperature setpoint, used to maintain zone temperature for each zone, is programmed
through WINCON software.The Intellimax controller receives the actual temperature data from a thermocouple that is located in each zone and compares this information to the programmed temperature
setpoint. The controller then opens and closes the SSRs, which apply power to each set of heaters to
maintain temperature at setpoint.
Each furnace zone has two thermocouple assemblies that measure and record the zone temperature. One
thermocouple monitors the temperature; the other provides over-temperature protection.
For a typical temperature control loop, refer to Figure 3-10.
3
2
1
4
5
6
DRYR1004R1
1
SSR
3
Intellimax
5
Heater
2
Relay Control Signal
4
Thermocouple Input
6
Power
Figure 3-10: Temperature Control Loop (Typical)
September 26, 2007
DESCRIPTION
3-19
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
COOLING SYSTEM
Product must be cooled at a controlled rate or thermal damage may occur. The cooling system provides
controlled cooling using several methods:
Passive Cooling:
• Insulated Cooling
Active Cooling:
• Water Cooling Jackets
• Case Cooling
Passive Cooling
Insulated Cooling Module
After thermal processing, product enters the insulated cooling module, which is located after the heated
zones and before the cooling module. It is here where product begins to cool by natural dissipation of
heat before entering the cooling section.
Active Cooling
Water Cooling Jackets
Water jackets, a series of copper tubes, are located on the top and bottom of the cooling muffle. Cool,
facility-supplied water is sent through the water jackets. The water absorbs and removes the heat emitted by product. To increase or decrease cooling rates, the water flow rate is adjustable. The water flow is
controlled by stop and waste valves or by optional thermostatic flow regulators. A drip tray underneath
the cooling module collects any condensation. Another set of water jackets may surround the separation
joint gasket for protection against thermal stress.
• Thermostatic Control
For furnaces equipped with water-cooled muffles, this option provides a temperature-actuated
valve inside the water supply line. A thermal probe on the water system causes the valve to open
if the temperature increases and to close if the temperature decreases.
Case Cooling
To keep the furnace case and electrical cabinet cool, BTU high-heat belt furnaces have either a casecooling fan or a series of perforated access panels located on top of the furnace, which allow heat escape
from the furnace.
3-20
DESCRIPTION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
CHAPTER 4
INSTALLATION
TABLE OF CONTENTS
Customer Site Requirements................................................................................................................. 4-2
Equipment Location................................................................................................................ 4-2
HVAC Requirements .............................................................................................................. 4-2
Exhaust Requirements ............................................................................................................ 4-3
Site Plumbing Requirements .................................................................................................. 4-3
Cooling Water Requirements.................................................................................................. 4-4
CDA and Nitrogen Requirements........................................................................................... 4-5
Electrical Requirements .......................................................................................................... 4-6
Installation Procedures .......................................................................................................................... 4-8
Receive Equipment ................................................................................................................. 4-8
Remove Crates........................................................................................................................ 4-9
Move the furnace .................................................................................................................. 4-10
Assemble Sections ................................................................................................................ 4-13
Installation Checklist........................................................................................................................... 4-15
System Startup..................................................................................................................................... 4-16
September 26, 2007
INSTALLATION
4-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
CUSTOMER SITE REQUIREMENTS
All site requirements must be understood and completed before furnace installation.
Equipment Location
• All BTU furnaces require a sturdy, level floor to support the equipment.
• Refer to the Installation Drawing located in Appendix A, DRAWINGS, SPECIFICATIONS &
OPTIONS for the exact dimensions of the furnace.
• There must be sufficient airflow around the equipment. Do not locate the equipment near doors, fans,
or other sources of draft. Drafts cause increased oxygen levels, which affects process temperature and
gas flow profiles.
• Allow sufficient clearance (36-in.) to move and perform maintenance on the equipment.
• The furnace must be positioned in a location that allows for access to the facility exhaust ducts/hood.
Store the system equipment:
If you need to store the system equipment for an extended period of time, make sure that you use a desiccant to absorb moisture and keep electrical and mechanical components dry. Calculate the requirement amount of desiccant by determining the volume of the storage container.
• in the original shipping containers
• in an area with a nominal ambient temperature of 21°C (70°F) and that is not exposed to frequent or
rapid changes in nominal ambient temperature
• in an area that is free of excessive moisture and with a nominal relative humidity between zero and 50
percent
HVAC Requirements
• Air conditioning and heating systems must be sufficient to keep the equipment within the
recommended ambient temperature range of 10 to 35°C (55 to 95°F). Recommended nominal
ambient temperature is 21°C (70°F) and the furnace should not be exposed to frequent or rapid
changes in nominal ambient temperature
• If necessary, move thermostats or heating/cooling ducts to keep the equipment within the above
recommended ambient temperature range.
• Ensure the fresh air supply equals the exhaust system volume minus any gas supplied to the
equipment (usually 80 percent of the exhaust blower requirements).
• The furnace may use gases that might promote suffocation or asphyxiation. For example, nitrogen is
consider harmless in small quantities; however, in large quantities nitrogen may prevent breathing in
a sufficient amount of oxygen to maintain proper breathing. In addition, the production process may
produce toxic gases like carbon dioxide. Be sure that the location of the furnace has sufficient
ventilation.
Humidity Requirements
The maximum dew-point requirement required for BTU International equipment is 50 percent nominal
relative humidity. This requirement is for the prevention of corrosion to electrical and mechanical components, especially components located in the electrical console and any exposed (i.e., unpainted) metal
(e.g., steel) surface. BTU International has taken precautions by coating, painting, and changing materials wherever possible to protect critical components.
4-2
INSTALLATION
September 26, 2007
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Exhaust Requirements
The following standards are provided as a guideline for installing an exhaust system that will properly
exhaust effluents from the furnace. All exhaust systems must comply with all local, state, and national
codes.
The specific utility requirements and connection locations for your furnace are located in Appendix A,
DRAWINGS, SPECIFICATIONS & OPTIONS.
NOTE: Each furnace installation is unique. Make sure that the exhaust system is sized properly to
expel furnace effluents so they do not collect indoors. Consult a qualified exhaust system
engineer, HVAC engineer, or the site facilities engineer to determine the proper exhaust system
requirements for the furnace location.
Exhaust specific guidelines:
• Sufficient fresh air must be available to compensate for the exhaust system requirements.
• To prevent fumes from the furnace from entering the room, sufficient air must be drawn into the
exhaust system to gather all effluent gases and vapors. The ratio of room air to effluent gases should
be 3:1 at the inlet. The exhaust system should be capable of handling more than the volume of gas
supplied to the furnace. For the recommended exhaust flow, refer to Appendix A, DRAWINGS,
SPECIFICATIONS & OPTIONS.
NOTE: Duct sizes are in reference to the supply connections at the furnace. The size of the pipes must
be sufficient to support the necessary volume at the furnace inlet.
• There must be sufficient clearance between the exhaust stack and exhaust hood to prevent excess
process atmosphere pull from the furnace and back pressure that can cause poor processing.
• A plugged test hole must be installed above the exhaust hood to measure static pressure readings with
a low pressure gage. These readings are used to adjust and monitor the system.
• Install a filtration system in the facility exhaust system to prevent contamination of the ducts.
• Install dampers to adjust ducts that are part of a common exhaust system (if one duct is shut you can
adjust the dampers to balance the flow to keep a steady atmosphere), to create a balance between the
entrance end and the exit end, and to keep neutral to positive pressure in the process chamber at
startup
NOTE: Exhaust temperature is related to furnace operation and damper setting.
• To sense a loss of flow in the facilities exhaust duct, wire an external pressure switch from the exhaust
duct to a terminal block provided in the furnace. This will provide an exhaust fail alarm to the system.
Refer to the Appendix A, DRAWINGS, SPECIFICATIONS & OPTIONS.
Site Plumbing Requirements
Only a full-qualified, licensed plumber shall install the plumbing system.
• Install all plumbing connections tightly.
• Install all plumbing pipes straight and with minimal bends.
• Install pipe that has the approximate diameter and minimum length.
• Keep reductions near the inlet/outlet.
• Insulate any longer plumbing pipes to prevent decreased cooling capacity.
• For connection locations refer to Appendix A, DRAWINGS, SPECIFICATIONS & OPTIONS.
September 26, 2007
INSTALLATION
4-3
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Cooling Water Requirements
CAUTION!
If you purchased a water-cooling option, make sure the water supply to the cooling
system is in place before you energize the furnace, otherwise gaskets and heat
exchangers will be damaged.
Refer to the installation drawing in Appendix A, DRAWINGS, SPECIFICATIONS & OPTIONS for all
furnace-specific water requirements. The following table contains site water cooling requirements.
Item
Requirements
Water filter
5 micron
Water filters remove particles from
facility water supply lines and protect
the re-circulating pump.
Water hardness range
Less than 200 ppm calcium
carbonate
If hard water is an issue, BTU
recommends that you install a water
softener to prevent contamination to
the heat exchangers.
Water line material
Stainless steel, copper, or plastic
Water lines may be made of a variety
of materials. Wrap water lines in
insulation to prevent condensation.
Water line connector
12.7 mm (0.5 in.) NPT
--
Pressure / Flow
30 - 85 psi at the furnace
If furnace contains the water-cooling
option, make sure there is a pressure
relief valve. Heat causes water to
expand, increasing pressure.
Measured water pressure to be
minimum of 30 psi at the furnace. The
nominal water flow is 2.5 GPM for
each heat exchanger. Make sure that
there is a difference of at least 30 psi
between the incoming pressure and
the drain.
Water temperature
range
5 (41) - 30°C (86°F) (minimum/
maximum)
Make sure that the water temperature
is within the acceptable range.
Nominal operating water 20°C (68°F)
temperature
4-4
Additional Information
INSTALLATION
The nominal water operating
temperature is 20°C. If the furnace
has a cooler, the minimum water
operating temperature can be as low
as 5°C.
September 26, 2007
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Item
Increase in water
temperature
Requirements
5°C (41°F) nominal
Additional Information
During operation, the nominal
increase in water temperature should
be approximately 5°C. The actual
operating temperature is in reference
to the current profile and furnace
settings.
If the water temperature is less than
the minimum requirements,
condensation will occur. If the water
temperature is more than the
maximum requirements, the cooling
system may not remove a sufficient
amount of heat.
Table 4-1: Recommended Cooling Water Requirements
CDA and Nitrogen Requirements
Only fully qualified personnel must calculate CDA (compressed dry air) and nitrogen requirements. For
furnace-specific requirements, refer to Appendix A, DRAWINGS, SPECIFICATIONS & OPTIONS.
CAUTION!
EQUIPMENT CONTAMINATION!
• Purge gas pipes before connecting them to the system to prevent contamination.
• Connect gas pipes to the correct facility connection to prevent system
contamination.
• Use clean, dry, oil-free nitrogen and CDA (if applicable) to prevent system contamination. A dedicated CDA line is recommended.
Air/Gas Filters
The In-Line Diffusion furnace does not have any internal air / gas filters. Install a pressure regulator and
filter in all gas / air supply lines before connection to the furnace. Refer to Figure 4-1.
• Keep the velocity of air constant. To keep the velocity of air flowing through filters constant, which
maximizes the ability of the filter to remove particulates from the air, do not decrease the size of the
airline within approximately 1 meter (about 3-ft.) before the filter.
• Compressed air must be filtered to 99.99 percent efficiency for 0.01-micron particles and droplets.
The size of the filter port must be equal to or larger than the line size to minimize the occurrence of
line restrictions.
• Install filters as close to the point of application (e.g., the spray coater) as possible. This decreases the
occurrence of additional water and oil vapor condensing after the filter.
• Install filters in a vertical position. Do not install filters downstream of quick-opening valves or
expose filters to reverse flow conditions.
• Make sure that there is sufficient space underneath the filters so that you can easily replace filters.
• Install a differential pressure gage to check the pressure decrease through the filters.
• Purge pipes that connect filters to the equipment.
• Regulators must have an accuracy of +/-1 percent of rated outlet pressure.
September 26, 2007
INSTALLATION
4-5
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
• Do not use a vented regulator for nitrogen or hydrogen if low oxygen levels are required by your
process.
• For connection locations, see Appendix A, DRAWINGS, SPECIFICATIONS & OPTIONS.
Filter Drains
Provide a facility to remove collected liquids from the filter drains using correctly sized tubing.
BTU International strongly recommends an automatic drain to decrease the amount of maintenance as
well as differential pressure gage or an indicator to monitor the pressure decrease among the filters. This
provides a method to visual monitor the condition of filter elements.
• Install a drain to collect liquid removed by filters.
• Install an automatic drain at the compressor.
• Make sure there are no obstructions in the drain pipe.
1
2
3
7
4
5
6
7
8
7
9
10
11
1
Air purifying system [Option]
5
Pre-filter
9
2
Oil-free compressor
6
Fine filter
10 Air dryer
11 Drain flow
3
Aftercooler
7
Bypass valves
4
Separator
8
Air filter
Flow out
Figure 4-1: CDA / Gas Filter Recommendations (Typical)
Electrical Requirements
The utility requirements and connection locations for your specific furnace are located in Appendix A,
DRAWINGS, SPECIFICATIONS & OPTIONS.
• Electrical installation shall only be performed by a licensed electrician.
• Electrical connections can be brought into the furnace by punching through the top cover, end
panel or furnace floor in the area of the electrical disconnect switch.
• Electrical conductors must be protected by conduit or tubing according to local and national
electrical codes.
• Power wiring connections should be at the main disconnect switch and at the main disconnect
switch and main ground block.
• Ensure that all electrical conductors and terminations are fully shrouded and protected. There
should be no exposed live conductors or terminations.
4-6
INSTALLATION
September 26, 2007
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
• Ensure that main incoming power cables are not in contact with any hot surfaces, sharp or rough
edges, or any other potentially damaging surfaces.
• This electrical installation must be inspected by your local authorized electrical inspector prior to
being energized.
DANGER!
ELECTRICAL HAZARDS!
The furnace uses dangerous levels of high-voltage, high-amperage electricity. Highvoltage, high-amperage electricity may cause severe personal injury or death.
To prevent electrical hazards:
• Do not perform any procedure by yourself. Always have at least one other person
working with you in case an emergency situation occurs.
• All electrical connections shall be performed by a licensed electrician and done in
reference to all applicable codes and laws.
• Make sure the furnace is grounded properly in reference to your local electrical
codes. In the United States, refer to the National Electrical Code published by the
National Fire Protection Association.
• Do not wear any jewelry (e.g., rings, ear rings, necklaces, watches, etc.) while
performing any procedure involving the electrical system. Jewelry is often
conductive, and may come in contact with energized circuits.
• If you do not obey all the safety precautions listed in this manual and any other
associated documents, you risk the occurrence of serious injury or death and a
cancelled manufacturer's warranty.
September 26, 2007
INSTALLATION
4-7
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
INSTALLATION PROCEDURES
Receive Equipment
Procedure Category:
Type 1
Special Tools:
None
Related Documents:
• Packing list
• Damage claim (if necessary)
Exit Criteria:
The furnace has been received correctly. All components have been
identified and verified in reference to the packing list. If necessary, a
damage claim has been filed.
To receive the equipment:
Equipment is shipped on skids (small items) and in wooden crates. Keep packing materials until you do
a full incoming inspection. If more than one furnace is delivered, keep parts with the correct furnace.
NOTE: Not all items may be applicable to your furnace.
Items that may be packed separately from the furnace
Light tower
Manuals with Software
Personal Computer
Uninterruptible Power Supply [option]
Monitor
Oxygen Analyzer [option]
Keyboard
Spare Parts Kit [option]
Adjustable Legs
Special Tools [option]
Perform an incoming inspection:
4-8
1
Verify that all equipment on the packing list is received.
2
Inspect components for visible signs of damage done in transit. If you find damage:
a
Sign the delivery receipt. Verify that you recorded the visible damage and immediately notify
the carrier of the damage.
b
In the USA, file a damage claim with the transportation carrier under the regulations of the
Interstate Commerce Commission.
c
If you need more information for insurance purposes, call BTU International.
INSTALLATION
September 26, 2007
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Remove Crates
Procedure Category:
Type 1
Special Tools:
•
•
•
•
Related Documents:
None
Pry bar, crow bar or flat claw bar
Claw hammer
Keyhole saw for metal (or an electric reciprocating saw)
Heavy duty cutting pliers or bolt cutter
To remove the shipping crates:
1
Pull the plywood end pieces from the wooden frame enough to slip in a saw blade or cutting tool.
(Nails can break through the plywood.)
NOTE: Be careful of nails when you disassemble the crate. Exposed nails can cause personal injury or
equipment damage.
2
Cut the nails with a saw, heavy duty cutting pliers or bolt cutter.
3
Remove the plywood end pieces. This allows you to see inside the crate so that you can plan the
removal procedure.
4
Pull the plywood side pieces from the wooden frame enough to slip in a saw blade or cutting tool.
(Nails can break through the plywood.) The frame studs of the crate are now exposed.
5
Pull the bottom frame studs from the skid.
6
Cut the nails with a saw, heavy duty cutting pliers or a bolt cutter.
NOTE: Do not the remove furnace from the skid until it is moved to a permanent location.
7
You can continue to disassemble the crate from the top and sides, or lift the entire crate.
8
Discard the crate.
September 26, 2007
INSTALLATION
4-9
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Move the furnace
Procedure Category:
Type 1
Special Tools:
Forklift Method
• Heavy-duty industrial casters or dollies
• Two heavy-duty forklift trucks or one overhead crane
Crane Method
• Lifting jack
• Two lifting straps
• Crane support
• Four 5 by 21 cm (2 by 8 in.) wood boards, 5cm (2-in.) longer than furnace
width)
Related Documents:
None
WARNING!
THE OWNER’S RESPONSIBILITY!
BTU International is not responsible for any damage that occurs to the furnace if you
unpack and move the furnace yourself. Read the following procedure carefully. If
you have any doubt about how to move the furnace, DO NOT MOVE THE furnace,
and contact BTU International Customer Service; otherwise, severe personal injury
or equipment damage may occur.
WEIGHT HAZARD!
The furnace weighs more than two tons! When moving the furnace, take all
necessary precautions to prevent any body parts from any potential crush hazards;
otherwise, severe personal injury or equipment damage may occur.
EQUIPMENT DAMAGE!
• Do not remove the furnace from the shipping skid until you have put the furnace in
a permanent location; otherwise, you may cause severe equipment damage.
• Do not lift or move the furnace from any location other than the furnace lift points;
otherwise, you may cause severe equipment damage.
• If the furnace is more than 30 ft. long, do not try to move it. It must first be disassembled into smaller sections; otherwise, you may cause sever equipment
damage and injuries to personnel.
• Do not attach components to one another until the furnace is in the final position.
To move the furnace:
4-10
1
Mark the equipment footprint on the building floor. For dimensions, refer to Appendix A,
DRAWINGS, SPECIFICATIONS & OPTIONS.
2
Remove all hardware that attaches the equipment to the shipping skid.
3
Remove the side and top panels. Refer to page 7-4, Removing Access Panels.
INSTALLATION
September 26, 2007
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Forklift Method:
a
Put the forklift tines through the ends of the skid until they touch the component lifting areas.
b
Lift the end until there is sufficient clearance to put an industrial dolly under the skid at the lift
point (Figure 4-2).
c
Lower the skid onto the dolly and remove the forklifts.
d
Move the furnace over the market footprint.
e
Position the forklift tines under the furnace lift points (over the skid).
f
Remove the bolts securing the furnace to the skid.
g
Lift the furnace off the skid.
h
Install the leveling feet in the holes that were used to secure the furnace to the skid.
i
Remove the skid and the casters or dollies.
j
Lower the furnace onto the marked footprint.
k
Store or discard the shipping skid.
Overhead Crane Method:
a
With a lifting jack, lift the sides, one at a time, and put the lifting straps in position under the
lift points.
CAUTION!
EQUIPMENT DAMAGE!
Do not jack the entrance or exit ends of the furnace. Damage from concentrated
weight will result.
Do not use the overhead crane without using wooden supports to spread the lift
straps; otherwise the furnace may be damaged.
b
Put the wooden supports in position to spread the lifting straps as shown (Figure 4-2).
c
Remove force from the slings. Make sure that the supports do not move.
d
Remove the bolts securing the furnace to the skid.
e
Lift the furnace off the skid.
f
Install the leveling feet in the holes that were used to secure the furnace to the skid.
g
Remove the skid.
h
Position and lower the furnace over the marked footprint.
i
Remove the lifting equipment.
j
Store or discard the shipping skid.
September 26, 2007
INSTALLATION
4-11
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
2
1
3
4
5
1
Lifting Equipment
4
Lifting Points
2
Exit Table (Removed)
5
Entrance Table (Removed)
3
Skid
Figure 4-2: Equipment Lifting Points
NOTE: The above drawing is for illustration only and may not look exactly like your furnace.
4-12
INSTALLATION
September 26, 2007
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Assemble Sections
In-Line Diffusion furnaces are shipped in many parts that require assembly by BTU field service personnel. Customers may assemble the furnace sections, in preparation for final installation.
Contact BTU International to prearrange your furnace installation.
Procedure Category:
Type 1
Special Tools:
• Floor jack
• Torque wrench, 80 in.-lb.
Related Documents:
None
To assemble the furnace:
1
Remove the clamps from the frame assemblies.
2
Level the largest section.
