DPL-24 Manual
Contents
1. 4 10 T Temperature Controllers 5 14 16 I e EA 10 V WAC UI CHA DE 4 15 Vacuum Dwell 5 7 10 14 vacuum PUND MEMINI 4 7 9 12 W AC c 18 SEL eee 8 182. 15 00 GAL 75 00 1094 SPRING DRAWER 4 PIECES 32 00 EA 8 00 1113 BOARD HOLD DOWN 1 PAIR 150 00 PR 150 00 1117 TIMER DIGITAL 1 PIECE 125 00 EA 125 00 TOTAL 2 234 00 Pricing shown is current at the time of publishing and is subject to change ORDER PARTS FROM OPERATIONS TECHNOLOGY INC 30 LAMBERT ROAD P O BOX 408 BLAIRSTOWN NJ 07825 Phone 908 362 6200 FAX 908 362 5966 16 OPTEK DPL 24 OPERATIONS TECHNOLOGY INC 30 LAMBERT ROAD P O BOX 408 BLAIRSTOWN NJ 07825 Phone 908 362 6200 FAX 908 362 5966 INNERVISION X RAY INSPECTION AND MEASUREMENT SYSTEM 75 oos is now possible with the OPTEK INNERVISION Immediately after lamination you measure registration error independently for each layer No need for sectioning or drilling and plating Determine layer locations to 0 2 mil accuracy Accumulated errors from process factors such as etch control and drilling accuracy are included in the measurements The OPTEK INNERVISION system provides a means to measure and report the positions of internal features such as pads on inner layers of multi layer printed P circuit boards reinforcement in gaskets and other such y oes encapsulated or laminated items The measurements O and images obtained by the INNERYISION reveal skew shift stretch shrink and other distortions that occur in imbedded layers The data provided allows fabrication processes such as lamination molding and dri
3. 1 Set both Temperature Controllers to 160 Degrees 2 Set Vacuum D well to 30 Seconds 3 Set Pressure Dwell to 20 Seconds 4 Place Prelaminated product on Platen 5 Slide Hold Down Device into place 6 Slide Drawer into Vessel 7 Momentarily depress the CYCLE START button 8 Machine will complete one AUTOMATIC CYCLE 9 CYCLE READY Light Illuminates 10 Slide the drawer out and remove substrate NOTE If at any time the operator desires to exit the cycle depress the CYCLE RESET button and machine will return to Step 0 Atmospheric pressure will be vented to the chamber and the drawer may be opened NOTE If at any time the operator wishes to hold the cycle at a given step depress the CYCLE STOP button The machine program will hold at the present step indefinitely To resume the program sequence press CYCLE START button NOTE If the operator wishes to step through the program manually depress the SINGLE STEP button Unit will advance one program step with each pressing of the button maintaining that step s conditions after completion of the timer setting 13 OPTEK DPL 24 PRECAUTIONS CAUTION NEVER ATTEMPT TO REMOVE DRAWER FROM VESSEL WITH VACUUM PUMP OFF EMERGENCY RESET BUTTON MUST BE DEPRESSED IN STEPS OTHER THAN STEP 0 VACUUM IS APPLIED TO THE DOOR AND WITHDRAWAL IS IMPOSSIBLE IF VACUUM PUMP IS OFF THE DIAPHRAGM MAY IN CONTACT WITH THE VULCANIZED PLATEN AND PER
4. board hold down bats OPTEK DPL 24 INSTALLATION Due to the weight of the unit a forklift 15 mandatory for removal of the DPL 24 from the pallet and for final positioning 1 Upon receipt of equipment inspect for obvious external damage 2 Remove Tri Wall cardboard box or wooden crating and inspect for damage to the machine itself Do not attempt to slide the chamber drawer Using a fotklift roughly place the DPL 24 utilizing the attached pallet Remove lower back panel Remove the four bolts securing unit to pallet Raise unit with forklift blades positioned under main vessel being careful not to damage main valve see illustration below On B OG 7 Install leveling feet included into threaded holes formerly occupied by shipping bolts 8 Position lower and level the unit 9 WARNING IT IS IMPERATIVE THAT OIL BE ADDED TO PUMP BEFORE OPERATION 10 OPTEK DPL 24 INSTALLATION CONTINUED 10 Supply Compressed Air to input nozzle on right side rear of the machine 11 Adjust primary regulator to 50 80 PSI 12 Adjust secondary regulator to 5 10 PSI WARNING DO NOT ATTEMPT TO ADJUST REGULATOR PAST STOP DO NOT REMOVE PIN UNDER ANY CIRCUMSTANCES 13 Ensure that switch on pump is in the OFF position 14 Wire and Connect 220 VAC 3 Phase 40 Ampere power to input cable 15 Activate Main Power switch on front panel 16 Momentarily depress Emergency Reset switch on