3
Adjust each section so that they touch each other (Figure 4-3). (Look through the process chamber
and make sure that you cannot see anything that comes out of the inside walls.)
4
If equipped, make sure that the muffle joint adjustment is aligned at the top, sides, and bottom (no
ridges or offsets at the joints).
5
Level each section to the larger section before attaching.
1
1
2
3
6
5
4
1
Atmosphere Curtains
3
Entrance Sections
5
Cooling Section
2
Gas Plenums
4
Heating Section
6
Exit Section
Figure 4-3: Aligning Sections
September 26, 2007
INSTALLATION
4-13
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
CAUTION!
EQUIPMENT DAMAGE!
If silicone rubber gasket is used, do not overtighten and compress the flange gasket
to less than two-thirds of its original thickness. Over tightening can cause damage to
the gasket. Do not use more than 70 in.-lb. of torque on the clamp screws or flange
bolts.
6
For systems with flange bolts: Sequentially tighten each bolt a little at a time until its split lock
washer is flattened (Figure 4-4).
7
If equipped, install the flange clamp assemblies (Figure 4-4). After assemblies are installed, tighten
each clamp screw in sequence until all assemblies are tightened evenly.
2
1
3
4
A
DOT
A
5
B
6
7
8
9
B
Section A-A
Section B-B
1
Entrance Table
4
Exit Table
7
Clamp
2
Heating Section
5
Process Chamber
8
Flange
3
Cooling Section
6
Heating Section
9
Cooling Section
Figure 4-4: Join Sections with Clamps
4-14
INSTALLATION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
INSTALLATION CHECKLIST
Use the following installation checklist to make sure that installation is complete before you start the
equipment:
• Facility design requirements have been met (site and space)
• Environmental requirements have been met
• Exhaust requirements have been met
• Plumbing requirements have been met
• Electrical requirements have been met
• Equipment is received and checked
• Equipment is moved into place
• Equipment is assembled and level
• Belt has been installed
• All options are installed
• Utilities are connected
After installation is complete, the equipment is ready to start.
September 26, 2007
INSTALLATION
4-15
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
SYSTEM STARTUP
WARNING!
READ!
• Read this manual in its entirety before you install, operate, troubleshoot or
maintain the furnace.
• Read a procedure in its entirety before you perform it.
• Always note and take any safety precautions recommended in this manual and
other documentation before you perform any procedure; otherwise, severe
personal injury or equipment damage may occur.
QUALIFIED PERSONNEL!
• Procedures include working with high amperage, high voltage and moving parts.
• Procedures must be performed by fully trained, fully qualified personnel.
• Most procedures require advanced knowledge of electrical, mechanical, and
plumbing theories and issues.
• DO NOT PERFORM THE PROCEDURE IF YOU HAVE ANY DOUBTS ABOUT
HOW TO ACCOMPLISH THE TASKS INVOLVED. Contact BTU International
Customer Service; otherwise, severe personal injury or equipment damage may
occur.
• If you do not obey all the safety precautions listed in this manual and any other
associated documents, you risk the occurrence of death or serious injury to
personnel, equipment and or facility damage, and a cancelled manufacturer's
warranty.
The furnace was fully tested at the BTU factory before being shipped to you. If you operate and maintain the furnace in reference to the procedures listed in this manual, it will provide you with many years
of reliable service and product of the highest quality.
If you are familiar with the equipment and know that the equipment and utilities are installed correctly,
you can start the furnace yourself. If you prefer factory service personnel to start the furnace, you can
request System Startup Service from BTU.
4-16
INSTALLATION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
CHAPTER 5
OPERATION
TABLE OF CONTENTS
General .................................................................................................................................................. 5-2
Summarized Checklist........................................................................................................................... 5-2
Calculate Cover Gas Flow (All Furnaces) ............................................................................................ 5-2
Common Measurements ......................................................................................................... 5-3
Calculate the Per-minute Volume of Cover Gas .................................................................... 5-3
English Measure (Example).................................................................................................... 5-3
Metric Measure (Example) ..................................................................................................... 5-4
Calculate Atmosphere Curtain Flow Rates............................................................................. 5-4
Start and Operate................................................................................................................................... 5-4
Normal Shutdown ................................................................................................................................. 5-7
Emergency Shutdown ........................................................................................................................... 5-8
Idle the Furnace..................................................................................................................................... 5-8
System Alerts and Alarms..................................................................................................................... 5-8
Alerts....................................................................................................................................... 5-8
Alarm ...................................................................................................................................... 5-8
Respond to Interlock and Alarm Conditions ........................................................................ 5-10
Recover from an Over-temperature Condition ..................................................................... 5-11
Operate Options................................................................................................................................... 5-13
Operate the Belt Cleaners ..................................................................................................... 5-13
Operate the Hand Crank [Option]......................................................................................... 5-13
Operate the O2 Analyzer [Option] ........................................................................................ 5-13
Operate the Product Feed Conveyor [Option] ...................................................................... 5-13
WARNING!
Obey all safety precautions when you operate and maintain the equipment.
Otherwise, personal injury and equipment can result.
Only qualified personnel should operate and maintain the equipment.
September 26, 2007
OPERATION 5-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
GENERAL
• This chapter gives instructions to operate the furnace. Read this manual and WINCON Online Help
before you operate the equipment.
• Your equipment may not include all of the options listed in this chapter.
• For a description of the main control panel, refer to page 3-11, Operator Control Panel.
SUMMARIZED CHECKLIST
Table 5-1: Summarized Checklist
Step
Item
1
Calculate the necessary gas flows
2
Turn on the gas supply to the furnace
3
Make sure that the atmosphere curtain assemblies are in the correct position
4
Make sure that the facility exhaust fan is operating
5
Energize the furnace
6
Turn on the cooling H2O supply
7
Pull out all EMO buttons
8
Start the computer and WINCON furnace control software
9
Set up and run a recipe for the furnace controller including temperature, speed, and
optional equipment
11
Set the necessary cover gas flows
12
Set the flowmeters for gas flow to the atmosphere curtains
13
Press START/RESET pushbutton (energizes conveyor and heaters)
15
Energize any optional equipment
21
When the monitor displays Ready, load product
* * * After You Run a Profile of the Product * * *
22
If necessary, adjust the left-center-right heaters in WINCON
24
Only if necessary, adjust the gas flows at the flowmeters
NOTE: Do not change the atmosphere curtains. This decreases the effectiveness as an atmosphere
barrier and increases O2 levels in the process chamber. Make sure that there is sufficient
clearance between the product to keep three curtains minimum in the down position.
CALCULATE COVER GAS FLOW (ALL FURNACES)
Use this procedure to calculate a safe cover gas flow for the process chamber and N2 purge gas for the
plenums inside the atmosphere curtains. Use the results in the start procedure.
5-2
OPERATION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Common Measurements
Table 5-2: Common Measurements
Dimension
Definition
Metric System or Système International
cm
Centimeter, one hundredth of a meter
cm3
Volume within cube measuring 1 x 1 x 1 cm
LPM/LPH
Liters per minute/liters per hour; measure of flow
English Common (or Customary) Measure
ft
Foot, unit of linear measure equal to 12 in. or 1/3 yd
ft3
Volume within cube measuring 1 x 1 x 1 foot; equal to 1728 in.3 1 ft3 = 28.317 liters
in.
in.
Inch, unit of measure equal to 2.54 cm
3
Volume within cube measuring 1 x 1 x 1 in.
gpm
Gallons per minute; 1 (U.S.) gallon equals 3.7852 liters; measure of flow
Calculate the Per-minute Volume of Cover Gas
1
Measure the muffle width, length, and height (including heating and cooling sections, but not the
area beneath the atmosphere curtains).
2
Calculate the volume of the process chamber as follows: Volume = Width x Length x Height
3
Based on the recipe to be run, select the number of atmosphere changes needed per hour to provide
sufficient gas flow (30 is typical).
4
Convert cubic feet per hour (or cubic centimeters per hour) to liters per minute (lpm) and adjust
flowmeters to process chamber and cooling system.
English Measure (Example)
Calculate gas flow for a muffle 15 in. wide, 240 in. long, 8 in. high.
1
Find volume of muffle: 15 x 240 x 8 in. = 28,800 in.3.
2
Divide 28,800 in.3 by 1728 (in.3 in one ft3) = 16.66 cubic ft.
3
Convert 16.66 ft3 to liters (1 ft3 holds 28.317 liters) = 472 liters static volume.
NOTE: For entrance and exit curtains, the change per hour must be 120.
4
Multiply static volume by gas changes per hour: 30 x 472 = 14,160 LPH.
5
Divide 14,160 LPH by 60 min = 236 LPM.
September 26, 2007
OPERATION 5-3
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Metric Measure (Example)
Calculate gas flow for a muffle 38 x 610 x 20.3 cm.
1
Find volume of muffle in cm3: 38 x 610 x 20.3 cm = 470,554 cm3.
2
Divide cm3 by 1000: 470,554/1000 = 471 dm3 static volume.
3
Convert dm3 to liters: 471 dm3 = 471 liters static volume.
NOTE: For entrance and exit curtains, the change per hour must be 120.
4
Multiply static volume by changes/hour: 30 x 471 liters = 14,130 LPH.
5
14,130 LPH / 60 = 235.5 LPM.
Calculate Atmosphere Curtain Flow Rates
1
Calculate the amount of gas that must flow from the plenums:
a
b
Measure the width, length, and height of the area under the atmosphere curtains at the entrance
of the muffle.
Calculate the volume under the atmosphere curtains at the entrance as follows: Volume =
Width x Length x Height
c
If measured in inches, convert this volume to ft.3 by dividing by 1728 and multiplying by
28.317 to find the number of static liters.
d
If measured in cm, divide cm3 by 1000 to find the number of dm3, which equals the number of
static liters.
e
If atmosphere quality is not critical, enter the volume in static liters (lpm). If atmosphere
quality is critical, double the static liters.
2
Calculate forming gas flow to the exit atmosphere curtain. Make sure that total purge gas flow to
the atmosphere curtains exceeds the total amount of the cover gas flow.
3
Monitor the O2 and dewpoint readings in the process chamber, and adjust the flow to the
atmosphere curtains if necessary. Increased O2 or dewpoint indications need more atmosphere
curtain flow rates.
4
The furnace is ready to start.
START AND OPERATE
WARNING!
Make sure that all gas input lines are connected to the correct inlets.
5-4
OPERATION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
NOTE: Each furnace is made for specific processes at specific temperature profiles and belt speeds.
Because furnace configurations and processes are furnace specific, the settings for gas flows,
zone temperatures, and belt speed are process dependent and not given.
1
Make sure all installation procedures are done.
2
Make sure that the atmosphere curtains are in the correct position.
3
Turn on the facility electric power to the equipment.
4
Remove the lockout/tagout. Refer to page 2-10, Lockout / Tagout Procedure.
5
Set the main power disconnect switch to ON.
6
Make sure the facility exhaust fan operates correctly. Open each butterfly damper.
NOTE: Do not use too much exhaust flow, as it can alter the process atmosphere in the furnace. Set
the exhaust flow on high to ensure that exhaust is removed from the exhaust stacks and
furnace entrance area. Do not set it so high that a negative pressure is created in the process
chamber.
7
Set the exhaust dampers or balance valves according to your process needs.
NOTE: The ideal H2O temperature depends on the necessary profile and furnace operating settings. If
the temperature decreases below the minimum, condensation can occur. If the temperature
increases above the maximum, sufficient heat might not be removed to cool the product and
protect the cooling system.
The H2O temperature must stay within the limits. The nominal H2O operating temperature for
your furnace is 20°C (68°F). If you are operating the furnace with a H2O cooler, the minimum
operating temperature can be as low as 5°C (40°F). If the H2O is filtered, close the H2O filter
bypass line.
8
Set the flowmeters for a safe gas flow to the atmosphere curtains.
NOTE: Before heatup, puge the furnace using nitrogen at the recommended flow rates for 30 minutes.
Purging the furnace, prevents oxidation of the belt from occuring under heated conditons.
9
Turn on the cooling H2O supply, if applicable.
10 Press MASTER START. (The conveyor system and heaters start up when DRIVE and HEAT are set
to ON and a recipe is enabled.)
11 Set DRIVE and HEAT to ON.
12 Start the computer and refer to WINCON Online Help for assistance in using WINCON to operate
the furnace. Equipment status (Table 5-3) is displayed in the upper left-hand corner of the monitor.
Table 5-3: Equipment Status in WINCON
Item
Function
INIT
Shows when the computer is first energized and establishing a link between the computer
and the Intellimax.
IDLE
Shows when the system is energized without any heater power energized.
September 26, 2007
OPERATION 5-5
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Item
Function
SETUP
Shows when a recipe is run and the heat is being stabilized. It stays in setup mode until
certain alert/alarm conditions are met.
READY
Shows when the furnace is stabilize and setup is complete.
13 For each zone, type a temperature setpoint in your WINCON controller recipe.
14 Unless told otherwise, use the coefficients in Table 5-4.
Table 5-4: Recommended Initial Temperature Control Coefficients
Proportional Band
Temperature Range
High
Low
Rate
Reset
150 to 300°C
20
20
2.0
0.05
300 to 400°C
20
20
1.8
0.10
400 to 500°C
15
15
1.5
0.10
500 to 750°C
15
15
1.3
0.15
750 to 1000°C
15
15
1.0
0.20
15 For accurate temperature control, adjust these entries as needed. When the operating parameters are
programmed in the recipe, they can be run. This process of adjusting temperatures is discussed in
PID Temperature Control in WINCON Online Help. If you require additional assistance, contact
Customer Service.
NOTE: Temperature ramp parameters are set at the factory, cannot be changed, and are available in
WINCON for viewing only. The ramp rate a quartz furnace is intentionally slow, as indicated in
Table 5-5.
Table 5-5: Factory Set Temperature Ramping
Temperature Ramp Rates
Temperature °C
Rate °C / Minute
1
25 - 200
5.0
2
200 - 280
0.5
3
280 - 550
5.0
4
550 - 600
0.5
5
600 - Operating
5.0
16 Run the processing recipe in WINCON.
17 Change flowrate as follows:
a
Examine the flowmeters for the correct flowrates to the entrance and exit curtains.
NOTE: The stack slot shows the position of the damper plate. When the slot is vertical, the valve is
open. When the nut is tight, the stack nut forms a gas-tight seal.
b
Adjust the exhaust butterfly valve on the exhaust stack.
• Loosen the nut.
• Use a screwdriver to set the valve to the correct setting.
5-6
OPERATION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
• Tighten the nut.
c
When you profile product, you can adjust the venturi valves for more or less exhaust gas.
d
Examine O2 in the process chamber, and adjust the flow to the atmosphere curtains if
necessary. To prevent room air from coming into the furnace, adjust the entrance and exit
curtain gas flows to a rate that is slightly higher than your cover gas flow rate.
e
After you profile the equipment to calculate the actual temperatures that the product
encounters, you can adjust the temperature setpoint for specific heater sets (refer to WINCON
Online Help). Heater output trim is available by the conveyor belt width):
• 9-in. (0.139 m) belts: no trim
• 14-in. (0.357 m) belts: center and side trim
• 25-in. (0.637 m) belts: left, center, and right trim
18 When WINCON status displays READY, load product on the conveyor. The system begins to
process product in reference to the selected recipe. As each product completes processing, it moves
onto the exit table for removal or transport to an adjoining piece of equipment.
CAUTION!
Product that exits the furnace is hot. Use protective gloves to handle product. Keep
hands away from moving parts when the power is on.
NOTE: All process functions (except gas flows) are controlled by the furnace controller. Zone
temperature settings depend on the process recipe being run. The zone temperatures are
programmed through the furnace controller, which keeps accurate temperature setpoints
through PID temperature control loops (refer to WINCON Online Help).
NORMAL SHUTDOWN
CAUTION!
Shut down the furnace with a COOLDOWN or SHUTDOWN recipe.
1
Remove all product from the furnace.
2
Run your cooldown recipe until the furnace is cool (less than 100°C).
3
Exit WINCON before shutting down power to the computer.
4
Do the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
September 26, 2007
OPERATION 5-7
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
EMERGENCY SHUTDOWN
Refer to page 2-13, EMO (Emergency Off).
CAUTION!
DO NOT USE THE EMO AS NORMAL SHUTDOWN
Do not press an EMO except in an emergency. Using the EMO button as the normal
shutdown can severly damage your system.
IDLE THE FURNACE
When not processing product, operate in idle mode (decreased temperature, decreased N2 flow, and
decreased belt speed). This saves gas and power and decreases restart time.
• Operate at an idle temperature of 100°C or 200°C below the usual operating setpoint.
• The decreased N2 flow must be set at the minimum possible flow that is sufficient to prevent
room air from entering the furnace.
• Reduce belt speed to a minimum to decrease air intake into the furnace and decrease heat transfer
to the cooling section.
SYSTEM ALERTS AND ALARMS
System alarms occur for various reasons. When there is a system alarm, the system sounds an audible
alarm that shows operator action is necessary. With the light tower, the red light comes on. Refer to
Chapter 6, TROUBLESHOOTING.
NOTE: For a description of the optional light tower, refer to page 3-12, Light Tower.
Alerts
An alert is a visual indication that temperature or pressure is more than the limits. When there is an
alert:
• A yellow light on the light tower comes on
• New Alarms message displays on the screen with the blinking ALERT (yellow)
• Process State button shows a yellow box with the word ALERT
• Operator action is necessary. Find the cause of the alert and correct the problem. Do the same as
an alarm condition.
Alarm
An alarm is an audible and visual indication of a critical problem. When there is an alarm:
• There is an audible alarm
• The red light on the light tower comes on
• A red ALARM window appears on the monitor screen in a red box
5-8
OPERATION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
If there is an alarm, do as follows:
1
Select Acknowledge in the ALARM window to silence the alarm. The alarm displays until it is
cleared. A New Alarm window is displayed (alarm type in red).
2
Location, type, date, and time show as follows:
• Yellow shows the location and type of alert condition
• Red shows the location and type of alarm condition
• Alerts and alarms are listed from latest to earliest
3
Access the Alarm Status window by doing one of the following steps:
• Click the yellow or red process state buttons (ALERT or ALARM displays).
• Choose Status > Alarms.
4
Locate and correct the condition that caused the alert or alarm.
NOTE: You can not clear an alert or alarm until the problem is corrected.
5
Press the Clear button on the alarm screen.
6
If the alarm sounds again, select Acknowledge Alarms. For more information, refer to WINCON
Online Help.
NOTE: Turn the outer ring on the alarm device (on the operator control panel) to set the volume of the
alarm.
September 26, 2007
OPERATION 5-9
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Respond to Interlock and Alarm Conditions
For interlock alarm conditions and recovery procedures, refer to Table 5-6. Recovery procedures
assume that you have first acknowledged an alarm.
Table 5-6: Interlock and Alarm Conditions and Recovery
Condition
Emergency Stop
Subsystem Status
Heaters Off
Conveyor Off
Computer On
Result
Action
All furnace subsystems are de- 1. Reset EMO.
energized and alarm is shown 2. Press RESET/ START on
in NEW ALARM dialog box.
control panel.
3. Clear alarm in WINCON.
4. Restart recipe.
Belt Motion
Heaters On
Conveyor On
Belt Speed Deviation
Heaters On
Conveyor On
Proximity switch senses
stopped idler pulley and alarm
is shown in NEW ALARM
dialog box.
1. Check shear pin.
Alarm is shown in NEW
ALARM dialog box.
1. Check WINCON Deviation
setting.
2. Check proximity switch setting to
sprocket.
3. Clear alarm in WINCON.
2. Check belt movement.
3. Correct as required.
4. Clear alarm in WINCON.
Temperature
Deviation
Heaters On
Conveyor On
Alert / Alarm
Thermocouples in heating
zones send signal to Intellimax
indicating temperature is not
within the limits, an alarm
shows in the NEW ALARM
dialog box (refers to heating
zone number).
1. Check temperature Delta
between zones.
2. Check for current, if below
setpoint.
3. Check for no current if above
setpoint.
4. Check Deviation Alarm setpoint.
5. Reset alarm in WINCON.
Over-temperature
Heaters Off
Conveyor On
Thermocouple in heated zone
sends signal to the
OverTemperature Unit
indicating temperature has
exceeded setpoints. Alarm
shows in the NEW ALARM
dialog box.
1. Examine LEDs in the OTM to
find defective heating zone, and
correct problem.
2. Press RESET/ START on
control panel.
3. Reset alarm in WINCON.
4. Restart recipe.
Belt Stretched
Heaters On
Conveyor On
Switch on bottom of ultrasonic
cleaner tank senses belt is
touching. Alarm is displayed in
NEW ALARM dialog box.
1. Stop conveyor.
2. Shorten conveyor belt.
3. Start conveyor
4. Clear alarm in WINCON.
5. Restart recipe and monitor belt
tracking.
H2O Flow Failure
Heaters Off
Conveyor On
5-10
OPERATION
The H2O flow switch senses
low H2O flow in the outflow
pipe. Low H2O Flow alarm
shows in the NEW ALARM
dialog box.
1. Restore H2O flow.
2. Clear alarm in WINCON.
3. Restart recipe.
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
Condition
TM 5259111 Rev. 0
Subsystem Status
Low N2 Pressure
Heaters On
or
Conveyor On
Low Air Pressure
Low O2 Pressure
Heaters On
Conveyor On
Gas Preheaters Flow
Gas Heaters Off
Conveyor On
Result
Action
The pressure switch for Low
N2 or Air has dropped below
setlimit (9 psi). Low N2 / Air
Pressure alarm shows in New
Alarm dialog box.
1. Restore gas pressure.
The pressure switch for Low
O2 has dropped below setlimit
(9 psi). Low O2 Pressure alarm
shows in New Alarm dialog
box.
1. Restore gas pressure.
Gas flow has dropped below
setting on flow switch.
1. Check flow switches below gas
panel (gauge needle is to the
right).
Low Flow Burn-out or Firing
Section alarm shows in New
Alarm dialog box.
2. Clear controller alarm in
WINCON.
2. Clear controller alarm in
WINCON.
2. Adjust flowmeter for Burn-out or
Firing section.
3. Clear alarm.
Open Heater alarms
Main Heat Contactor On
• Furnace Heat
Zones
Conveyor On
Alarm shows in New Alarm
dialog box.
1. Check circuit breakers for failed
heater in Alarm dialog box.
• Belt Dryer Heater
2. Check green light on SSR (Refer
to schematic in Appendix A,
DRAWINGS, SPECIFICATIONS
& OPTIONS).
• Incerator Heaters
3. Check current using amp meter.
• Gas Pre-heaters
Water
OverTemperature
Heaters Off
Klixon sensor on H20 drain has
exceeded its limits.
Conveyor On
1. Check H20 flow.
2. Clear alarm in WINCON.
3. Restart recipe.
Recover from an Over-temperature Condition
Procedure Category:
Type 1
Special Tools:
None
Related Documents:
None
To recover from an over-temperature condition:
NOTE: The OverTemperature Unit setpoints are preset at the factory (to 25°C (77°F) over WINCON
limits) and should not be changed.
Each heated zone is monitored by an OverTemperature thermocouple that is independent from
the zone control circuitry.
If any zone is more than the preset safe maximum temperature, the OverTemperature Unit deenergizes all heater power, and sounds an alarm.
The conveyor continues to operate so that you can remove product.
1
Find the OverTemperature Unit. Location varies on each furnace.
September 26, 2007
OPERATION 5-11
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
2
Remove the applicable access panels. Refer to page 7-4, Removing Access Panels.
3
Find the energized LED on the OverTemperature Unit.
• The LED indicates the furnace zone that activated the OverTemperature Unit (Figure 5-1).
• The OverTemperature Unit thermocouple inputs are labeled with the corresponding zone number.
• Also, refer to Appendix A, DRAWINGS, SPECIFICATIONS & OPTIONS for the overtemperature channel/zone assignment.
NOTE: The over- temperature condition must be corrected before you reset the OverTemperature Unit.
4
Find and correct the cause of the over-temperature condition. As each alarm input is found and
corrected, the corresponding channel alarm LED is de-energized.
5
On the master control panel, press START/RESET. The OverTemperature Unit is reset and the
heaters are energized.
6
Examine equipment operation.
1
24-VDC power
4
Reset input from the furnace
7
Power LED indicator
2
Relay contact output (This deenergizes the heater contactor.)
5
Thermocouple type selection
switch
8
Thermocouple inputs
3
Open collector outputs
6
Reset button
Figure 5-1: OverTemperature Unit
5-12
OPERATION
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
OPERATE OPTIONS
Operate the Belt Cleaners
Controls for the ultrasonic belt cleaner are integrated into the software package. Refer to WINCON
Online Help for more information.
Operate the Hand Crank [Option]
The conveyor belt stops if a power failure occurs or if the conveyor drive system fails. You can remove
product from the furnace as follows:
1
Remove the hand crank from its storage location at the exit end of the furnace, and plug it into the
tension pulley drive shaft.
2
Turn the hand crank until all product is removed from the furnace.
WARNING!
If the furnace starts with the hand crank engaged, the crank can turn and cause
injury.
3
Remove the hand crank and return it to its storage location.
Operate the O2 Analyzer [Option]
Refer to Appendix E, VENDOR MANUALS.
Operate the Product Feed Conveyor [Option]
If you have a product feed conveyor at the entrance, observe the following precautions to ensure correct
product transfer and prevent misloading:
1
Set the height of the feed conveyor equal to or slightly more than the height of the entrance
conveyor belt.
2
Set the feed conveyor speed slightly slower than the conveyor belt speed.
September 26, 2007
OPERATION 5-13
TM 5259111 Rev. 0
5-14
OPERATION
IN-LINE DIFFUSION SYSTEM MANUAL
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
CHAPTER 6
TROUBLESHOOTING
WARNING!
Troubleshooting techniques covered in this chapter require the removal of safety
shields and will expose hazardous voltages, temperatures and mechanical
hazards.
Obey all safety precautions when you operate and maintain the equipment.
Otherwise, personal injury and equipment can result.
Properly dispose of all hazardous waste.
Only qualified personnel should operate and maintain the equipment.
Refer to Chapter 1: INTRODUCTION for the recommended tools.
TABLE OF CONTENTS
Troubleshoot the Frame and Panel System ........................................................................................... 6-2
Troubleshoot the Conveyor System ...................................................................................................... 6-2
Troubleshoot the Temperature System ................................................................................................. 6-5
Troubleshoot the Atmosphere System .................................................................................................. 6-7
Troubleshoot the Exhaust System ......................................................................................................... 6-8
Troubleshoot the Furnace Controller System........................................................................................ 6-8
September 26, 2007
TROUBLESHOOTING 6-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
TROUBLESHOOT THE FRAME AND PANEL SYSTEM
No Applicable Procedures.
TROUBLESHOOT THE CONVEYOR SYSTEM
Refer to Table 6-1.
Table 6-1: Troubleshoot the Conveyor System
Problem
Conveyor system runs at erratic
speeds
Curled belt
Conveyor belt drive pulley slips under
load
6-2
TROUBLESHOOTING
Possible Cause
Possible Solution
Blocked process chamber or belt
edges catching on sides of process
chamber
Make sure that there is a 0.9 cm (0.375
in.) gap between the belt edge and the
interior of the process chamber. If the
belt touches the bricking, there will be a
white residue on the belt. Refer to page
7-7, Examine and Adjust Conveyor
Belt Tracking.
Defective drive motor shaft encoder
(incorrect position, loose wires, or
EMF).
Examine encoder, replace if necessary.
Incorrect pressure on snub roller
Increase pressure on snub roller pulley.
Shear pin assembly or torque limiter
assembly
Inspect setscrew or torque limiter.
Worn drive motor brushes
Examine the motor brushes for wear. If
worn, replace the brushes. Refer to
page 7-26, Replace Drive Motor
Brushes.
Defective drive motor
Replace motor.
Loose drive sprocket set screws
Tighten set screws on drive sprocket.
Defective or incorrectly adjusted drive
chain and sprockets
Adjust or replace if necessary. Refer to
page 7-23, Examine and Adjust Drive
Chain Tension.
Contamination on belt.
Clean belt.
Continuous operation of furnace at
high temperature (especially with
heavy product loads)
1. Periodically turn the belt over. This
increases the life of the belt.
Belt speed is slow or belt has stopped
in a hot furnace
Increase belt speed or avoid stopping
the belt in a hot furnace.
Worn out belt
Replace the belt.
Loosen pressure pulley tension on
drive pulley assembly
Adjust the drive pulley tension. Refer to
page 7-24, Fill Drive Motor Gearbox
with Oil.
Contamination on belt.
Clean belt.
The shear pin is designed to break if a
jam occurs in the conveyor system. If
the shear pin breaks, carefully examine
the conveyor system to determine the
course of action.
2. Replace the belt.
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
Problem
Conveyor system does not move
TM 5259111 Rev. 0
Possible Cause
Conveyor system is blocked
Possible Solution
Remove obstruction.
Loose or broken shear pin (Figure 7-2) Replace the shear pin.
Loose drive motor slip clutch in the
torque limiter (if equipped with a torque
limiter)
1. Find and correct the cause of the
conveyor system overload or
readjust the torque limiter.
2. Examine the slip clutch on the drive
motor. Adjust or replace, if
necessary.
Pressed EMO
1. Release the EMO.
2. Press START/RESET.
3. Clear Alarm.
Tripped conveyor system circuit
breaker
1. Find and correct the cause of the
tripped breaker.
Worn drive motor brushes
Examine the motor brushes for wear. If
worn, replace the brushes. Refer to
page 7-26, Replace Drive Motor
Brushes.
Defective drive controller
Replace controller.
Defective drive motor
Replace motor. Refer to page 8-6,
Replace the Drive Motor.
Examine optical shaft encoder output
with a multimeter (0 to 5 V DC square
wave) for a defective drive motor shaft
encoder
Replace drive shaft encoder, if
defective.
If product feed conveyor is used,
downstream equipment (SMEMA) is
not ready
Clear downstream equipment.
Conveyor turned off in recipe.
Turn conveyor on in recipe.
Furnace in manual mode.
Switch to automatic mode.
Belt motion sensor
Check / set sensor.
Drive pulley or idler pulleys not
adjusted correctly
Examine and adjust the pulleys. Refer
to page 7-7, Examine and Adjust
Conveyor Belt Tracking.
Return rollers are not adjusted,
steering belt to one side
Examine and adjust rollers. Refer to
page 7-7, Examine and Adjust
Conveyor Belt Tracking.
Snub roller pressure pulley too strong
or pressure not equal on both sides of
pulley
Examine and adjust pressure on pulley
assembly. Refer to page 7-15,
Examine and Adjust Pressure Pulley
Tension.
Damaged belt
Examine the belt. Adjust or replace as
necessary. Refer to page 8-3, Replace
the Conveyor Belt.
Incorrect conveyor belt splice
Examine the conveyor belt splice.
Damaged quartz tubes or process
chamber
Call BTU International.
2. Reset the tripped circuit breaker.
Belt does not track correctly
September 26, 2007
TROUBLESHOOTING 6-3
TM 5259111 Rev. 0
Problem
Noisy or worn drive chain or sprockets
IN-LINE DIFFUSION SYSTEM MANUAL
Possible Cause
Misadjusted drive sprockets
Possible Solution
1. Adjust the sprockets and adjust
chain tension.
2. If damaged or worn, replace the
chain or sprockets.
6-4
TROUBLESHOOTING
Tight or loose drive chain tension
Adjust the chain tension. Refer to page
7-24, Fill Drive Motor Gearbox with
Oil.
Chain requires lubrication
Lubricate chain.
Damaged or worn gearbox gears.
Replace gearbox.
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
TROUBLESHOOT THE TEMPERATURE SYSTEM
Refer to Table 6-2.
Table 6-2: Troubleshoot the Temperature System
Problem
Product processing quality is
decreased
Possible Cause
A temperature profile problem that
causes incorrect product heating
Possible Solution
1. Make sure that all zones and
controlled heating sections are at
their setpoint temperatures,
recheck the profile temperature
setpoints, and then re-enter your
settings to achieve a new profile.
Refer to the WINCON Operation
Manual.
2. Examine the trim power settings
and the belt speed calibration in the
recipe.
Incorrect PID settings in recipe
1. If a zone of the furnace is not at
setpoint temperature, examine the
controller PID settings. Typically if
the temperature is oscillating
around the setpoint, you can adjust
the PID settings to dampen
oscillation.
2. If the oscillating cannot be
dampened, call your service
representative.
Incorrect gas flow to the atmosphere
curtains
1. Make sure curtains are down.
Defective thermocouple
1. Do a temperature profile. Refer to
page 7-7, Perform a Temperature
Profile.
2. Examine flow of gas to atmosphere
curtain plenums.
2. Replace the thermocouple.
Defective heater
1. Measure current to each heater.
2. No current indicates a failed heater
or SSR. Refer to page 8-18,
Replace an SSR. For heater
replacement, call BTU Customer
Service.
Defective SSR
1. Measure current to each heater.
2. No current indicates a failed heater
or SSR.
Excessive exhaust flow that stirs
process atmosphere
Examine the exhaust flow.
Process chamber leak
1. Perform a leak test.
2. Examine plumbing line gaskets and
replace if necessary.
September 26, 2007
Incorrect belt speed
Refer to page 6-2, Troubleshoot the
Conveyor System.
Incorrect recipe
Check to be sure the correct recipe is
running.
TROUBLESHOOTING 6-5
TM 5259111 Rev. 0
Problem
IN-LINE DIFFUSION SYSTEM MANUAL
Possible Cause
Products exiting the furnace are too hot Cooler not working
Conveyor belt running too fast
Possible Solution
Examine cooling H2O flow.
1. Make sure that belt speed is within
the set speed range.
2. Decrease the belt speed.
Conveyor belt overloaded
1. Decrease product load on the belt.
2. Examine maximum load per square
meter.
Controller temperature indication is
1850°C
Replacement belt may be too heavy
Make sure the belt is correct belt for
your furnace.
Broken or open circuit thermocouple
connection
1. Examine for open circuit
thermocouple connections or open
thermocouple.
2. Repair or replace as necessary.
Over-temperature condition
Loss of heater power
High temperature deviation alarm or
Over-temperature condition in a zone
de-energize heater power
1. Refer to page 5-11, Recover from
an Over-temperature Condition.
Thermocouple failure
Replace thermocouple.
Defective or short-circuited SSR
Examine the SSR. Replace if
necessary.
Intellimax controller failure
Replace Intellimax controller. Refer to
page 8-13, Replace Intellimax
Controller.
Over-temperature condition deenergized all heater power
Refer to page 5-11, Recover from an
Over-temperature Condition.
Defective heater contactor
Replace the heater contactor
The furnace controller is in an idle
mode (heat contactor is off)
Examine the status box in the top line
of the monitor. Refer to WINCON
Online Help.
Defective SSR
1. Examine the SSR with an
ohmmeter.
2. Examine the setpoint value of the
high temperature deviation alarm.
2. Replace if necessary.
Tripped power circuit breaker.
Loss of heater power to one zone
6-6
TROUBLESHOOTING
Examine the circuit breakers, fuses,
interlocks and EMOs.
Defective or open thermocouple circuit: Replace the thermocouple. Refer to
controller reads 1850°C
page 8-42, Replace Bottom Heaters.
A failure in the heater control or power
circuit (may include a defective SSR,
CB, Intellimax board, or wiring)
Examine voltage at the breaker and on
each SSR terminal (terminals 3 and 4
are control terminals). Refer to
Appendix A, DRAWINGS,
SPECIFICATIONS & OPTIONS.
Defective heater caused by break in
heater coils
Examine for heater failure with a clipon ammeter (For the required heater
current, refer to Appendix A,
DRAWINGS, SPECIFICATIONS &
OPTIONS). If there is voltage but not
current, there is an open heater.
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
Problem
TM 5259111 Rev. 0
Possible Cause
Temperature of one zone must be set
lower than an adjacent zone to
maintain the profile
Possible Solution
Defective heater thermocouple
Replace the thermocouple. Refer to
page 8-42, Replace Bottom Heaters.
Heat barrier is not lowered
Lower the correct heat barrier(s).
TROUBLESHOOT THE ATMOSPHERE SYSTEM
Refer to Table 6-3.
Table 6-3: Troubleshoot the Atmosphere System
Problem
Low gas flow volume
High dewpoint reading on hygrometer
Possible Cause
Possible Solution
Low gas inlet pressure
Examine gas inlet pressure regulator
setting or air/gas supply pressure to the
furnace.
Blocked gas inlet
Make sure that gas inlet line is not
blocked.
Excessive room drafts around vicinity
of furnace entrance and exit ends
1. Examine room air conditioner
blower ducts, and exhaust fans.
2. Prevent them from blowing directly
at the furnace entrance or exit
ends.
Gas plumbing system leak
Make sure that plumbing connections
are satisfactory.
Incorrectly installed atmosphere
curtains
Make sure the curtains are hanging
perpendicular to the belt.
Excessive gas flow rate to the
atmosphere curtains or venturicontrolled exhaust stacks
Adjust the venturi and curtain
flowmeters to prevent pulling ambient
air into the process chamber.
Plenum module assembly gasket leaks 1. Examine or tighten the clamp
screws on plenum module
assembly.
2. Examine condition of gasket,
replace if necessary.
Process chamber muffle leak
Examine for leaks around the muffle,
gaskets, and plumbing fittings.
Defective air solenoid
Disconnect pressurized air supply to
furnace to make sure that solenoid or
make sure that the valve is not
defective.
High dewpoint in gas supply (especially Make sure that gas or air supply has a
when operating in a N2 atmosphere)
humidity level at least 10 percent lower
than the necessary dewpoint.
Incorrect hygrometer indication
September 26, 2007
Calibrate the hygrometer in reference
to its reference manual.
TROUBLESHOOTING 6-7
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
TROUBLESHOOT THE EXHAUST SYSTEM
Refer to Table 6-4.
Table 6-4: Troubleshoot the Exhaust System
Problem
Possible Cause
Possible Solution
Reduce process quality
Excessive venturi exhaust stack flow
which causes damage to the process
atmosphere
Furnace exhaust effluents are
collecting in the room
Incorrect furnace exhaust flow. Exhaust Examine and adjust the furnace
blower may not be operating or duct is exhaust system and/or exhaust
blocked
dampers.
Exhaust flow dampers may be closed
or not sufficiently opened
Examine the exhaust flow rate and
exhaust dampers
Open the dampers to let exhaust flow
remove effluents.
TROUBLESHOOT THE FURNACE CONTROLLER SYSTEM
For information about WINCON, refer to the WINCON Online Help.
For problems related to the computer, refer to the applicable vendor manual.
6-8
TROUBLESHOOTING
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
CHAPTER 7
PREVENTIVE & CORRECTIVE MAINTENANCE
TABLE OF CONTENTS
Observing Safety Precautions ............................................................................................................... 7-2
Main Power Disconnect Switch [OPTION] ........................................................................... 7-2
Electrical Hazards ................................................................................................................... 7-3
Required Tools and Consumable Items ................................................................................................ 7-4
Removing Access Panels ...................................................................................................................... 7-4
Preventive Maintenance Schedule ........................................................................................................ 7-6
Weekly Preventative Maintenance........................................................................................................ 7-7
Perform a Temperature Profile ............................................................................................... 7-7
Examine and Adjust Conveyor Belt Tracking ........................................................................ 7-7
Backup WINCON Files ........................................................................................................ 7-11
Monthly Preventative Maintenance .................................................................................................... 7-12
Examine Conveyor System................................................................................................... 7-12
Examine and Shorten the Conveyor Belt.............................................................................. 7-13
Examine and Adjust Pressure Pulley Tension ...................................................................... 7-15
Clean External Surfaces........................................................................................................ 7-17
Clean Conveyor System........................................................................................................ 7-17
Align Entrance and Exit Pulleys ........................................................................................... 7-19
Test Furnace Interlocks......................................................................................................... 7-20
Quarterly Preventative Maintenance................................................................................................... 7-21
Examine and Lubricate the Drive Chain and the Drive Chain Sprockets ............................ 7-21
Examine and Adjust Drive Chain Tension ........................................................................... 7-23
Fill Drive Motor Gearbox with Oil....................................................................................... 7-24
Semi-Annual Preventative Maintenance............................................................................................. 7-26
Replace Drive Motor Brushes............................................................................................... 7-26
Lubricate Idler Pulley Bearings ............................................................................................ 7-27
Annual Preventative Maintenance ...................................................................................................... 7-29
Verify Intellimax Calibration................................................................................................ 7-29
Clean the Exhaust Ducts ....................................................................................................... 7-29
Empty Exhaust Traps............................................................................................................ 7-30
Test Exhaust.......................................................................................................................... 7-32
As Required Maintenance ................................................................................................................... 7-33
Clean Ultrasonic Belt Cleaner Tank ..................................................................................... 7-33
Reset a Circuit Breaker ......................................................................................................... 7-34
Verify and Calibrate Conveyor Speed .................................................................................. 7-34
Calibrate Conveyor Belt Motion........................................................................................... 7-36
Replace the Air / Gas Filters................................................................................................. 7-38
Calibrate the O2 Analyzer with Calibrated Gas [Option] ..................................................... 7-38
Test Heater Current............................................................................................................... 7-39
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
OBSERVING SAFETY PRECAUTIONS
Make sure you are familiar with all the hazards, general safety related procedures, and safety labels for
the furnace (refer to Chapter 2: SAFETY). If you have any doubt about a procedure, contact BTU International Customer Service.
WARNING!
READ!
• Read this manual in its entirety before you install, operate, troubleshoot or
maintain the furnace.
• Read a procedure in its entirety before you perform it.
• Always note and take any safety precautions recommended in this manual and
other documentation before you perform any procedure; otherwise, severe
personal injury or equipment damage may occur.
• If your company utilizes a lockout/tagout policy, lock the main power disconnect
switch in the OFF (0) position to prevent unauthorized use. Refer to page 2-10,
Lockout / Tagout Procedure for a proper lockout/tagout procedure.
QUALIFIED PERSONNEL!
• Procedures include working with high amperage, high voltage, high temperatures,
compressed gas, moving parts, and refractory ceramic fiber insulation (RCF).
• Procedures must be performed by fully trained, fully qualified personnel.
• Most procedures require advanced knowledge of electrical, mechanical, and
plumbing theories and issues.
• DO NOT PERFORM THE PROCEDURE IF YOU HAVE ANY DOUBTS ABOUT
HOW TO ACCOMPLISH THE TASKS INVOLVED. Contact BTU International
Customer Service; otherwise, severe personal injury or equipment damage may
occur.