5. Operations Technology Inc OPTEK DPL 24 Users Guide Operations Technology Inc 30 Lambert Road PO BOX 408 Blairstown NJ 07825 Phone 908 362 6200 Fax 908 362 5966 OPTEK DPL 24 Table of Contents Introduction 4 Overview 5 Principles of Operation 6 Site Requirements 8 Specifications 9 Installation 10 Operation 12 Example 13 Precautions 14 Maintenance 14 Recommended Spare Parts 16 Ordering Information 16 Warranty 18 Index 19 OPTEK DPL 24 A Differential Pressure Laminator INTRODUCTION T he DPL 24 Differential Pressure Laminator has been designed to give the operator a superior method for laminating sheet supported emulsions such as dry film solder mask etc Such materials can be applied to various thicknesses and sizes of substrates Experimentation is being done on alternative uses for this device among them High Vacuum Multi Layer Pressing of Printed Circuit Boards and microBGA interconnects The substrate prelaminated either manually or utilizing the A cold roll lamination technique is placed on the vulcanized rubber platen mounted in the drawer and positioned in the vacuum chamber Products of differing thicknesses and geometries can be intermixed during a cycle if adequate hold down techniques are employed The massive 1000 LB chamber is constructed of Ductile Iron and uses only two o rings This design ensures a positive seal for best vacuum performance Utilizing a hig
6. SISTENT PULLING MAY CAUSE DAMAGE MAINTENANCE Vacuum Pump The 45 Rotary Vane Vacuum Pump is supplied to you with no oil installed The oil should be changed after every 500 hours of operation and is available directly from Operations Technology Inc WARNING IT IS IMPERATIVE THAT OIL BE ADDED TO PUMP BEFORE OPERATION NOTE A separate manual for the pump has been included and all maintenance directives therein should be adhered to Vacuum Gauge The 0 20 Torr Solid State Vacuum Gauge is a precision rugged device used to constantly monitor the vacuum present in the vacuum chamber A level approaching two Torr or better indicates proper machine operation 14 OPTEK DPL 24 MAINTENANCE Digital Proportional Temperature Controllers These devices provide precise control of temperature for the upper and lower heater platens independently They are calibrated at the factory and should not need further adjustment Programmable Controller and Power Supply These units control activation deactivation and timing of the various valves and lights in the DPL A program stored in memory is utilized to direct the sequence of events Custom programming can be accomplished by the factory for specialized applications Neither the controller nor the power supply requires preventive maintenance Filter Regulator Normally clean filtered dry air should be supplied to the machine The DPL 24 however has an a
7. aten Heated Platen Figure 3 Differential Pressure Vacuum MEM PRINCIPLES OF OPERATION CONTINUED At the end of the pressure dwell cycle the top port is connected to the vacuum pump again and the bottom port is vented to atmospheric pressure As shown in figure 4 this returns the diaphragm and drawer platen to their original positions and allows the drawer to be opened for unloading Top Heater Diaphram 4B ise Laminated Material Drawer Platen Heated Platen Figured Material Finished Drawer Open SITE REQUIREMENTS Dimensions 44 Wide X 44 Deep X 60 High exclusive of leveling feet 1 to 2 Weight 2 200 LBS shipping Electrical Requirements 205 220 VAC 3 Phase 40 Ampere 7 Phase Compressed Air Dry Filtered 70 PSI 3 OPTEK DPL 24 SUBSTRATE SPECIFICATIONS Productivity Cycle time is adjustable from 0 to infinity and is determined by application parameters such as circuit complexity ground plane areas circuit heights flow temperatures etc Typical times for a dry film solder mask application would be 30 seconds for Vacuum Dwell and 20 seconds for Pressure Dwell Substrate size Items up to 24 X 24 can be laminated Smaller substrates can be processed in multiples if space permits and can be intermixed providing adequate hold down techniques are observed Substrate Thickness Thicknesses from 001 to 375 can be accommodated though standard