• If you do not obey all the safety precautions listed in this manual and any other
associated documents, you risk the occurrence of death or serious injury to
personnel and a cancelled manufacturer's warranty.
Main Power Disconnect Switch [OPTION]
If your company utilizes a lockout/tagout policy, you can lock the main power disconnect switch in the
OFF position to prevent unauthorized use.
Lockout/Tagout Procedure
Set the main power disconnect switch to the OFF (0) position. Afterward, pull out the tab on the switch
handle and insert a padlock to lock the switch in the OFF (0) position. If your furnace has an optional
UPS, it is disabled when the main power disconnect switch is set to the OFF (0) position.
Replacing the Main Power Disconnect Switch
When replacing the main power disconnect switch, always use a switch of a equal or greater power rating. For example, If the power rating of the power disconnect switch is 100,000 AIC, the replacement
switch must have a minimum rating of 100,000 AIC.
7-2
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Electrical Hazards
All procedures that could expose you to an electrical hazard include a electrical danger symbol.
DANGER!
HIGH-VOLTAGE ELECTRICITY!
Electrical maintenance on this furnace often involves working with high-voltage
electricity. Only qualified personnel should perform electrical maintenance procedures. Do not touch the high-voltage connections when working with this equipment
or serious injury or death may occur.
Identifying the Level of Electrical Hazard in Maintenance Tasks
The level of electrical hazard for each maintenance task is identified by Type numbers 1 through 5 at the
beginning of each maintenance procedure that involves electrical work.
Table 7-1: The Five Types of Energized Electrical Work
Item
Definition
Type 1
Equipment is fully de-energized (electrically cold).
Type 2
Equipment is energized. Live circuits are covered or insulated.
Type 3
Equipment is energized. Live circuits are exposed and accidental
contact is possible. Potential exposures are less than 30 volts RMS,
42.2 volts peak, 240 volt-amps, and 20 Joules.
Type 4
Equipment is energized. Live circuits are exposed and accidental
contact is possible. Voltage potentials are greater than 30 volts
RMS, 42.2 volts peak, 240 volt-amps, and 20 Joules, or radio
frequency (rf) is present.
Type 5
Equipment is energized and measurements and adjustment
requires physical entry into the equipment, or equipment
configuration will not allow the use of clamp-on probes.
Chemical Hazards
Processes and maintenance procedures used in this furnace may include exposure to hazardous materials. All procedures that could expose you to a dangerous chemical hazard include a chemical danger
symbol. Some types of optional oxygen analyzers may contain a hazardous electrolyte fluid. Recommended cleaning solvents, lubricants, adhesives and other chemicals are listed in this chapter (refer to
page 7-4, Required Tools and Consumable Items). Potentially hazardous items include a Material
Safety Data Sheet (MSDS) located in Appendix C: MATERIAL SAFETY DATA SHEETS. When using
and disposing of general cleaning solutions, chemicals and associated application materials such as
rags, wipes and brushes, refer to the appropriate MSDS warning sheet. Also refer to all local, state and
federal regulations for disposal of these item. For other general purpose chemicals and process materials
not specifically identified in this manual, it is the end user's responsibility to provide MSDS information
regarding use and disposal.
When using cleaning solvents or other vaporous chemicals, always provide adequate ventilation and
appropriate safety equipment. Make sure the equipment surface is cool before applying any solvent or
cleaning fluid.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-3
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Ceramic Fiber Insulation Hazard
This furnace contains Refractory Ceramic Fiber (RCF) in the insulation around the heated zones. Under
normal operating conditions, exposure to RCF should not occur. However, when performing furnace
maintenance procedures that expose this insulation, take care to avoid inhaling the fibers. Use protective
dust mask, clothing and gloves (refer to Appendix C: MATERIAL SAFETY DATA SHEETS).
REQUIRED TOOLS AND CONSUMABLE ITEMS
The following is a list of tools and equipment required to perform the maintenance procedures contained in this chapter:
Table 7-2: Required Tools and Consumable Items
Required Tools
• Ammeter, clip-on
• Brush, soft-bristle
• Brush, stainless-steel wire
• Grease gun
• Hammer
• Multimeter, digital or analog (must be true RMS)
• Needle-nose pliers
• Screwdriver set
• Torque wrench, 0–50 in.-lb.
• Torque wrench, 0–50 ft.-lb.
• Wrench set, Allen
• Wrench set, SAE and metric
• Identification labels
Consumable Items
• Cleaning solution (90 percent water / 10 percent
Isopropyl alcohol)
• Adhesive, high-temperature RTV gasket or
sealant
• Lubricating grease (EP-1)
• Oil, gear
• Oil, gear and chain lubricating
• Thread adhesive (Loctite No. 222 or equivalent)
• Thread dope, nickel anti-seize pipe
• Thread tape (Teflon®)
• Water, distilled or purified (do not use de-ionized)
• Wipes, lint-free
• Vacuum cleaner with HEPA-rated filter bag
REMOVING ACCESS PANELS
All access panels and doors include a type of latch to prevent inadvertent entry. If your furnace includes
an optional interlock safety package, the furnace is de-energized to prevent furnace operation if any
access panel is removed.
To remove exit table side panels:
The side access panels on the exit table include quarter-turn latching screws; these screws must be
turned with a screwdriver to unlatch them. After unlatching the quarter-turn latching screws, the panel
can be removed by lifting it slightly and pulling it off.
1
Using a screwdriver, loosen the quarter-turn latch screws.
2
Remove the access panel by lifting it straight up, and then away, from the furnace.
To remove the process chamber side and top panels:
The top and side access panels to the processing area of the furnace are held in place with a nut and
small panel bracket. After the nut and bracket are removed, the top cover panels can be removed, and
the side access panels can be removed by lifting them slightly and then pulling them off.
7-4
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
1
Using a wrench, remove the nut that attaches the bracket.
2
Remove the bracket.
3
Remove the access panel by lifting it straight up, and then away, from the furnace.
To remove the entrance and exit table tops:
The entrance and exit table tops are secured in place with bolts and nuts. To remove these panels, you
may have to remove the side access panels to get access to the nuts. It may be necessary to remove these
top panels when performing some drive system maintenance.
1
Using a wrench, remove the nuts that attach the table top.
2
Remove the table top by lifting it straight up, and then away, from the furnace.
Top View
2
1
Side View
1
Entrance Table
2
Exit Table
3
2
Exit Table Side Panels
Figure 7-1: Entrance / Exit Table Tops and Access Panels
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-5
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
PREVENTIVE MAINTENANCE SCHEDULE
Table 7-3: Preventive Maintenance Schedule
Frequency
x
x
x
Align entrance and exit pulleys
x
Test furnace interlocks
Maintain the O2 analyzer
Examine and adjust pressure
pulley tension
Examine and adjust drive chain
tension
x
x
Calibrate conveyor belt motion
As Required
x
x
Lubricate the drive chain and the
drive chain sprockets
Verify and calibrate conveyor
speed
Yearly
x
Examine and shorten conveyor belt
Fill drive motor with oil
6 Months
Monthly
Examine and adjust conveyor belt
tracking
Clean external surfaces
Examine conveyor system
Clean conveyor system
Weekly
Perform a temperature profile
Time
Req’d (hr)
3 Months
Procedure
x
x
x
x
x
x
Lubricate idler pulley bearings
x
Replace drive motor brushes
x
Verify Intellimax calibration
Empty exhaust traps
Test exhaust
x
x
x
Clean ultrasonic belt cleaner tank
x
Replace the air/gas filters
x
Test heater current
Reset a circuit breaker
x
x
7-6
PREVENTATIVE & CORRECTIVE MAINTENANCE
Reference
Refer to page 7-7 , Perform a Temperature
Profile.
Refer to page 7-7 , Examine and Adjust
Conveyor Belt Tracking.
Refer to page 7-17 , Clean External Surfaces.
Refer to page 7-12 , Examine Conveyor System.
Refer to page 7-17 , Clean Conveyor System.
Refer to page 7-13 , Examine and Shorten the
Conveyor Belt.
Refer to page 7-19 , Align Entrance and Exit
Pulleys.
Refer to page 7-20 , Test Furnace Interlocks.
Refer to the page E-1 , VENDOR MANUALS.
Refer to page 7-15 , Examine and Adjust
Pressure Pulley Tension.
Refer to page 7-23 , Examine and Adjust Drive
Chain Tension.
Refer to page 7-24 , Fill Drive Motor Gearbox
with Oil.
Refer to page 7-21 , Examine and Lubricate the
Drive Chain and the Drive Chain Sprockets.
Refer to page 7-34 , Verify and Calibrate
Conveyor Speed.
Refer to page 7-36 , Calibrate Conveyor Belt
Motion.
Refer to page 7-27 , Lubricate Idler Pulley
Bearings.
Refer to page 7-26 , Replace Drive Motor
Brushes.
Refer to page 7-29 , Verify Intellimax Calibration.
Refer to page 7-30 , Empty Exhaust Traps.
Refer to page 7-32 , Test Exhaust.
Refer to page 7-33 , Clean Ultrasonic Belt
Cleaner Tank.
Refer to page 7-38 , Replace the Air / Gas
Filters.
Refer to page 7-39 , Test Heater Current.
Refer to page 7-34 , Reset a Circuit Breaker.
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
WEEKLY PREVENTATIVE MAINTENANCE
Perform the following preventative maintenance procedures every week:
Perform a Temperature Profile
Procedure Category:
Type 2
Special Tools:
None
Related Documents:
WINCON Online Help
If your equipment is used to process a variety of products, establish a profiling schedule so that each
process can be examined periodically. Refer to WINCON Online Help.
Examine and Adjust Conveyor Belt Tracking
Procedure Category:
Type 2
Special Tools:
• Measuring tape
• Rubber gloves
• Protective clothing
Related Documents:
None
To examine conveyor belt tracking:
1
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
2
Make sure the furnace frame is level and adjusted.
3
Make sure both the process chamber and the hearth line are aligned, straight, and cleared of
obstructions.
• With a tape measure, examine and make sure that the process chamber and hearth line are
centered with the frame.
• Make sure the hearth line is clean and is not damaged.
4
Make sure the entrance and exit tables are aligned with the hearth line.
5
Make sure both idler pulley (entrance) and drive pulley (exit) are perpendicular to the direction of
belt travel. Belt travel must be centered between the belt guides and process chamber walls as it
passes through the furnace.
• There are two sets of conveyor belt guides, one set is located on top of the entrance table and the
other set is located on top of the exit table. Belt tracking should be adjusted so that the conveyor
belt is centered as it travels through both sets of guides.
• The belt guides are adjusted at the factory and require no further adjustments.
6
Make sure the belt is unobstructed as it passes through the under-frame and drive:
• Belt is centered and not touching sides.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-7
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
• Return rollers are not damaged. Rollers are used under the furnace to return the belt to the
entrance table. Rollers must be perpendicular to the direction of belt travel. If not, the belt travels
in the direction the roller is positioned.
• The belt catenary is in the correct position and does not touch the bottom of the frame, or the
bottom or sides of the ultrasonic belt cleaner.
NOTE: The length of the catenary is important to the life of the belt, rollers, and belt cleaner. Do not let
the belt touch the furnace frame or the belt cleaner tank. Belt length increases when it becomes
hot and shortens as it cools.
7
Make sure the drive is adjusted correctly.
CAUTION!
Do not adjust pressure pulley position with different spring compressions. If the belt
slips, increase both sides half a turn and examine again. Because the belt is always
being heated and cooled, it is very soft. Too much spring compression causes the
loops to flatten and can cause the belt to increase in length or to become deformed.
Be sure to adjust the compression springs under full furnace load. Spring tension
should be adjusted to the minimum that does not allow the conveyor belt to slip.
• At the exit end, examine the compression springs to make sure they are adjusted the same on
both sides. Refer to Figure 7-2. The pressure pulley must be tight against the drive pulley to pull
the loaded belt correctly.
• Make sure all fasteners are tight.
• Make sure the drive chain is not loose and is adjusted correctly.
CAUTION!
Do not apply too much tension to the compression spring assemblies. Too much
tension can cause damage to the belt and the drive and pressure roller. Springs
should be adjusted to the minimum that does not allow the conveyor belt to slip.
Adjust the belt tracking as follows:
1
Operate the drive slowly until the furnace drive is in usual operation.
NOTE: Do not load the belt or operate the heaters.
2
Operate the drive at full speed.
NOTE: Tracking is dependent upon setup to the point that if the setup is correct then the tracking is
correct. When the unit needs an adjustment, shut off the drive, do the adjustment and
restart the drive to examine. It is not uncommon to return to the setup instruction on occasion
to make adjustments and then proceed.
7-8
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
4
5
A
6
DOT
1
A
2
DOT
3
13
7
8
15
12
14
11
9
10
16
17
18
BELT1003R1
1
Splice Wire
10
Drive Pulley
2
Tension Rollers
11
Mounting Bracket Nuts
3
Conveyor Belt Over Return Rollers
12
Adjustable Mounting Bracket
4
Shear Pin
13
Pressure Pulley
5
Drive Sprocket
14
Pressure Pulley Shaft
6
Drive Chain
15
Compression Spring
7
Drive Motor
16
Compression Spring Tension Adjustment & Locknuts
8
Belt Catenary
17
Belt Tracking Adjustment Nuts
9
Ultrasonic Belt Cleaner
18
Fixed Bracket
Figure 7-2: Conveyor Belt Tracking and Tension Adjustment
3
Adjust tracking at exit table. The tracking adjustment, located in the exit table, moves one side of
the drive pulley forward or backward. This is the only adjustment needed at the exit table.
a
September 26, 2007
Shut off the drive.
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-9
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
b
Loosen the mounting bracket nuts (11) and adjust the two belt tracking adjustment nuts (17).
See Figure 7-2.
• Move the adjustable mounting bracket to the rear to move the belt to the adjustment side.
• Or, move the adjustable mounting bracket forward to move the belt away from the
adjustment side.
c
Start the drive and observe tracking at the exit end of the furnace.
• Observation must be at the exit end of the furnace.
• Observation of the belt at the entrance table is not related to what happens at the exit end.
4
5
7-10
Adjust tracking at the entrance table. Belt tracking at the entrance is dependent on the
perpendicularly of the return rollers (Figure 7-2) to the line of belt travel.
a
Shut off the drive.
b
Return rollers are mounted on a 90 to 120 cm (3 to 4 ft.) tray, which is attached by clamps.
Install or remove shims from under the clamps to center the tray within the furnace frame. This
adjusts the rollers relative to the belt and sends the belt in the correct direction.
c
Start the drive and observe tracking at the entrance end.
The adjustment is complete when:
a
When the drive operates for several hours without incident, set the furnace to operating
temperature and load product.
b
Monitor belt tracking for the first few hours of operation.
c
Make necessary adjustments. However, there must be sufficient time to observe the results of
any adjustment before processing product with the furnace.
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Backup WINCON Files
Procedure Category:
Type 2
Parts Referenced:
None
Special Tools:
None
Related Documents:
WINCON Online Help
Backing up WINCON system files will protect both your process related data and equipment configuration data. BTU recommend you backup your data on a weekly basis or when you make system changes
to WINCON such as recipe, security, scheduler, data set or system event changes etc.
NOTE: Configuration (.CFG) files contain critical information necessary to operate the equipment. Do
not edit these files outside of WINCON, or the equipment will become inoperable.
Each configuration is unique and should never be used on other equipment.
Shut down WINCON before copying these files.
WINCON files are located in C:\Wincon folder. Backup the following WINCON files weekly.
File Name
Description
File Name
Description
*.rcp
All files ending in .rcp
WCDCDB.MDB
Data Collections Database
ICMO1888.CFG
Intellimax Calibration data;
each ICM file is unique
(ICMxxxxx.CFG).
WINCON.ODB
Data Set and Event details
SCHEDULE.CFG
Recipe scheduling details
monitor.wmf
Monitor Graphic background
monitor.INI
Defines Monitor Graphic
layout
WCSDB.MDB
Operator Security records and
Access Levels
RECIPE.ACT
Active Recipe information
SYSTEM.cfg
Equipment specific configuration
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-11
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
MONTHLY PREVENTATIVE MAINTENANCE
Perform the following preventative maintenance procedures every month:
Examine Conveyor System
Refer to Table 7-4.
Table 7-4: Inspect Conveyor System
Item
Entrance and exit pulleys
Problem
Not level
Belt pins
Action
Refer to page 7-19 , Align Entrance and Exit
Pulleys.
Replace the belt pins.
Not joined correctly
Not level and/or perpendicular to belt line,
Rollers
Adjust and/or replace the rollers and/or flanges.
and flanges have damage
Belt touches furnace or ultrasonic belt
Shorten the conveyor belt. Refer to page 7-17 ,
Belt catenary
cleaner
Clean Conveyor System.
NOTE: Examine the oil level in the drive motor must periodically. Examine the level more often if you think that there is a leak.
Add oil. Refer to page 7-24 , Fill Drive Motor
Gear reducer
Low oil level
Gearbox with Oil.
NOTE: The rate of wear in the drive motor brushes is related to the motor speed and amount of load. If the brushes are below the
limits, the motor commutator could be damaged.
Replace the drive motor brushes. Refer to page
Drive motor brushes
Wear to 5 mm (0.20 in.) or less.
7-26 , Replace Drive Motor Brushes.
NOTE: Operate the conveyor system at an average speed for a few minutes or until the belt has completed at least three or four full
cycles.
Make sure that there is a 0.9 cm (0.375 in.) gap
between the belt edge and the interior of the
Not tracking correctly (during the cycle, the process chamber. If the belt touches the
belt edge may move away from the
bricking, there will be a white residue on the belt.
reference point on the drum).
If there is a belt tracking problem, refer to page
7-7 , Examine and Adjust Conveyor Belt
Tracking.
Stop the belt and correct the problem. If the belt
is damaged near one of the ends, remove that
Defective weave in the belt that can interfere portion of the belt and replace it with some of the
with correct belt travel
surplus belt shipped with the furnace. If there is
a belt tracking problem, refer to page 7-7 ,
Conveyor belt
Examine and Adjust Conveyor Belt Tracking.
Stop the belt and correct the problem. If there is
Twists or has too much side-to-side
a belt tracking problem, refer to page 7-7 ,
movement
Examine and Adjust Conveyor Belt Tracking.
Touches an item that prevents smooth
operation (belt does not need to be centered Stop the belt and correct the problem. If there is
through the vestibules, as long as there is
a belt tracking problem, refer page 7-7 ,
clearance between the belt and vestibule
Examine and Adjust Conveyor Belt Tracking.
walls)
Adjust the belt tracking. Refer to page 7-7 ,
Not tracking correctly, defective belt,
Examine and Adjust Conveyor Belt Tracking.
touches other parts of the furnace
Make sure that there is 0.9 cm (0.375 in.)
between belt edge and muffle wall.
7-12
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Examine and Shorten the Conveyor Belt
Procedure Category:
Type 2
Parts Referenced:
Conveyor belt
Special Tools:
None
Related Documents:
None
All conveyor belts stretch after a period of extended use. The length can change with temperature. If the
belt touches the bottom of the furnace (or the bottom of the ultrasonic belt cleaner) it must be shortened.
To shorten the conveyor belt:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
NOTE: Do not remove the belt from the furnace.
4
Stand at the furnace entrance.
5
Make a new belt connection splice by cutting the weld at the ends and removing the splice pin. Pull
it out from the side with the bead attached. Keep the splice. Refer to Figure 7-3.
6
When you cut the belt, leave sufficient belt for a catenary. (The belt must not touch the bottom of
the furnace (or the bottom of the ultrasonic belt cleaner.)
7
With wire cutters, remove the necessary amount of belt length.
a
Cut the belt near the weld bead at the edge of the belt.
b
Cut off the weld bead on one side.
c
Leave the weld bead on the other side to match the belt splice.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-13
TM 5259111 Rev. 0
8
9
IN-LINE DIFFUSION SYSTEM MANUAL
Overlap and join the two ends of the belt using the splice.
a
Make sure that one joined spiral is left-hand and that the other is right-hand.
b
Insert the splice from the end without the bead.
c
Make sure that you join a left-hand spiral to a RH spiral.
d
If you join a left-hand and a left-hand spiral, the belt can walk from side to side.
Examine the conveyor belt and splice. Make sure the belt does not touch anything except the return
rollers.
10 If maintenance is complete, remove the lockout/tagout. Refer to page 2-10, Lockout / Tagout
Procedure.
11 Operate the belt slowly. Make sure that the belt is tracking correctly.
12 Catenary length is important to the life of the belt, rollers, and belt cleaner. Do not let the belt touch
the furnace frame or drag on the belt cleaner vessel. Remember that the belt increases in length
when it is hot from the process chamber. Refer to Figure 7-3.
Splice
DOT
MISC1030
Figure 7-3: Conveyor Belt (Shows Splice and Direction of Travel)
7-14
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Examine and Adjust Pressure Pulley Tension
There are two possible drive assembly adjustments: pressure pulley tension and alignment. If the conveyor belt tracks incorrectly at the exit end of the furnace, readjust the position of the drive roller shaft
that is on the opposite side of the furnace from the drive motor. The only adjustment necessary on the
drive roller assembly is the two nuts on the fixed mounting bracket of the roller tension assembly (Figure 7-4). Changing the drive roller’s shaft alignment may change the spring tension on the pressure
roller; therefore, check the pressure roller tension.
Procedure Category:
Type 1
Special Tools:
• Ruler or tape measure
• Open end wrenches
Related Documents:
None
Adjustable Mounting Bracket
DrivePulley
Pulley
Drive
PressurePulley
Pulley
Pressure
Fixed Mounting
Bracket
Pressure
Shaft
Pressure Pulley
Pulley Shaft
Pressure Pulley
Pulley
Pressure
Spring
TensionSpring
Compression
Compression
Spring Tension
Adjustment and
Lock Nuts
Belt Tracking
Adjusting Nuts
Mounting Bracket
Nuts
Equal Spring Tension
on Both Sides
Viewed from Opposite the Drive Side
Figure 7-4: Drive Tension Assembly
To check and adjust the pressure roller tension:
CAUTION!
Avoid applying excessive pressure pulley tension. Overtightening the spring
tension does not help conveyor belt alignment and can damage the belt. The
compression springs on both sides of the furnace should have equal tension.
Normally, it is not necessary to change the spring tension because it has been preset for the proper tension at the factory. If the pressure pulley tension is too loose, the belt will slip under load, and the compression springs should be equally tightened.
1
Run the conveyor belt through two or three complete cycles to let it stabilize.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-15
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
2
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
3
Remove the side panels from the exit table. Refer to page 7-4, Removing Access Panels.
4
Measure and compare the width of the tension spring on both sides of the furnace, which is the
distance between the two washers on the tension spring (Figure 7-4).
5
Tighten the pressure pulley tension springs equally on both sides of the furnace as follows:
a
Unlock the two tension locknuts on each side.
b
Tighten the two tension locknuts equally on each side only a little more than necessary to
prevent the belt from slipping under a heavy load.
6
If the springs are not equal width, adjust the tension lock nuts until the springs are equal length.
7
Lock the locknuts together.
8
Remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout Removal Procedure.
9
Turn on the power to the furnace, and run the conveyor belt through two or three complete cycles to
let it stabilize.
10 Check the conveyor belt alignment at the exit end, and if necessary, adjust the drive roller. Refer to
page 7-19, Align Entrance and Exit Pulleys.
11 If the alignment is OK, close and latch the access panels. Refer to page 7-4, Removing Access
Panels.
12 Examine equipment operation.
7-16
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Clean External Surfaces
Procedure Category:
Type 2
Special Tools:
•
•
•
•
•
Related Documents:
None
Vacuum
Lint-free wipes
Soapy water
Rubber gloves
Protective clothing
CAUTION!
Contamination collects on the equipment when it is shipped. Contamination can get
into the equipment and cause damage or an electrical problem.
Do not use compressed air to remove contamination.
To clean the external surfaces:
1
With a vacuum cleaner, clean the external surfaces.
2
With lint-free wipes and soapy water, clean the external surfaces.
Clean Conveyor System
Procedure Category:
Type 1
Parts Referenced:
None
Special Tools:
•
•
•
•
Related Documents:
Lockout / Tagout Procedure (page 2-10)
Vacuum
10% isopropyl alcohol/90% H2O
Rubber gloves
Protective clothing
To clean the conveyor system:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-17
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
4
With a vacuum cleaner, clean the belt, the belt rollers, and the drive shafts.
5
With lint free wipes and a cleaning solution (10% isopropyl alcohol / 90% water), clean the belt, the
belt rollers, the drive shafts (including the polished drive shafts that the bearings move on).
6
Dispose of hazardous materials. Refer to page 2-14, Disposal of Equipment.
7
Install the access panels. Refer to page 7-4, Removing Access Panels.
8
If maintenance is complete, remove the lockout/tagout. Refer to page 2-10, Lockout / Tagout
Procedure.
9
Examine equipment operation.
1
4
3
2
1
2
Belt Rollers
3
Ultrasonic Belt Cleaner Tank
Conveyor Belt
4
Drive Motor
Figure 7-5: Conveyor System Locator (Typical)
7-18
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Align Entrance and Exit Pulleys
Procedure Category:
Type 1
Parts Referenced:
None
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
NOTE: Adjustment is set by the alignment of the entrance to exit pulleys, which are factory-set. Refer to
Figure 7-6. Belt and pulley condition affects belt tracking.
To align the entrance and exit pulleys:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove the access panels on the entrance and exit tables.
4
Measure the distance from the edge of the entrance pulley to the edge of the exit pulley on the both
sides of the pulley. All dimensions must be equal. Refer to Figure 7-6.
5
Adjust the belt guides at the entrance end, if necessary.
• The belt guides are set at the factory and normally require no adjustment.
• The conveyor belt should be centered between both the entrance and exit belt guides and should
not touch the walls of the process chamber.
6
Adjust the drive pulley assembly at the exit end.
7
Install access panels. Refer to page 7-4, Removing Access Panels.
8
If maintenance is complete, remove the lockout/tagout. Refer to page 2-10, Lockout / Tagout
Procedure.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-19
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
A
A
B
C
B
A
C
C
C
A
B
B
BELT1006
Dim. A Dimensions A must be equal
Dim. C Dimensions C must be equal
Dim. B Dimensions B must be equal
Dim. D Dimensions D must be equal
Figure 7-6: Parallel / Perpendicular Belt Pulley Alignment
Test Furnace Interlocks
Procedure Category:
Type 2
Parts Referenced:
None
Special Tools:
None
Related Documents:
None
For safety purposes periodically test all the interlocks in the system to make sure they operate correctly.
To test furnace interlocks:
When the system is in operation (gas, heaters, exhaust blowers, and other options all energized), test all
the interlocked devices for correct operation. Refer to Appendix A: DRAWINGS, SPECIFICATIONS &
OPTIONS.
7-20
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
QUARTERLY PREVENTATIVE MAINTENANCE
Perform the following preventative maintenance procedures every three months:
Examine and Lubricate the Drive Chain and the Drive Chain Sprockets
Procedure Category:
Type 1
Special Tools:
•
•
•
•
•
Related Documents:
WINCON Online Help
Cleaning solution (10% isopropyl alcohol / 90% H2O)
Soft, bristle brush
General purpose gear / chain lubricating oil
Rubber gloves
Protective clothing
To lubricate the drive chain and drive chain sprockets (Figure 7-7):
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove applicable access panels at the exit end of the furnace.
4
Examine the drive chain and drive chain sprockets.
a
Make sure the chain and sprockets are aligned correctly with one another.
b
Make sure the set screws that attach the sprockets are tight.
c
If necessary, using an Allen wrench, loosen the set screws that attach the sprockets; align the
chain and sprockets with one another; then tighten the set screws.
5
Using lint-free wipes and a cleaning solution (10% isopropyl alcohol / 90% water), clean the drive
chain and associated sprockets. Remove old lubricant and accumulated debris from the chain and
associated sprockets.
6
Using a soft-bristle brush, apply lubricant to the drive chains and associated sprockets. Apply
lubricant to all sides of the chains.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-21
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
7
Install the access panel covers.
8
Dispose of hazardous materials. Refer to page 2-14, Disposal of Equipment.
9
If maintenance is complete, remove the lockout/tagout. Refer to page 2-10, Lockout / Tagout
Procedure.
10 Examine equipment operation.
1
2
TFQ1002
1
Drive Chain
2
Chain Drive Sprockets
Figure 7-7: Lubricate the Drive Chain and Drive Chain Sprockets
7-22
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Examine and Adjust Drive Chain Tension
Procedure Category:
Type 1
Parts Referenced:
None
Special Tools:
•
•
•
•
Related Documents:
Lockout / Tagout Procedure (page 2-10)
Tape measure
Straight edge
Rubber gloves
Protective clothing
NOTE: Adjustment is set by the alignment of the entrance to exit pulleys, which are factory-set. Refer to
Figure 7-6. Belt and pulley condition affects belt tracking.
To adjust the drive chain tension:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
4
Examine the drive chain for signs of wear.
a
Look for loose chain links. Tighten loose chain links.
b
Look for worn chain links, especially where the sprockets engage the chain links. Replace
worn chain links or the entire chain. Refer to page 8-5, Replace the Drive Motor Chain.
5
Put a straightedge across the chain sprockets and make sure that the drive chain sprockets are
aligned. If the sprockets are not aligned, make the correct sprocket adjustments before you adjust
the chain tension.
6
Examine the tension of the drive chains. There must be 6 mm (0.25 in.) of slack.
a
September 26, 2007
If chain tension and adjustment are correct, no adjustment is necessary.
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-23
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
b
If the chain tension is incorrect, adjust it as follows:
• Loosen the motor/gear reducer mounting screws.
• Keep the sprockets adjusted.
• Move the gear reducer until the chain tension and adjustment is correct.
• Slightly tighten the gear reducer mounting screws.
• Put the gear reducer in position so that drive chain tension and adjustment are correct. Hold
it in position while you tighten the mounting screws.
7
Remove the lockout/tagout. Refer to page 2-10, Lockout / Tagout Procedure.
8
Energize and operate the conveyor system.
a
The drive system must operate correctly.
• If chain tension is too loose, the chain jumps
• If chain tension is too tight, the chain clicks or makes straining noises
b
9
Adjust the chain tension if necessary.
Install the access panels. Refer to page 7-4, Removing Access Panels.
10 Examine equipment operation.
Fill Drive Motor Gearbox with Oil
Procedure Category:
Type 1
Parts Referenced:
• 4111 Metalicoil (Hodson Corporation) (gear reducer/motor combination
integrated in the same housing)
• Mobil 600W Extra Hecia Super
• AGN4A-47 Oil (Motor/worm gear reducer combination, separate
housings)
• No. 8 Oil (Motor/worm gear reducer combination, separate housings)
Special Tools:
• General purpose gear/chain lubricant
• Rubber gloves
• Protective clothing
Related Documents:
WINCON Online Help
To fill the drive motor with oil:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
7-24
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove applicable access panels at the exit end of the furnace.
4
Remove the fill plug (Figure 7-8).
5
Fill the drive motor to the fill line with the recommended gear oil.
6
Install the fill plug.
7
Install the access panel covers.
8
Dispose of hazardous materials. Refer to page 2-14, Disposal of Equipment.
9
If maintenance is complete, remove the lockout/tagout. Refer to page 2-10, Lockout / Tagout
Procedure.
10 Examine equipment operation.
1
1
2
Drive Motor (Removed for clarity)
2
Fill Plug
Figure 7-8: Fill the Drive Motor with Oil
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-25
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
SEMI-ANNUAL PREVENTATIVE MAINTENANCE
Perform the following preventative maintenance procedures every six months:
Replace Drive Motor Brushes
Procedure Category:
Type 1
Parts Referenced:
Motor Brush (Refer to Appendix B: RECOMMENDED SPARE PARTS.)
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
To replace the drive motor brushes:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
7-26
2
Let the furnace fully cool.
3
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
4
Remove one motor brush at a time from the motor. Record the position so that you can install it into
the same position. Refer to Figure 7-9.
5
Examine the brush wear line.
a
If the brush is in good condition, install the brush in the same position as when it was before it
was removed.
b
If the brush is worn (wear to 5 mm (0.20 in.) or less), install a new brush. The orientation of the
new brush is not important. It will put itself in the correct position.
6
Examine equipment operation.
7
Dispose of hazardous materials. Refer to page 2-14, Disposal of Equipment.
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
1
2
1
Armature Rotation
3
Brush Cap
2
Bevelled Brush
4
Brush Spring and Terminal
4
3
Figure 7-9: Motor Brush Orientation
Lubricate Idler Pulley Bearings
Procedure Category:
Type 1
Parts Referenced:
None
Special Tools:
•
•
•
•
•
•
Related Documents:
Lockout / Tagout Procedure (page 2-10)
Cleaning solution (10% isopropyl alcohol / 90% H2O)
Lint-free wipes
Grease gun
Lubricating grease (EP-1)
Rubber gloves
Protective clothing
To lubricate the idler pulley bearings:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-27
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove the access panels from the entrance table to gain access to the idler pulley bearings. The
idler pulley bearings are located at both ends of the pulley shaft.
4
Using lint-free wipes and a cleaning solution (10% isopropyl alcohol / 90% water), clean the idler
pulley bearings and the grease fittings on the pillow blocks.
5
Using a grease gun and general purpose lubricating grease, apply enough lubricant to each grease
fittings until lubricant seeps out along the bearing block.
6
Using lint-free wipes, remove all excess lubricant from the bearing block grease fitting and bearing
block. This prevents dirt accumulation.
7
Install the access panel covers.
8
Dispose of hazardous materials. Refer to page 2-14, Disposal of Equipment.
9
If maintenance is complete, remove the lockout/tagout. Refer to page 2-10, Lockout / Tagout
Procedure.
10 Examine equipment operation.
Figure 7-10: Lubricate the Idler Pulley Bearings (Entrance Table)
7-28
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
ANNUAL PREVENTATIVE MAINTENANCE
Perform the following preventative maintenance procedures yearly
Verify Intellimax Calibration
Procedure Category:
Type 2
Special Tools:
• Calibrated thermocouple simulator
• Wiring harness for all Intellimax channels using copper wire
• Calibrated digital voltmeter to measure the voltage at Intellimax/harness
terminal block
• The original Intellimax calibration values (located in Appendix D of the
BTU System Manual for your furnace)
Related Documents:
WINCON Online Help
Periodically test and verify the Intellimax calibration through WINCON. Refer to Intellimax Calibration in WINCON Online Help for procedures.
For electrical component layout, refer to Appendix A: DRAWINGS, SPECIFICATIONS & OPTIONS.
Clean the Exhaust Ducts
After a long period of extended use, the exhaust ducts may accumulate a coating of residue process
materials and dust. Cleaning the exhaust ducts may require disassembling or replacing the sections. If it
is impractical to clean the ducts, replace them.
Procedure Category:
Type 1
Special Tools:
• Rags, wipes, brushes or other suitable application materials
• Methanol (methyl alcohol), ethanol (denatured alcohol), or isopropyl
alcohol
• Strong commercial detergent cleaner or furnace cleaner (for removing
greasy, oily, or carbonaceous soils or resins from furnace parts)
• Methanol (methyl alcohol), or ethanol (denatured alcohol), or isopropyl
alcohol (for cleaning resin from the furnace components)
• Rubber gloves and protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-29
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
DANGER!
DANGEROUS SUBSTANCE!
The customer must be aware of the outgasses and emissions of their process!
This furnace may use gases that pose danger from asphyxiation or suffocation. Also,
industrial processes at this site may produce toxic gases. Make sure the site is
adequately ventilated.
BTU International strongly recommends testing and cleaning the exhaust periodically
in reference to facility or local regulations; otherwise, serious injury or death to
personnel may occur.
To clean the exhaust ducts:
1
Turn off all power to the furnace and allow it to cool. (See flash point of any solvents to be used in
the MSDS sheets for the solvent.)
2
Disassemble the duct sections and place them in a well ventilated area to be cleaned.
3
Using rags or other application materials dampened with cleaning solvent, clean the interior of the
ducts.
4
Dispose of cleaning solutions, chemicals and associated application materials such as rags, wipes
and brushes. Refer to the appropriate MSDS warning sheet. Also refer to all local, state, and federal
regulations for disposal of these items.
5
Reassemble the exhaust ducts.
6
Test and readjust the exhaust flow to your furnace needs (see page 7-32, Test Exhaust).
Empty Exhaust Traps
Procedure Category:
Type 1
Parts Referenced:
None
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
The In-Line Diffusion furnace is equipped with an exhaust trap below each exhaust stack. The exhaust
traps collect contaminants from the exhaust as it is expelled from the furnace. Venturis on the stacks,
assist in directing the gas flow up and out of the furnace gas stacks into the facility ducts.
7-30
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
To clean the exhaust traps:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove the exhaust traps from the furnace. Each exhaust stack is held in place by a clamp.
4
Empty the trap. Dispose of the contents in a responsible manner, according to local and state laws
for the disposal of hazardous material.
5
With lint-free wipes soaked in water, clean the interior of the traps.
6
Install the exhaust traps onto the furnace.
7
If maintenance is complete, remove the lockout/tagout. Refer to page 2-10, Lockout / Tagout
Procedure.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-31
TM 5259111 Rev. 0
8
IN-LINE DIFFUSION SYSTEM MANUAL
Test and adjust the exhaust flow as necessary.
2
1
1
Exhaust Trap
2
Clamp
Figure 7-11: Exhaust Trap and Clamp
Test Exhaust
WARNING!
DANGEROUS SUBSTANCE!
The customer must be aware of the outgasses and emissions of their process!
This furnace may use gases that pose danger from asphyxiation or suffocation. Also,
industrial processes at this site may produce toxic gases. Make sure the site is
adequately ventilated.
BTU International strongly recommends testing the exhaust periodically in reference
to facility or local regulations; otherwise, serious injury or death to personnel may
occur.
To test the exhaust:
Using a manometer, check that the exhaust system is drawing properly to expel effluents. Refer to the
Installation Drawing, located in Appendix A: DRAWINGS, SPECIFICATIONS & OPTIONS, for the estimated effluent flow expected with this furnace.
7-32
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
AS REQUIRED MAINTENANCE
Perform the following preventative maintenance procedures as required.
Clean Ultrasonic Belt Cleaner Tank
Procedure Category:
Type 2
Parts Referenced:
None
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
None
The ultrasonic belt cleaner (USBC) is used to clean irregular surfaces of the conveyor belt. The USBC
uses sound to agitate a tank of water, which rinses deposits from the belt. Periodically clean the tank by
flushing the system a few times.
To clean the ultrasonic belt tank [Option]:
1
Let the furnace fully cool.
2
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
3
Flush the ultrasonic belt cleaner tank a few times:
a
Turn on the ultrasonic belt cleaner. The tank fills.
b
Turn off the ultrasonic belt cleaner. The tank drains.
1
1
Ultrasonic Belt Cleaner
Figure 7-12: Ultrasonic Belt Cleaner Tank Location
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-33
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Reset a Circuit Breaker
Procedure Category:
Type 2
Parts Referenced:
None
Special Tools:
None
Related Documents:
None
To reset a circuit breaker:
1
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
2
Find the cause of the fault. Do the necessary repairs.
3
Reset the tripped circuit breaker as follows:
a
For button-type circuit breakers, press in the button.
b
For switch-type circuit breakers, set the circuit breaker to the OFF position and then to the ON
position.
4
Start the furnace. Refer to page 3-7, paragraph 3.5, Start and Operate.
5
Examine equipment operation.
Verify and Calibrate Conveyor Speed
Procedure Category:
Type 2
Special Tools:
Ruler
Related Documents:
WINCON Online Help
Exit Criteria:
The speed of the conveyor belt is calibrated.
The conveyor is calibrated at the factory before shipment. Verification and calibration (if required)
should be performed after any work on the drive system or as part of a periodic maintenance check.
To verify the conveyor speed, you will need to time an object as it travels over a specific distance and
compare the results to the belt speed in WINCON.
To verify conveyor speed:
7-34
1
Set the belt speed in the WINCON main screen (Monitor Graphic).
2
Determine measurement length. Refer to Figure 7-13.
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
A
Top View
Direction of Travel
TFQ1005
A = Distance from edge of entrance table to edge of exit table
Figure 7-13: Determine Measurement Distance
3
Place an object that will not melt on the conveyor belt.
4
Using a stop watch, measure the time required for the object to travel the measured distance.
5
Calculate the results in inches or mm / minute and compare the results with the conveyor speed in
WINCON.
1
2
7
3
6
4
1
Save button
4
Calculate button
2
Power field
5
STOP button
3
Distance field
6
START button
5
7
AUTOMATIC button
Figure 7-14: Conveyor Speed Calibration Page in WINCON
To calibrate the conveyor belt speed:
NOTE: Note that during calibration the system will be in Setup Mode. This calibration procedure uses
the Conveyor Configuration page in WINCON (Config >System > Conveyor Speed).
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-35
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
1
Open the Conveyor Configuration page (Config > System> Conveyor Speed) in WINCON
(Figure 7-14).
2
Enter 50 as the percentage of speed in the Power field. This provides a set stable power output to
the controller for calibration.
3
Click on the STOP button to stop the conveyor.
CAUTION!
EQUIPMENT DAMAGE!
To prevent damage to the conveyor, avoid leaving the conveyor stopped for more
than a few minutes if the equipment is hot.
4
Place product (or something that will not melt) on the conveyor.
5
Click on the START button to get the conveyor moving.
6
Allow the conveyor to run the maximum measurable distance then click on the STOP button to stop
the conveyor.
7
Measure the exact distance the conveyor traveled and enter this value in the Distance field, you
must enter the distance in the length units that are displayed. e.g., in the example above the length
units are Inches, so we would enter the distance traveled in Inches.
8
Click Calculate to calculate the Pulses per Unit. The value may change.
9
Click the Save button, to save and store the new calibration number. If the Save button is not
visible, select Button Bar from the Window pull-down menu.
10 Click the AUTOMATIC button to return to normal operation.
11 Close the Conveyor Configuration page.
Calibrate Conveyor Belt Motion
Procedure Category:
Type 2
Special Tools:
Tape Measure
Related Documents:
WINCON Online Help
Exit Criteria:
Drive Pulses Per Motion Pulse and Drive Pulse Tolerance counts are
updated with the new calibration numbers.
The Conveyor Motion is calibrated at the factory before shipment. The following procedure should be
performed after any work on the drive system, any changes to the conveyor speed configuration setup,
or as part of a periodic maintenance check. For a complete theory of operation, refer to WINCON
Online Help.
7-36
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
To Calibrate the Conveyor Motion:
The Conveyor Speed must be calibrated first, and should be set to the fastest speed before
proceeding with the Conveyor Motion calibration. The conveyor speed should not be adjusted
during calibration. Refer to page 7-34, Verify and Calibrate Conveyor Speed.
1
NOTE: During calibration or if calibration fails, the system will be in Setup Mode. The Setup Status
Dialog displays the calibration state as either “Calibrating” or as “Not Calibrated” if calibration
fails.
This calibration procedure uses the Conveyor Motion Configuration page in WINCON (Config >
System > Conveyor Motion). System Administrator or Factory Service level access is required
to modify this page.
1
7
2
6
3
5
4
1
Save Button
5
Drive Pulse Tolerance: field
2
Calibration State: field
6
Drive Pulses Per Motion Pulse: field
3
Drive Pulses Per Motion Pulse: Current and
Previous fields
7
Calibrate button
4
Calibration Cycle Count: field
Figure 7-15: Conveyor Motion Configuration Page in WINCON
2
Open the Conveyor Motion Configuration page (Config>System> Conveyor Motion) in
WINCON (Figure 7-15).
3
Verify you are getting Drive Pulses Per Motion Pulse, both current and previous. If the current
count is not changing then the conveyor in either not on or has a problem and this needs to be
resolved before calibrating. If the previous count is not changing then there is a problem with the
conveyor motion signal and this needs to be resolved before calibrating. Refer to WINCON Online
Help if either of these conditions occur.
4
Make sure the Calibration Cycle Count is correct, typically set to the number of teeth on the
sprocket.
5
Click the Calibrate Button. The calibration state changes to calibrating.
6
After the Calibration cycle count completes the system is calibrated, the Drive Pulses Per Motion
Pulse and Drive Pulse Tolerance counts are updated with the new calibration numbers.
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-37
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
7
Click Save to save the new settings. If the Save button is not visible, select Button Bar from the
Window pull-down menu.
8
Verify that Calibrated appears in the Calibrated State field on the Conveyor Motion Configuration
page
9
Close the Conveyor Motion Configuration page.
Replace the Air / Gas Filters
The In-Line Diffusion furnace does not have any internal air / gas filters. BTU International strongly
recommends installing a pressure regulator and filter in all gas / air supply lines before connection to the
furnace. To maintain the filters, periodically replace the filter elements. Refer to page 4-5, CDA and
Nitrogen Requirements.
Calibrate the O2 Analyzer with Calibrated Gas [Option]
Procedure Category:
Type 2
Parts Referenced:
None
Special Tools:
None
Related Documents:
None
NOTE: One calibration gas cylinder is needed to set the span. To examine the span or to adjust the
span, use a calibration gas with an O2 content between 10 and 90 percent of the range on a
single range instrument, or between 10 and 90 percent of the middle range on a multi-range
instrument. Use a gas similar to the sample gas that has an O2 content that approximates either
the expected O2 limit of level to be monitored.
To calibrate the O2 analyzer:
7-38
1
Operate the O2 analyzer for at least eight hours to make sure that there will be a stable reading.
2
Select a certified cylinder of appropriate background gas in which the O2 content has been
accurately determined. Use a thoroughly purged regulator on the cylinder.
3
Energize the O2 analyzer. Set a flow rate of 2.0 scfh.
4
Monitor the response of the O2 analyzer to the certified gas until you get a stable reading. Use a
recorder to make sure that the sensor has reached an equilibrium point.
5
If necessary, reset the SPAN dial until the analyzer reading corresponds to the O2 level listed for the
certified gas cylinder. Record the SPAN dial reading.
6
For more information, refer to the O2 analyzer manual in Appendix E: VENDOR MANUALS.
PREVENTATIVE & CORRECTIVE MAINTENANCE
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Test Heater Current
Procedure Category:
Type 2
Parts Referenced:
None
Special Tools:
None
Related Documents:
None
To test the heater current:
NOTE: All heater wiring is labeled. Refer to Appendix A: DRAWINGS, SPECIFICATIONS & OPTIONS
for the Heater Data Sheet and corresponding electrical drawings.
1
Remove the applicable access panels. Refer to page 7-4, Removing Access Panels.
2
On the Master Control Panel, set HEAT ON/OFF to ON.
3
Wait until the heaters are fully energized.
4
Attach an ammeter to a heater wire.
5
Compare the ammeter indication with the current ratings on the Heater Data Sheet in Appendix A:
DRAWINGS, SPECIFICATIONS & OPTIONS for that heater.
6
Repeat 4 and 5 on all heater wiring. Refer to Figure 7-16.
2
1
TFF11050
1
Heater wires (attach ammeter along each wire)
2
Thermocouple housing
Figure 7-16: Test Heater Current
September 26, 2007
PREVENTATIVE & CORRECTIVE MAINTENANCE 7-39
TM 5259111 Rev. 0
7-40
PREVENTATIVE & CORRECTIVE MAINTENANCE
IN-LINE DIFFUSION SYSTEM MANUAL
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
CHAPTER 8
COMPONENT REPLACEMENT
TABLE OF CONTENTS
Conveyor System .................................................................................................................................. 8-3
Replace the Conveyor Belt ..................................................................................................... 8-3
Replace the Drive Motor Chain .............................................................................................. 8-5
Replace the Drive Motor......................................................................................................... 8-6
Replace the Drive Motor Optical Encoder ............................................................................. 8-8
Replace the Drive Motor Shear Pin ........................................................................................ 8-9
Replace Drive Return Rollers ............................................................................................... 8-11
Electrical and Control System............................................................................................................. 8-12
Replace the Belt Speed Module............................................................................................ 8-12
Replace Intellimax Controller............................................................................................... 8-13
Replace the Light Tower....................................................................................................... 8-16
Replace a Light Tower Bulb ................................................................................................. 8-17
Replace the Computer........................................................................................................... 8-18
Replace an SSR..................................................................................................................... 8-18
Replace the UPS [Option]..................................................................................................... 8-20
Replace the Belt Speed Module............................................................................................ 8-21
Atmosphere System............................................................................................................................. 8-23
Replace an Atmosphere Curtain ........................................................................................... 8-23
Replace a Gas Dispersion Tube ............................................................................................ 8-24
Replace a Flowmeter ............................................................................................................ 8-25
Heating System ................................................................................................................................... 8-27
Replace Top Heaters ............................................................................................................. 8-27
Replace Bottom Heaters ....................................................................................................... 8-42
Replace a Thermocouple ...................................................................................................... 8-46
Cooling System ................................................................................................................................... 8-47
Muffle System ..................................................................................................................................... 8-48
Replace a Silicone Gasket..................................................................................................... 8-48
September 26, 2007
COMPONENT REPLACEMENT 8-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
WARNING!
READ!
• Read this manual in its entirety before you install, operate, troubleshoot or
maintain the furnace.
• Read a procedure in its entirety before you perform it.
• Always note and take any safety precautions recommended in this manual and
other documentation before you perform any procedure; otherwise, severe
personal injury or equipment damage may occur.
Refer to Chapter 1, INTRODUCTION for the recommended tools.
QUALIFIED PERSONNEL!
• Procedures include working with high amperage, high voltage and moving parts.
• Procedures must be performed by fully trained, fully qualified personnel.
• Most procedures require advanced knowledge of electrical, mechanical, and
plumbing theories and issues.
• DO NOT PERFORM THE PROCEDURE IF YOU HAVE ANY DOUBTS ABOUT
HOW TO ACCOMPLISH THE TASKS INVOLVED. Contact BTU International
Customer Service; otherwise, severe personal injury or equipment damage may
occur.
• If you do not obey all the safety precautions listed in this manual and any other
associated documents, you risk the occurrence of death or serious injury to
personnel and a cancelled manufacturer's warranty.
8-2
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
CONVEYOR SYSTEM
Replace the Conveyor Belt
Procedure Category:
Type 1
Special Tools:
None
Parts Referenced:
Replacement belt (Refer to Appendix B, RECOMMENDED SPARE
PARTS.)
Related Documents:
Lockout/Tagout Procedure (page 2-10)
To replace the conveyor belt:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
2
Dissemble the connector clip and master link from the drive chain (Figure 8-4), and remove the
chain.
3
Remove the entrance and exit curtains.
NOTE: When replacing the conveyor belt, two people are required.
4
Place the rolled up belt at the entrance end of the furnace and orient.
5
Cut the old belt and securely attach the leading edge of the new belt to the old belt.
Figure 8-1: Guide New Belt
6
Carefully pull the belt through the furnace from the exit end, while an assistant unrolls and guides
the belt into the furnace (Figure 8-1).
September 26, 2007
COMPONENT REPLACEMENT 8-3
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
NEW BELT ATTACHED
TO OLD BELT
DRIVE
ROLLER
PRESSURE
ROLLER
CATENARY
WEIGHT
Figure 8-2: Belt Installation
7
When the belt has been pulled through the furnace chamber, continue pulling the belt through the
drive system, until the belt path is complete, as shown in Figure 8-2. Be sure the catenary weight is
positioned approximately 3-in. above the frame.
A catenary is an unsupported length of conveyor belt that forms a sagging loop. The purpose of the
catenary loop is to absorb belt length variations due to thermal expansion and load changes. In the
In-Line Diffusion furnace, a weight is installed in the catenary for belt tracking. The belt catenary
hangs inside the ultrasonic cleaner at the exit end of the furnace.
8
Splice the belt, as shown in Figure 8-3.
Figure 8-3: Inserting Belt Splice
9
Install the drive chain.
10 Install the entrance and exit curtains.
11 If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
12 Examine equipment operation:
8-4
a
Operate the belt slowly.
b
Make sure the belt tracks correctly.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Replace the Drive Motor Chain
Procedure Category:
Type 2
Parts Referenced:
Drive Chain (Refer to Appendix B, RECOMMENDED SPARE PARTS.)
Special Tools:
None
Related Documents:
None
To remove the drive motor chain:
1
Remove access panels from the exit table. Refer to page 7-4, Removing Access Panels.
2
Dissemble the connector clip and master link from the drive chain (Figure 8-4), and remove the
chain.
1
1
1
Connector Clip
Figure 8-4: Connector Clip
To install the drive motor chain:
1
Position the replacement chain over the drive pulley and drive motor sprockets.
2
Connect the two ends together using a master link and connector clip.
3
Examine chain tension and adjust as required. Refer to page 7-23, Examine and Adjust Drive
Chain Tension.
4
Install access panels. Refer to page 7-4, Removing Access Panels.
5
Operate the drive motor and examine equipment operation.
September 26, 2007
COMPONENT REPLACEMENT 8-5
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Replace the Drive Motor
Procedure Category:
Type 1
Parts Referenced:
Drive Motor
Special Tools:
• Wrench
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
To remove the drive motor:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
8-6
2
Let the furnace fully cool.
3
Remove access panels from the exit table. Refer to page 7-4, Removing Access Panels.
4
Remove the connector clip and master link from the motor drive chain (Figure 8-4).
5
Remove the chain.
6
Disconnect the wires from the motor.
7
Remove the mounting bolts that secure the motor to the exit table frame (Figure 8-5).
8
Remove the motor.
9
Disassemble and remove the drive sprocket assembly from the motor shaft.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
1
2
CONV1029
1
Motor
2
Bolt, Washers
Figure 8-5: Replace the Drive Motor
NOTE: The new drive motor has an optical encoder that is factory adjusted. Additional adjustments are
not necessary.
To install the replacement motor:
1
Install the sprocket assembly onto the replacement motor’s drive shaft.
2
Place the replacement motor in position and install the mounting bolts.
3
Install the drive chain. Refer to page 8-5, Replace the Drive Motor Chain.
4
Connect the drive motor and optical encoder wires.
5
Examine the sprocket/chain adjustment and adjust if necessary. Refer to page 7-23, Examine and
Adjust Drive Chain Tension.
6
Fill the motor with oil. Refer to page 7-24, Fill Drive Motor Gearbox with Oil.
7
Remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout Removal Procedure.
8
Operate the drive motor and examine the direction of travel. If the direction is not correct:
9
a
Examine the installation for defective wire connections and correct as required.
b
Operate the drive motor and examine equipment operation.
Install the access panels. Refer to page 7-4, Removing Access Panels.
September 26, 2007
COMPONENT REPLACEMENT 8-7
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Replace the Drive Motor Optical Encoder
Procedure Category:
Type 1
Parts Referenced:
Drive Motor Optical Encoder
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
To remove the drive motor optical encoder:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
1
Remove access panels from the exit table. Refer to page 7-4, Removing Access Panels.
2
Disconnect the optical encoder wiring connector.
3
Refer to manufacturer instructions (Appendix E, VENDOR MANUALS) and remove the encoder.
Do not remove the extension shaft from the motor unless it is damaged.
To install the drive motor optical encoder:
8-8
1
Refer to manufacturer instructions (Appendix E, VENDOR MANUALS) and install the encoder.
Install a new extension shaft if the current shaft is damaged.
2
Reconnect the optical encoder wiring connector.
3
Install the access panels. Refer to page 7-4, Removing Access Panels.
4
If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
5
Examine equipment operation.
6
Calibrate the belt speed. Refer to WINCON Online Help.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Replace the Drive Motor Shear Pin
Procedure Category:
Type 2
Parts Referenced:
Shear pin (spare shear pins are in an envelope by the drive motor)
Special Tools:
•
•
•
•
•
•
Related Documents:
None
Thread adhesive (removable grade)
Pliers
Drift pin punch
Light-weight hammer
Rubber gloves
Protective clothing
NOTE: Use the correct shear pin. Usually, the shear pin block has four different sized holes and two set
screws.
To remove the drive motor shear pin:
1
Remove access panels from the exit table. Refer to page 7-4, Removing Access Panels.
2
Find the cause of the belt overload and correct it. Refer to page 6-2, Troubleshoot the Conveyor
System.
3
Remove the drive motor chain.
4
a
Remove the connector clip.
b
Remove the master link.
Using pliers or a drift pin punch and light-weight hammer, remove shear pin from the pin block and
sprocket. Refer to Figure 8-6.
To install the drive motor shear pin:
1
Push the drive sprocket against the shaft collar.
2
Examine the adjustment. If the chain and sprocket are not aligned:
a
Loosen the shaft collar set screws.
b
Reposition the sprocket and collar.
c
Tighten the shaft collar set screws. Use removable grade thread adhesive.
September 26, 2007
COMPONENT REPLACEMENT 8-9
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
a
2
1
3
8
4
5
6
7
1
Setscrew
4
Key Stock
7
Drive Sprocket
2
Setscrew
5
Drive Jack Shaft
8
Shaft Collar
3
Shear Pin
6
Shear Pin Block
Figure 8-6: Drive Sprocket and Shear Pin Assembly
3
8-10
Push the shear pin block against the sprocket:
a
Make sure the key stock is properly installed in the keyway.
b
Tighten the shear pin block setscrews.
c
Make sure the drive sprocket rotates freely on the drive shaft with the shear pin removed.
4
Turn the sprocket until the correct shear pin hole is aligned with the shear pin hole in the block.
5
Tap in the new shear pin using a light-weight hammer. Make sure that it is tight.
6
Install the drive chain on the sprockets.
7
Install the access panels. Refer to page 7-4, Removing Access Panels.
8
Examine equipment operation.
9
Refer to Figure 8-6.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Replace Drive Return Rollers
Procedure Category:
Type 1
Parts Referenced:
Roller
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
To remove a drive return roller:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
4
Record the mounting hole in which the defective roller (Figure 8-7) is installed.
3
3
1
2
2
3
1
Slot
2
Drive Return Roller
3
CONV1031
Pins (One end is spring-loaded. Press in to release.)
Figure 8-7: Return Roller (Top View)
September 26, 2007
COMPONENT REPLACEMENT 8-11
TM 5259111 Rev. 0
5
IN-LINE DIFFUSION SYSTEM MANUAL
Press the spring-loaded end to release it from the furnace frame and remove the roller.
To install a drive return roller:
1
Insert the new roller and press the spring-loaded end into the same hole from which it was
removed.
2
Install the access panels. Refer to page 7-4, Removing Access Panels.
3
If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
4
Examine equipment operation.
ELECTRICAL AND CONTROL SYSTEM
Replace the Belt Speed Module
Procedure Category:
Type 1
Parts Referenced:
Belt speed module
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
NOTE: If you replace the belt speed module, you must replace a circuit board module in the electric
cabinet.
To remove the belt speed module:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
8-12
Let the furnace fully cool.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
3
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
4
Record the wire connections to the belt speed module.
5
Disconnect the wires from the belt speed module.
6
Remove the screws.
7
Remove the belt speed module.
To install the belt speed module:
1
Set the potentiometers and switches of the new belt speed module to the same settings as the old
belt speed module.
2
Install the new belt speed module.
3
Install the screws.
4
Connect the wires.
5
Install the tie down clips.
6
Install the access panels. Refer to page 7-4, Removing Access Panels.
7
If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
8
Examine conveyor operation at maximum and minimum speeds.
Replace Intellimax Controller
Procedure Category:
Type 1
Parts Referenced:
Intellimax board
Special Tools:
• Labels
• Rubber gloves
• Protective clothing
Related Documents:
WINCON Online Help
Lockout / Tagout Procedure (page 2-10)
NOTE: Only fully trained and qualified personnel shall be authorized to replace an Intellimax. If you
have any questions or issues, call BTU International Customer Service.
The Intellimax Installation Wizard automatically configures any applicable Intellimax controller board
to the furnace in which it is installed. After you have installed a new Intellimax, the Installation Wizard
starts automatically, and does the following:
• Checks channel compatibility
• Checks Intellimax input and output (I/O) capability
• Verifies software compatibility
• Updates software (if available)
• Verifies and stores gain and offset data
September 26, 2007
COMPONENT REPLACEMENT 8-13
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
The Installation Wizard also guides you through a read-only memory (ROM) image update when a software update is available, and if invalid calibration is detected.
To remove the Intellimax Controller:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
2
Remove the applicable access panels to gain access to the electrical panel.
3
Label and disconnect all connectors on the existing Intellimax. Be careful when disconnecting the
connectors! Do not pull on the wires! Pulling on the wires will damage them.
4
Disconnect the Ethernet cable from the Intellimax. The Ethernet cable is located on the left-hand
side of the Intellimax.
5
Using a screwdriver, loosen, but do not remove, the screws that attach the Intellimax to the
electrical panel.
6
Carefully remove the Intellimax from the furnace. Lift the Intellimax up and then away from the
electrical panel.
To install the Intellimax Controller:
1
Install the Intellimax in the furnace. Lower the Intellimax onto the four screws on the electrical
panel.
2
Using a screwdriver, tighten the screws that attach the Intellimax.
3
Connect the connectors onto the Intellimax. Be careful when connecting the connectors! Do not use
excessive force on the connectors! Excessive force will damage the connector pins.
4
Connect the Ethernet cable to the Intellimax.
5
Install all access panels.
6
Remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout Removal Procedure. After
WINCON starts, the Intellimax Wizard locates the new Intellimax control module.
7
Sign on to WINCON. After signing on, the Intellimax Wizard checks channel configuration to
ensure the new Intellimax will operate properly with your furnace (e.g., the Wizard verifies that the
newly installed Intellimax has the correct number of channels, 16, 32, or 48). Then the Wizard
checks I/O capability and WINCON compatibility, which includes the following:
• Checking user privileges...
8-14
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
• Checking channel configuration...
• Checking Intellimax software versions...
8
If there is a matching ROM image available, the ROM image will update automatically. If there is
no matching ROM image available, the Wizard will provide you with options to either browse for
an ROM image file, to use the most compatible available image, or use the existing image on the
Intellimax (if compatible).
• Recording physical characteristics...
• Recording software version information...
• Recording calibration information...
• Set System...
9
Click Run WINCON.
NOTE: After the Intellimax has restarted, any latching circuits will need to be manually reset, i.e., the
START/RESET push button.
10 On the operator control panel, press and hold the START/RESET push button for 5 seconds.
11 Examine equipment operation.
September 26, 2007
COMPONENT REPLACEMENT 8-15
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Replace the Light Tower
Procedure Category:
Type 2
Parts Referenced:
Light Tower
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
None
To remove the light tower:
NOTE: If this is the first installation of the light tower, refer to the INSTALLATION DRAWING in
Appendix A for the location of the light tower.
1
Remove the applicable access panels. Refer to page 7-4, Removing Access Panels.
2
Disconnect the light tower electrical connector under the top panel.
3
Loosen and remove the four nuts, washers, and screws from the light tower bottom.
4
Remove the light tower by sliding the electrical wires and connector up through the opening in the
panel.
To install the light tower:
NOTE: The light tower is removed for shipment. The gasket is attached to the light tower.
8-16
1
Install the light tower by threading the electrical connector and wires through the panel opening. Be
sure the gasket is installed.
2
Secure the light tower using the four screws, washers, and nuts.
3
Connect the light tower electrical connector.
4
Install the access panels. Refer to page 7-4, Removing Access Panels.
5
If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
6
Examine equipment operation.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Replace a Light Tower Bulb
Procedure Category:
Type 1
Special Tools:
None
Related Documents:
Lockout/Tagout Procedure (page 2-10)
The light tower contains bayonet based lamps that are located behind the colored lenses. In order to
reach one of the lower lamps, you must first remove the lenses that are above the desired lens.
To replace a light tower bulb:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
2
Loosen the screw on the top cover plate of the light tower, then remove the cover plate.
3
Depending on which lamp you need to replace, remove the lenses until you have accessed the
desired lamp.
4
Remove the existing lamp by pushing in and turning it counterclockwise.
5
Insert the new replacement lamp by pushing it in and turning it clockwise.
6
Replace all of the lenses in the proper order.
7
Replace the cover plate and install the screw securing the cover plate on the top of the light tower.
8
Remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout Removal Procedure.
9
Examine equipment operation.
September 26, 2007
COMPONENT REPLACEMENT 8-17
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Replace the Computer
Procedure Category:
Type 2
Parts Referenced:
Computer
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
WINCON Online Help
The computer is located inside the exit table.
CAUTION!
If you install a new computer, you must install WINCON again. Use this procedure
when you replace the computer, the motherboard, or the hard drive. Do not use this
procedure if you replace the monitor or keyboard.
To remove the computer:
1
Remove access panels from the exit table. Refer to page 7-4, Removing Access Panels.
2
De-energize the computer.
3
Label the connectors.
4
Disconnect the cables.
To install the computer:
1
Place the new computer in position inside the exit table.
2
Connect the cables.
3
Energize the computer.
4
Reinstall WINCON using the back-up disk located inside the front cover of the user manual.
5
For information on installing and connecting the computer or to configure the controller, refer to
WINCON Online Help.
6
Examine equipment operation.
Replace an SSR
8-18
Procedure Category:
Type 1
Parts Referenced:
• SSR
• Thermal Pad, Insulated
Special Tools:
• Rubber gloves
• Protective clothing
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Lockout / Tagout Procedure (page 2-10)
Related Documents:
To remove the SSR:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
2
Let the furnace fully cool.
3
Remove applicable access panels. Refer to page 2-11, Lockout / Tagout Removal Procedure.
4
Remove the plastic cover.
5
Label and disconnect the wire connections to the SSR.
6
Remove the SSR mounting screws (Figure 8-8).
7
Remove the SSR.
INPUT
3
1
4
1
A
OUTPUT
2
1
A
1
Mounting Screws
2
2
Plastic Cover
Figure 8-8: Replace an SSR
September 26, 2007
COMPONENT REPLACEMENT 8-19
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
To install the SSR:
1
Install the new thermal pad.
2
Install the SSR.
3
Install the SSR mounting screws.
4
Connect the wire connections to the SSR.
5
Install the plastic cover.
6
Install the access panels. Refer to page 7-4, Removing Access Panels.
7
If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
8
Examine equipment operation.
9
Refer to Figure 8-8.
Replace the UPS [Option]
Procedure Category:
Type 1
Parts Referenced:
UPS
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
To remove the UPS:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
8-20
2
Let the furnace fully cool.
3
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
4
Label and disconnect the electrical connections.
5
Remove the old UPS.
To install the UPS:
6
Put the new UPS into position. Make sure that there is sufficient clearance for airflow.
7
Connect the male and female power plugs.
8
Make sure that ENABLE OUTPUT is on. Refer to Appendix E, VENDOR MANUALS.
9
Re-install the access panels.
10 If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
11 Charge the UPS for 24 hours before you operate the furnace. If the lamp blinks when energized, the
battery is charging.
12 Examine equipment operation.
Replace the Belt Speed Module
Procedure Category:
Type 1
Special Tools:
None
Related Documents:
• Applicable manufacturer's data sheet
• Lockout / Tagout Procedure (page 2-10)
The belt speed module is located in the electrical compartment.
To remove the belt speed module:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
2
Remove the applicable access panel to gain access to the belt speed module.
3
Using a screwdriver, remove the mounting screws that secure the protective cover.
4
Remove the connectors from the module.
5
Using a screwdriver, remove the mounting screws that attach the belt speed module.
6
Remove the existing belt speed module.
September 26, 2007
COMPONENT REPLACEMENT 8-21
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Figure 8-9: Belt Speed Module and Protective Cover
To install the belt speed module:
8-22
1
Make sure the potentiometers and switches of the new belt speed module match those of the
existing module. If necessary, adjust the potentiometers of the new module (refer to the
manufacturer's data sheet).
2
Put the new module into position.
3
Using a screwdriver, install the mounting screws that attach the module.
4
Install the connectors to the module. Secure the connectors with tie wraps.
5
Replace and secure the protective cover.
6
Install the access panels.
7
Remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout Removal Procedure.
8
Examine equipment operation. Operate the conveyor at minimum and maximum speeds.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
ATMOSPHERE SYSTEM
Replace an Atmosphere Curtain
Procedure Category:
Type 2
Parts Referenced:
atmosphere curtain
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
None
Atmosphere curtain assemblies located at the entrance and exit ends of the furnace allow product to
pass through while keeping the outside atmosphere from entering the furnace. Curtain assemblies are
custom cut and assembled to ensure a minimum of atmosphere transfer.
Each assembly consists of a metal frame and hanging rows of sheet metal curtains. Individual rows
contain four sections of sheet metal. This enables individual curtains to remain closed in product lanes
not being used.
Occasionally, sections of sheet metal can become damaged during profiling. If an individual curtain is
bent or damaged, it can be individually replaced.
To remove an individual atmosphere curtain:
1
Pull out the curtain assembly by the handle.
2
Examine the individual sheet metal curtains for damage.
3
Remove a damaged curtain by removing the cotter pins that secure the sheet metal curtain to the
frame.
To install an individual atmosphere curtain:
1
Place the replacement curtain in position.
2
Install new cotter pins.
3
Install the curtain assembly.
4
Examine equipment operation.
September 26, 2007
COMPONENT REPLACEMENT 8-23
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Replace a Gas Dispersion Tube
Procedure Category:
Type 2
Parts Referenced:
Gas Dispersion Tube
Special Tools:
• China marker
• Rubber gloves
• Protective clothing
Related Documents:
None
To remove a gas dispersion tube:
1
Turn off the gas supply at the source.
2
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
3
Disconnect the elbow (1) and the adapter (2).
4
Remove the fiber insulation (3) assembly.
5
Mark the edges of the dispersion tube (5) in line with the slotted openings with a china marker.
6
Refer to Figure 8-10.
1
2
3
4
A
45
A
1
Elbow
3
Bracket
2
Adapter
4
Dispersion Tube
45
A-A
Figure 8-10: Gas Dispersion Tube
To install a gas dispersion tube:
8-24
1
Use the china marks as a guide and insert the tube into the process chamber with the slotted
openings at a 45 degree angle to the belt. (On tubes with only one set of slotted openings, put the
openings to face the entrance.)
2
Connect the tube to the adapter assembly and the elbow fittings.
3
Install the access panels. Refer to page 7-4, Removing Access Panels.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
4
Turn on the gas supply.
5
Examine equipment operation.
6
Refer to Figure 8-10.
Replace a Flowmeter
Procedure Category:
Type 2
Parts Referenced:
Flowmeter
Special Tools:
• Rubber gloves
• Protective clothing
Related Documents:
None
CAUTION!
Make sure that all gas lines have labels so that you can connect them correctly to
the facility hookup.
Flowmeters are factory tested. If you purchase a flowmeter from another source,
make sure that you do a leak test on it.
To remove a flowmeter (Figure 8-11):
1
Turn off the gas supply at the source.
2
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
3
Bleed the gas from the line.
4
Record the flow rate setting of the old flowmeter.
Figure 8-11: Flowmeter Plumbing
September 26, 2007
COMPONENT REPLACEMENT 8-25
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
5
Remove the label from the flowmeter. Keep the old label.
6
Disconnect the flowmeter plumbing.
7
Remove the nuts securing the flowmeter to the panel.
8
Remove the flowmeter.
To install a flowmeter:
8-26
1
Position the flowmeter.
2
Connect and tighten the nuts securing the flowmeter to the panel.
3
Connect and tighten the plumbing fittings.
4
Install the label on the new flowmeter.
5
Install the access panels. Refer to page 7-4, Removing Access Panels.
6
Set the flowmeter to the recorded flow rates.
7
Do a leak test of the flowmeter fittings.
8
Turn on the gas supply.
9
Examine equipment operation.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
HEATING SYSTEM
Replace Top Heaters
Procedure Category:
Type 1
Parts Referenced:
Set of replacement heaters
RTC gasket
Special Tools:
• Input/Heater Power Wiring Diagram (refer to Appendix A, DRAWINGS,
SPECIFICATIONS & OPTIONS)
• Putty knife
• Eight .5-in. OD x 10-in copper pipes
• Four 10-in. blocks
• Labels
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
Replace Gasket Procedure (page 8-48)
Top heaters are replaced as sets--- Left and Right. Use this procedure to replace a set of top heaters.
NOTE: The furnace frame includes welded cross members. Every other zone is under a welded cross
member. In order to remove a faulty heater under a cross member, an adjacent set of heaters
must be removed. This creates the clearance required to lower the faulty heater under the cross
member for removal.
To remove a set of top heaters:
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
2
Let the furnace fully cool.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
September 26, 2007
COMPONENT REPLACEMENT 8-27
TM 5259111 Rev. 0
3
IN-LINE DIFFUSION SYSTEM MANUAL
Remove the side and top access panels necessary to access the zone containing the faulty heater. If
the zone is under a cross member, the top heaters in an adjacent zone must also be removed to give
access to the faulty heater. Refer to page 7-4, Removing Access Panels.
NOTE: If replacing a heater in a zone under an exhaust assembly, disassemble the exhaust venturi and
condensation trap plumbing connections, and remove the exhaust pipe/trap assembly before
removing the process chamber top panel. Refer to Figure 8-12.
1
1
2
2
Plumbing Connections
Exhaust Pipe / Trap Assembly
Figure 8-12: Exhaust Plumbing Connections
4
8-28
Disassemble electrical connections to heater leads extending through process chamber top cover(s).
Refer to figure Figure 8-13.
a
Record and label electrical connections before disconnecting.
b
Slide sleeve covering electrical connection back.
c
Loosen and remove split nut and electrical wire from heater lead.
d
Remove mica washer.
e
Remove Viton fitting cover, inner seal, and rubber grommet.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
2
1
3
2
6
4
3
4
5
5
1
Sleeve
3
Mica Washer
5
Viton Cover
2
Split Nut
4
Viton Rubber Grommet & Seal
6
Heater Lead
Figure 8-13: Top Heater Electrical Connections
5
Disassemble electrical connections to thermocouple(s) extending through side of process chamber
and remove thermocouple. Refer to Figure 8-14.
a
Record and label electrical connections before disconnecting.
b
Disconnect wires from terminal block.
c
Remove thermocouple by turning counterclockwise.
NOTE: The thermocouple is covered in quartz; take care not to drop it.
Figure 8-14: Zone Thermocouple
6
If removing heaters in a zone under an exhaust, remove the exhaust assembly (Figure 8-15):
a
September 26, 2007
Disassemble the remaining plumbing connections to the exhaust assembly.
COMPONENT REPLACEMENT 8-29
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
b
Disassemble electrical connections to exhaust heater leads (4) and exhaust thermocouple.
Record and label electrical connections before disconnecting.
c
Disassemble electrical ground connection.
d
Disassemble connections to exhaust plenum.
e
Remove corner bolts (4) securing assembly to furnace frame.
f
Lift exhaust assembly up and off the furnace.
NOTE: The exhaust assembly is heavy. If possible, lift the assembly using a crane.
1
4
1
Heater Electrical
Connections (2/side)
2
Ground Connection
2
3
3
Thermocouple Connection 4
Exhaust Plenum
Connections
Figure 8-15: Exhaust Electrical Connections
7
If zone is equipped with a preheater, disconnect the plumbing connections and remove preheater.
Refer to Figure 8-16.
Figure 8-16: Preheater Connections
8-30
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
8
TM 5259111 Rev. 0
If zone is equipped with a dispersion tube, remove the dispersion tube (Figure 8-17):
a
Disconnect the plumbing to the fitting.
b
Disconnect the fitting holding the tube.
NOTE: The dispersion tube is made of quartz; take care not to drop it.
c
Carefully slide the tube out.
Figure 8-17: Dispersion Tube and Fitting
9
Remove applicable process chamber top cover(s):
a
Remove brackets securing process chamber cover.
• Seam brackets secure top covers to welded frame cross members. Remove five nuts /
washers and remove bracket(s).
• Side brackets secure top covers to process chamber frame (Figure 8-18). Loosen bolts and
remove brackets.
b
Break the seal by running a putty knife around the complete perimeter between the gasket and
the furnace (Figure 8-19).
NOTE: The gasket is attached to the cover with RTV adhesive. The gasket can be reused if not
damaged. Run the putty knife along the edge of the furnace case. Do not insert the knife
between the gasket and the cover.
c
Lift the cover up and off the furnace frame from the 4 corners (requires four people).
d
Inspect gasket. If gasket is damaged, replace gasket. Refer to page 8-48, Replace a Silicone
Gasket.
September 26, 2007
COMPONENT REPLACEMENT 8-31
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Figure 8-18: Top Cover Brackets
Figure 8-19: Break Gasket Seal
10 Remove the ceramic spacer from each heater lead. Refer to “B” in Figure 8-20.
11 Heaters NOT under a frame cross member are removed with the insulation in place.
• If replacing a heater NOT under a cross member, use this step to remove the top heaters.
• If replacing a heater UNDER a cross member, use this step to remove the top heaters in the
adjacent zone to gain access to the faulty heater. Cross members are part of the welded frame and
are not removable.
a
Inspect the insulation. If the insulation extends under the furnace frame’s cross member or an
adjacent support bracket, fold back the insulation if possible, or cut the installation
approximately one to two inches from the cross member or bracket. The dotted line in Figure
8-20 represents the proper position to cut the insulation.
NOTE: There are two layers of insulation. Cut the insulation so that when replaced, the top layer
(Duraback) overlaps the seam in the lower layer (Durablanket), and the lower layer overlaps the
seam created by the heaters.
b
8-32
Heaters are suspended over the process chamber by two heater support brackets. Remove the
end bolts (4) that secure the support brackets (2) to the frame. Refer to “A” in Figure 8-20.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
WARNING!
Do not loosen or remove the inner nuts (4) on each bracket, or the heaters may fall
onto and break the quartz plates below.
A
B
Figure 8-20: Support Bracket Bolts and Insulation Cut Location
c
September 26, 2007
Being careful not to tilt the heaters into the quartz below, lift the heater assembly out of the
furnace by lifting the heater support brackets at both ends (two people required). Refer to
Figure 8-21.
COMPONENT REPLACEMENT 8-33
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Figure 8-21: Top Heaters Removed with Insulation in Place
12 If you have removed heaters in the adjacent zone in order to access the faulty heater, set the heater
assembly aside and skip this step. If the heater assembly contains the faulty heater, place the heater
assembly on a flat surface and disassemble it:
a
Remove the nuts (4) and washers (4) securing each support bracket (2) to the heaters and
remove the brackets.
b
Taking note of order of installation, remove the two layers of insulation.
NOTE: Note the order of installation of each piece of insulation and do not intermingle the top layer
(Duraback) with the bottom layer (Durablanket). They are two different types of insulation.
When disassembling the oven, lay the pieces aside in the order they are removed.
c
Remove the old heaters and place the replacement heaters in position.
NOTE: Heaters are labeled left and right. Be sure to replace each heater with the correct replacement.
d
Install the two layers of insulation using the order and orientation previously used with the
original heaters.
e
Install the support brackets (2) over the threaded rods and secure each bracket with the nuts (4)
and washers (4).
f
To reinstall the heater assembly, refer to page 8-39.
13 Remove the quartz plates (2) from the adjacent zone (Figure 8-22).
8-34
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
Figure 8-22: Adjacent Zone with One Quartz Plate Removed
14 Remove the quartz plates (2) from under the faulty heater:
a
Slide the first quartz plate from under the faulty heater into the adjacent zone and lift out. Refer
to (Figure 8-23).
b
Slide the second quartz plate from under the faulty heater into the adjacent zone and lift out.
Figure 8-23: Slide Quartz from Under Heater into Adjacent Zone
WARNING!
Before removing the heater support brackets, place support blocks under the
heaters. If the heaters are not blocked, they will fall onto and break the quartz tubes
and plates below the conveyor belt.
15 Place support blocks under the heaters. If the heaters are not temporarily supported, they will fall
onto and break the quartz tubes and plates below the belt. Refer to Figure 8-24.
September 26, 2007
COMPONENT REPLACEMENT 8-35
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
a
Measure the distance between the bottom of the heaters and the belt.
b
Cut temporary supports (4) to the measured height.
c
Place the supports under the heaters toward the center of the furnace.
Figure 8-24: Temporary Heater Supports (support brackets & insulation removed for clarity)
16 The set of heaters are suspended over the process chamber by two heater support brackets. Remove
the support brackets (Figure 8-25):
a
Remove the end bolts (4) that secure the support brackets (2) to the frame.
b
Remove the nuts (4) and washers (4) securing each support bracket (2) to the heaters and
remove the brackets.
17 Remove the two layers of insulation.
NOTE: Note the order of installation of each piece of insulation and do not intermingle the top layer
(Duraback) with the bottom layer (Durablanket). They are two different types of insulation.
When disassembling the oven, lay the pieces aside in the order they are removed.
18 If the heaters are not under an exhaust port, skip this step. If removing heaters in a zone under an
exhaust (Figure 8-25):
8-36
a
Remove small brick from top of each end of exhaust plenum.
b
Remove .5-in M-Board from top of exhaust plenum.
c
Remove exhaust plenum.
d
Remove .25-in. M-Board (protects heater leads from shorting against exhaust plenum).
COMPONENT REPLACEMENT
October 4, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
A
TM 5259111 Rev. 0
B
3
1
1
3
2
3
2
C
D
A1
Heater Support Brackets
B2
.5-in. M-Board
A2
Heater Support Bracket End Bolts (2 / bracket)
B3
Welded Frame Cross Member
A3
Heater Support Bracket Nuts / Washers (4 / bracket)
C
Exhaust Plenum
B1
Small Brick (2)
D
.25-in. M-Board
Figure 8-25: Heater Removal Under Exhaust
19 Remove heaters (Figure 8-26).
a
Remove cast-fiber side block from adjacent zone. Refer to “A” in Figure 8-26.
b
Remove cast-fiber side block from under heater (requires two people). Refer to “B” in Figure
8-26.
• Lift and hold first heater above process chamber.
• Remove temporary support blocks.
• Slide cast-fiber side block from under heater into adjacent zone.
• Remove cast-fiber side block from process chamber.
c
Carefully tilt the heater under the welded cross member, and remove it from the process
chamber. Refer to “C” in Figure 8-26.
d
Remove the second heater:
• Lift and hold second heater above process chamber.
• Remove temporary support blocks.
September 26, 2007
COMPONENT REPLACEMENT 8-37
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
NOTE: It is not necessary to remove the opposite cast-fiber side block.
• Carefully tilt the heater and remove it from under the welded cross member. Refer to “C” in
Figure 8-26.
A
B
C
D
A
B
Remove Side Block in Adjacent Zone
C
Lower Heater and Tilt to Remove
Remove Side Block from Under Heater
D
Remove Second Heater
Figure 8-26: Heater Removal Under Cross Member
8-38
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
To install replacement top heaters:
1
Before installing replacement heaters, follow the above procedure to remove the faulty heater(s). If
the faulty heater is under a cross member, the top heaters in an adjacent zone must also be removed
to give the necessary clearance for installation.
NOTE: Heaters are labeled left and right. Be sure to replace each heater with the correct replacement.
2
Complete this step to install top heaters in a zone UNDER a welded cross member. Refer to
Figure 8-26. If the heaters are not under a welded cross member, skip this step.
a
Position the first replacement heater:
• Place one cast-fiber side block against the furnace side wall.
• Tilt the replacement heater under the cross member and hold it over the process chamber.
• Have a second person place two temporary support blocks, on the belt, towards the center of
the furnace.
• Lower the heater so it rests on the side wall and the temporary support blocks.
b
Position the second replacement heater:
• Tilt the second replacement heater under the cross member and hold it over the process
chamber.
• Have a second person place the cast-fiber side block against the side wall and two temporary
support blocks towards the center of the furnace.
• Lower the second heater so it rests on the side wall and the temporary support blocks.
c
Install two layers of insulation over the replacement heaters using the order and orientation
previously used with the original heaters.
NOTE: Do not intermingle the top layer (Duraback) with the bottom layer (Durablanket). They are two
different types of insulation. Be sure that all seams are overlapping.
d
Install the heater support brackets (2) over the threaded heater rods and secure each bracket
with the nuts (4) and washers (4).
NOTE: Ensure the tops of both heaters are aligned and level.
e
Remove the temporary support blocks from under the heaters.
f
Secure the heater support brackets (2) to the furnace frame using the end bolts (4).
g
Install the quartz plates (2) under the replacement heaters:
• If necessary, reinstall the cast-fiber side blocks in the adjacent zone.
• Using the adjacent zone for access, lower a quartz plate onto the cast-fiber side blocks in the
adjacent zone, and slide the plate under the replacement heaters.
• Repeat the procedure with the second quartz plate (Figure 8-23).
3
Complete this step to reinstall top heaters that were removed in an adjacent zone for
clearance, or to install replacement heaters in a zone NOT under a welded cross member.
a
If necessary, reinstall the cast-fiber side blocks against both furnace side walls.
b
Carefully rest both quartz plates on the cast-fiber side blocks.
September 26, 2007
COMPONENT REPLACEMENT 8-39
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
c
Being careful not to tilt the heaters into the quartz below, lower the heater assembly into the
furnace by holding the heater support brackets at both ends (two people required). Refer to
Figure 8-21.
d
Secure the brackets (2) to the furnace frame using the end bolts (4). Refer to Figure 8-20.
e
If necessary, adjust each heater’s height:
NOTE: Adjusting heater height is only required if the heater assembly was disassembled for heater
replacement. If the heater assembly was removed to provide clearance for adjacent heaters,
height adjustment is not required.
• Each heater is supported by two brackets. Loosen the two nuts closest to the furnace frame
(“A” Figure 8-27) and lower the first heater until it rests on the cast-fiber side block. Tighten
nuts.
• Pull back the insulation and loosen the two nuts closest to the center of the furnace (“B”
Figure 8-27) and lower the heater until the top is flush with the top of the adjacent heater.
Tighten the nuts.
• Repeat the procedure with the second heater.
• Reposition the insulation. Be sure that all seams are overlapping.
B
A
Figure 8-27: Adjust Heater Height
4
5
8-40
If replacing heaters under an exhaust assembly, reinstall the exhaust plenum and insulation
(Figure 8-25):
a
Install .25-in. M-Board over heaters (protects heater leads from shorting against exhaust
plenum).
b
Install exhaust plenum.
c
Install .5-in M-Board over exhaust plenum.
d
Install small brick on top of each end of exhaust plenum.
Install process chamber top covers:
a
Cut eight (8) pieces of .5-in x 10-inch copper pipe.
b
Place a pipe over each heater lead to help align the leads with the cover.
c
Cut and position a 10-inch high block (4) at each corner of the cover opening.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
6
TM 5259111 Rev. 0
a
Using 4 people, lower cover onto corner blocks.
b
Align the viton fittings in the cover with the copper pipes over the leads.
c
Remove the four blocks and lower the cover into position over the furnace frame.
d
Remove copper pipes.
e
Secure cover to furnace frame using top and side (Figure 8-18) cover brackets.
If the heaters are not under an exhaust assembly, skip this step. If installing heaters in a zone under
an exhaust assembly:
a
Lower exhaust assembly into position.
NOTE: The exhaust assembly is heavy. If possible, lift the assembly using a crane.
b
Secure the exhaust assembly to process chamber frame with the corner bolts (4).
c
Secure the following connections:
• exhaust plenum couplings
• electrical ground
• electrical connections to exhaust heater leads (4) and exhaust thermocouple (Figure 8-15).
7
If the zone included a preheater, install the preheater (Figure 8-16).
8
Connect electrical connections to heater leads extending through the top cover (Figure 8-13).
9
a
Insert a 3-inch ceramic spacer over each heater lead. The spacer protects the lead from shorting
against the Viton fitting.
b
Install packing around the lead to keep it centered.
c
Insert the rubber grommet and seal.
d
Install the Viton fitting cover and place a mica washer over the heater lead.
e
Install the split nut and secure the electrical wire to the heater lead.
f
Slide sleeve over electrical connection.
Install zone thermocouple in process chamber side cover and reconnect electrical connections to
the thermocouple. Refer to Figure 8-14.
10 If the zone was equipped with a dispersion tube, install the dispersion tube and reconnect the
plumbing. Refer to Figure 8-17.
11 Install top and side access panels. Refer to page 7-4, Removing Access Panels.
12 If exhaust assembly was removed, reinstall exhaust venturi and condensation traps (Figure 8-12).
13 If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
14 Examine equipment operation.
September 26, 2007
COMPONENT REPLACEMENT 8-41
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Replace Bottom Heaters
Procedure Category:
Type 1
Parts Referenced:
Set of replacement heaters
RTC gasket
Special Tools:
• Input/Heater Power Wiring Diagram (refer to Appendix A, DRAWINGS,
SPECIFICATIONS & OPTIONS)
• Putty knife
• Labels
• Rubber gloves
• Protective clothing
Related Documents:
Lockout / Tagout Procedure (page 2-10)
Replace Gasket Procedure (page 8-48)
Bottom heaters are replaced as sets--- Left and Right. Use this procedure to replace a set of bottom
heaters.
NOTE: The top heaters in a zone must be removed to give access to bottom heaters.
To remove a set of bottom heaters:
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
2
Let the furnace fully cool.
WARNING!
Make sure that the equipment is cool before you do maintenance. You will be
burned if you touch hot equipment.
3
4
Remove the side and top access panels necessary to access the zone containing the faulty heater.
Remove the top heaters in the zone containing the faulty heater. Refer to page 8-27, Replace Top
Heaters.
5
Disassemble electrical connections to heater leads extending through process chamber side covers
Figure 8-13.
a
8-42
Record and label electrical connections before disconnecting.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
b
Slide sleeve covering electrical connection back.
c
Loosen and remove split nut and electrical wire from heater lead.
d
Remove mica washer.
e
Remove Viton fitting cover, inner seal, and rubber grommet.
4
5
2
6
2
1
3
4
3
5
1
Sleeve
3
Mica Washer
5
Viton Cover
2
Split Nut
4
Viton Rubber Grommet & Seal
6
Heater Lead
Figure 8-28: Bottom Heater Electrical Connections
6
Remove applicable process chamber side cover(s):
a
Loosen bolts and remove brackets securing process chamber side cover.
b
Break the seal by running a putty knife around the complete perimeter between the gasket and
the furnace (Figure 8-29).
NOTE: The gasket is attached to the cover with RTV adhesive. The gasket can be reused if not
damaged. Run the putty knife along the edge of the furnace case. Do not insert the knife
between the gasket and the cover.
c
Pry the cover off the furnace frame.
d
Inspect gasket. If gasket is damaged, replace gasket. Refer to page 8-48, Replace a Silicone
Gasket.
Figure 8-29: Breaking Seal on Side Cover
September 26, 2007
COMPONENT REPLACEMENT 8-43
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
A
B
C
D
E
F
A
1-in. K FAC-19
C
Side Block
E
Quartz Plates
B
.5-in. M-Board
D
Bottom Side Block
F
Bottom Heater
Figure 8-30: Remove Bottom Heaters
7
8-44
Remove bottom heaters:
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
a
Remove .5-in. K-FAC insulation. Refer to “A” in Figure 8-30.
b
Remove 1-in. M-Board insulation. Refer to “B” in Figure 8-30.
c
Remove cast-fiber side block. Refer to “C” in Figure 8-30.
NOTE: Be careful not to drop the quartz onto the heaters when removing the bottom side block.
d
Remove bottom cast-fiber side block. Refer to “D” in Figure 8-30.
e
Carefully support the quartz plates as you slide them out of the process chamber. Refer to “E”
in Figure 8-30. Try not to slide them against the top of the heaters.
f
Slide out and remove first heater. Refer to “F” in Figure 8-30.
g
Slide the second heater over toward the opening by pushing on the heater leads from the other
side of the furnace.
h
Remove the second heater.
To install replacement bottom heaters:
NOTE: Heaters are labeled left and right. Be sure to replace each heater with the correct replacement.
1
Slide the first replacement heater into the process chamber.
a
Push the heater into the process chamber until the heater leads protrude through the process
chamber far wall.
b
From the other side of the furnace, pull the heater into position by the heater leads.
2
Slide the second replacement heater into the process chamber. Refer to “F” in Figure 8-30.
3
Carefully slide the quartz plates into position.
Normally, each quartz plate is supported by bottom side blocks and along one edge by .25-in. MBoard. Because only one bottom side block is currently installed, each quartz plate must be
carefully supported to prevent it from scraping across the top of the heaters as it is installed.
4
Install the bottom cast-fiber side block. Refer to “D” in Figure 8-30.
5
Install the cast-fiber side block. Refer to “C” in Figure 8-30.
6
Install 1-in. M-Board insulation. Refer to “B” in Figure 8-30.
7
Install .5-in. K-FAC insulation. Refer to “A” in Figure 8-30.
8
Install the process chamber side cover.
9
Connect electrical connections to heater leads extending through the side covers (Figure 8-28).
10 Reinstall the top heaters. Refer to page 8-39, To install replacement top heaters:
11 If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
12 Examine equipment operation.
September 26, 2007
COMPONENT REPLACEMENT 8-45
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Replace a Thermocouple
Procedure Category:
Type 2
Parts Referenced:
Thermocouple
Special Tools:
•
•
•
•
•
Related Documents:
None
Teflon thread tape
Nickel anti-seize pipe thread dope (for threaded thermocouples)
Labels
Rubber gloves
Protective clothing
WARNING!
Use a protective dust mask, clothing, and gloves when you do maintenance that
causes exposure to insulation (for example, around the process chamber).
Make sure that the thermocouples are set above product clearance height.
To remove a thermocouple:
1
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
2
Record and label the wire connections of the defective thermocouple.
3
Disconnect the thermocouple wires from the terminal block (Figure 8-31).
4
Remove the thermocouple by turning threaded thermocouples, or remove the screws from the
thermocouple brackets and remove the thermocouple. Keep the bracket parts.
To install a thermocouple:
1
Remove the cover from the new thermocouple.
2
Install the tube end of the thermocouple in the correct channel in the process chamber. The channel
and thermocouple are marked with matching numbers.
3
Tighten the thermocouple:
• For threaded thermocouples, wrap anti-seize tape around the threads. Hand-tighten each
thermocouple into the receiving coupling on the process chamber wall. Carefully tighten the
thermocouple to keep the gas integrity of the threaded seal.
• For thermocouples using brackets, install the screws (supplied) in the thermocouple brackets and
tighten. The springs must be lightly compressed and the thermocouple tube must press lightly
against the muffle.
8-46
4
Connect the thermocouple wires to the correct terminals on the terminal block. Refer to Table 8-1.
5
Calibrate the thermocouple analog inputs. Refer to WINCON Online Help.
6
Install the access panels. Refer to page 7-4, Removing Access Panels.
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
1
3
4
1
3
4
2
TFF11017
1
Threaded Thermocouple
3
Control, Negative Output Terminal
2
Bracket-Type Thermocouple
4
Control, Positive Output Terminal
Figure 8-31: Thermocouple Assemblies
7
Do a temperature profile. Refer to page 7-7, Perform a Temperature Profile.
8
Examine equipment operation.
Table 8-1: Terminal Connections
Wires
To
Terminal Connection
Control
Intellimax
Match the color of the input thermocouple wire to the color of the output
wires (yellow = positive, red = negative). Wire name Annn-WC
Overtemperature
OTM
Match the color of the input thermocouple wire to the color of the output
wires: yellow is positive, red is negative. Wire name: C080n
Binding post
GND
Connect GND wire to the terminal of the Control negative (Red) wire.
COOLING SYSTEM
No Applicable Procedures.
September 26, 2007
COMPONENT REPLACEMENT 8-47
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
MUFFLE SYSTEM
Replace a Silicone Gasket
Procedure Category:
Type 1
Parts Referenced:
Gasket
Special Tools:
•
•
•
•
Related Documents:
Lockout / Tagout Procedure (page 2-10)
RTV silicone adhesive
Lint-free wipes
Notched spreader
Cleaning solution
WARNING!
QUALIFIED PERSONNEL!
• This is a general procedure for replacing silicone gaskets. Replacing a silicone
gasket may require disassembling sections of the furnace. Do not perform the
procedure if you have any doubts about how to accomplish the tasks involved.
• DO NOT PERFORM THE PROCEDURE IF YOU HAVE ANY DOUBTS ABOUT
HOW TO ACCOMPLISH THE TASKS INVOLVED. Contact BTU Customer
Service; otherwise, severe personal injury or equipment damage may occur.
To remove a silicone gasket:
DANGER!
ELECTRICAL HAZARD! PERFORM THE LOCKOUT / TAGOUT PROCEDURE!
Do not continue with this procedure if the furnace or any accompanying equipment is
energized; otherwise, high-voltage electrical current may electrocute you!
Perform the lockout / tagout procedure before continuing with this procedure.
1
Perform the lockout/tagout procedure. Refer to page 2-10, Lockout / Tagout Procedure.
2
Remove applicable access panels. Refer to page 7-4, Removing Access Panels.
3
Disassemble applicable sections of the furnace.
CAUTION!
EQUIPMENT DAMAGE!
When using a tool like a putty knife to remove gaskets and adhesive residue, make
sure not to scratch the gasket mating surface; otherwise, the damaged surface may
negatively affect gasket performance by preventing the gasket from forming a proper
seal.
Always use caution when using tools to remove gaskets and adhesive residue.
8-48
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
4
TM 5259111 Rev. 0
With a putty knife, remove the gasket and adhesive.
CAUTION!
COMBUSTIBLE SUBSTANCE!
Some procedures in this manual recommend a cleaning solution of 10 percent
isopropyl alcohol/90 percent water. Isopropyl alcohol is explosive in a non-diluted
state (flash point: 14°C (57°F)).
• Refer to the applicable MSDS of any cleaning solution you may use.
• Do not make a cleaning solution on or near the furnace.
• Do not use any cleaning solution on a furnace in operation.
• Make sure there is sufficient ventilation when using cleaning solutions to clean the
furnace and its components.
• Before using any cleaning solutions, make sure the surface to be cleaned is cool to
the touch.
5
With lint-free wipes and a cleaning solution, clean the gasket mating surface.
To install a silicone gasket:
1
Using a knife, cut four pieces of silicone gasket using butt joints. Refer to Figure 8-32.
2
Apply a 7-mm (0.25-in.) bead of RTV adhesive along the center of the gasket-mounting area.
3
Using a notched spreader, spread the adhesive evenly throughout the gasket-mounting area.
4
Install the gasket onto the gasket-mounting area.
5
Using only your hands, press the gasket down firmly.
6
Apply adhesive onto the seams located in each corner of the gasket.
7
Using a lint-free wipe dampened with water, smooth the adhesive evenly over the seams.
8
Let the adhesive dry for 24 hours.
9
Reassemble the furnace sections.
September 26, 2007
COMPONENT REPLACEMENT 8-49
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
1
1
2
1
1
1
2
Cut butt joints
IR1002_0
Gasket-mating surface
Figure 8-32: Example of a Silicone Gasket with Butt Joints
Examine the separation joint:
1
Examine hearth level (where the belt rides between the sections). Make sure that it is not out of
level by more than 1 mm (0.04 in.)
2
If the hearth level exceeds the specifications, adjust the joint. Refer to Figure 8-33.
2
DOT
3
1
TFF11036
1
Cooling Muffle
2
Separation Joint
3
Process Chamber
Figure 8-33: Separation Joint
8-50
COMPONENT REPLACEMENT
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
3
Install the access panels. Refer to page 7-4, Removing Access Panels.
4
If maintenance is complete, remove the lockout/tagout. Refer to page 2-11, Lockout / Tagout
Removal Procedure.
5
Examine equipment operation.
September 26, 2007
COMPONENT REPLACEMENT 8-51
TM 5259111 Rev. 0
8-52
COMPONENT REPLACEMENT
IN-LINE DIFFUSION SYSTEM MANUAL
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
APPENDIX A
DRAWINGS, SPECIFICATIONS & OPTIONS
INTRODUCTION
NOTE: This is not a full description of BTU or industry drawing methods.
• OEM drawings are available on the CD-ROM. Use Adobe Acrobat Reader® to read the online
drawings.
• For a list of abbreviations that are used in the drawings, refer to page 1-5, Symbols,
Abbreviations & Terms.
• For drawings / schematics, refer to inserts.
NOTE: Refer to the power input schematic for the main circuit breaker AIC rating.
ENGINEERING DIAGRAM AND EQUIPMENT IDENTIFICATION
A list and corresponding drawings are at the end of this appendix.
Electrical Diagram Lines and Line Codes
Electrical diagrams have alpha-numeric codes on the left-hand margin (for example, A010).
• The codes are groups of letters and numbers that start with A000 and increase by ten (for example,
A010, A020, A030).
• The letter refers to specific equipment components. For an explanation, refer to Table A-1.
• The three-digit number identifies a line of the diagram.
• Wire codes relate to the line code. For each additional wire that is used for a given line, the code is
increased by one (for example, A010, A011, A012).
Power circuit diagrams are drawn with vertical power lines on the left-hand side of the diagram. Branch
circuits extend horizontally from these vertical lines to the right-hand side, return or neutral. Refer to
Figure A-1.
Vertical lines represent the source of control power. All control devices are shown between them.
Switch and relay contacts are shown next to the right-hand vertical line. Pilot lights, relay coils, etc. are
between them and the right-hand vertical line. Refer to Figure A-1.
Circuits that connect to other diagrams are referenced by a line number and name at the connection
points (for example, A140 on one drawing can connect to A150 on another drawing). Electrical lines
that start at other electrical diagrams are marked by type of voltage (VAC or VDC). There may be a
description of the origin of the source voltage below the voltage type. Refer to Figure A-1.
September 26, 2007
APPENDIX A
A-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Electrical cabinet parts are identified by their names on the electrical diagrams. Refer to Figure A-1. For
example:
A130 of A130-CB is the diagram line number location of the part.
A131-TB is the terminal block below A130-CB, a circuit breaker on line A130 of the electrical diagram.
Electrical Wire Identification
Electrical wire size and insulation type and color are shown at the source voltage connection. Ground
wires are green/yellow No. 14 AWG unless specified differently. Ground wires do not usually have
color or size labels.
Refer to Appendix A, DRAWINGS, SPECIFICATIONS & OPTIONS for the electrical requirements. For
electrical wire identification, refer to Table A-1.
Wire Color
Table A-1: Electrical Wire Identification
Color Abbreviation
Circuit
NOTE: Exceptions are as follows:
• Multi-conductor cables are an exception to the above standard color codes.
• Neutral wires are light blue for equipment shipped to Europe (European Community).
• Customer-specified color codes are used as required.
Black
BK
Line, load, and control circuits at line voltage
Blue
BU
DC control circuits
Gray
GR
Grounded circuit conductor for UPS control circuits
Green/Yellow
GN/YL
Equipment grounding conductor
Red
RD
AC control circuits at less than line voltage
White
WT
Grounded circuit conductor (neutral)
White/Blue
WT/BU
DC common
Yellow
YL
Interlock control circuits supplied from an external power source
or UPS
A-2
APPENDIX A
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
3
2
5
1
4
6
PGON1069
Item
Figure A-1. Electrical Schematic (Example)
Description
1
Source Voltage
2
Reference From
3
Power Line
4
Electrical Wire Identification
5
Line Numbering
6
Reference To
September 26, 2007
APPENDIX A
A-3
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Plumbing Identification
Color-coded tape identifies the plumbing. If there is more than one pipe at a location, a number shows
the matching flowmeter, entrance-to-exit.
Refer to Appendix A, DRAWINGS, SPECIFICATIONS & OPTIONS for the plumbing requirements. For
plumbing identification, refer to Table A-2.
Table A-2: Plumbing Identification
Plumbing Color
Fluid/Gas
Black
Carbon Dioxide
Black/Green
Carbon Monoxide
Blue
Water Feed (Inlet)
Brown
Freon
Gray
Exothermic
Green
Air (optional)
Orange
Oxygen
Orange/Green
Argon
Purple
Natural Gas (City)
Red
Hydrogen
Red
Dissociated Ammonia
Red/Green
Endothermic
Red/Yellow
Forming Gas
White
Water Drain (outlet)
Yellow
Nitrogen
Specifications
Refer to BTU Specification.
Options
Refer to BTU Production Order.
A-4
APPENDIX A
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
APPENDIX B
RECOMMENDED SPARE PARTS
NOTE: If necessary, contact BTU Technical Support to get the correct part number.
INTRODUCTION
Parts may become defective after use. It is recommended that you obtain advance parts that are likely to
wear out. For recommended spare parts, refer to inserts.
If you need technical assistance or have questions about the warranty, contact BTU. Have your furnace
manuals and serial number available.
ORDERING SPARE PARTS OR WARRANTY PARTS
To order spare parts or warranty parts:
1
Place the order with the BTU Parts Sales Department.
• Include the serial number (1) and model number (2). Refer to Figure B-1.
2
If you order warranty parts, you must return the defective part to BTU.
International
N. Billerica, MA USA 01862
SERIAL
1
MODEL
2
ATMOSPHERE
VOLT
AMP
PH.
KVA
HZ.
IN RUSH
AMP
SEC.
MAX TEMPERATURE
SHIPMENT DATE
Figure B-1: Equipment Label (Typical)
September 26, 2007
APPENDIX B
B-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
Table B-1: Parts Form
Item:
Fill In:
Customer Name
Shipping Address
Billing Address (Non-Warranty Parts)
Warranty Part?
Yes / No (Circle Applicable)
Preferred Shipment Method
Purchase Order Number
Company Contact
Contact Telephone Number
MRA Number
furnace Serial Number
Part Numbers and Name
Detailed Description of the Problem
Date
B-2
APPENDIX B
September 26, 2007
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
APPENDIX C
MATERIAL SAFETY DATA SHEETS
Refer to inserts.
September 26, 2007
APPENDIX C
C-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
APPENDIX C
September 26, 2007
C-2
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
APPENDIX D
CALIBRATION SHEETS
Refer to inserts.
September 26, 2007
APPENDIX D
D-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
APPENDIX D
September 26, 2007
D-2
IN-LINE DIFFUSION SYSTEM MANUAL
TM 5259111 Rev. 0
APPENDIX E
VENDOR MANUALS
Refer to inserts.
September 26, 2007
APPENDIX E
E-1
TM 5259111 Rev. 0
IN-LINE DIFFUSION SYSTEM MANUAL
APPENDIX E
September 26, 2007
E-2
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