8. consumable items The user shall return all allegedly defective materials to Operations Technology Incorporated via approved routing charges prepaid Upon determination of liability Operations Technology Incorporated will either submit a quotation for repairs or rectify the defect at no charge This warranty cannot be countermanded by the purchaser and is the only warranty relative to the transaction No other warranty expressed implied or statutory shall apply Effective Date 1 1 96 Revised 6 1 2004 18 A AlE ne 6 7 8 11 15 AUTOMATIC 14 Iu Sa ated 7 C CYCLE READY eere ne 14 CYCLE 14 CYCLE 14 CYCLE S FOP 14 oa E rr terre 10 D diaphra TEL usce 5 6 7 9 Digital CORTON ELS 13 dimensions 9 dwell time 7 E Electrical 9 Epernay 12 THERE easi 4 H 13 kold GW 1 4 6 10 M Maintenance creer eee eren enne nnn nn neus 14 Index 19 OPTEK DPL 24 O eiu 6 P TART S ospiti dad UR MU 17 Peec ONE en 14 Press ttt 5 10 14 TPH A td aorta tes ten igastucteveeteanceets 5 R ROTON 11 S INN 14 16 SINGLE STE P 15 SPECIA ONS MEM UN 9 DE Fete NCSC e MN NM 7 SETS Eo
9. dditional filter incorporated into the primary regulator This filter requires minimal maintenance Open petcock and drain out water occasionally Diaphragm The 50 Durometer 125 thick Silicone Rubber Diaphragm is the major wear item in the system It is advisable to keep a replacement Diaphragm on hand in the event of a puncture or rupture This unit is available pre punched from factory Cleaning of the Diaphragm is accomplished with Isopropyl Alcohol only Platen All work is pressed on this Vulcanized Rubber Platen It is advisable to keep a standby Platen on hand if replacement becomes necessary due to normal wear or abrasion Cleaning is accomplished either on or off the machine with a soft cloth moistened with Isopropyl Alcohol only 15 OPTEK DPL 24 RECOMMENDED SPARE PARTS PART DESCRIPTION QUANTITY PRICE TOTAL 1007 CONTROL TEMP 9900 1 PIECE 350 00 ea 350 00 1008 HEATER SILICONE 1 PIECE 450 00 E A 450 00 1024 BULB INDICATOR 4 PIECES 2 00 EA 8 00 1026 DRAWER SLIDE LARGE 1PAIR 130 00 PR 130 00 1027 O RING DOOR 1 PIECE 38 00 EA 38 00 1028 O RING VESSEL 1 PIECE 30 00 EA 30 00 1041 FAN EXHAUST 220V 1 PIECE 47 00 EA 47 00 1042 RELAY SOLID STATE 1 PIECE 53 00 E A 53 00 1043 RELAY MAIN 1 PIECE 120 00 EA 120 00 1070 VALVE ACTUATOR 1 PIECE 50 00 EA 50 00 1077 DIAPHRAGM 1 PIECE 300 00 EA 300 00 1078 PLATEN 24 X 24 1 PIECE 300 00 EA 300 00 1089 VACUUM PUMP OIL 5 GAL
10. front panel 17 Activate Vacuum Pump switch on front panel 18 With one person at switch and one person at the pump JOG the vacuum pump switch and monitor the pump to ensure proper rotation indicated by the arrow found on motor end case Note If the rotation is opposite to that indicated reverse any two phases of incoming power 19 Upon determination of proper pump rotation leave pump mounted switch in ON position Your DPL 24 unit is now ready for operation 11 OPERATION 1 Insure circuit breaker 15 in the ON position 2 Activate MAIN POWER switch 3 Activate VACUUM PUMP switch 4 Chamber drawer may now be opened for inspection WARNING PLATEN MUST BE IN POSITION WHEN CYCLING MACHINE 5 Return drawer to home position 6 Activate TOP and BOTTOM Heaters by depressing and illuminating switches beneath digital controllers 7 Press asterisk and up down arrows until desired temperature is indicated on digital readout 8 Release asterisk and note temperature indication on readout 9 A flashing green light below the temperature readout indicates the controller is triggering the solid state relay to supply current to the respective heater blanket 10 Allow 20 40 minutes for unit to reach set point and stabilize if under 200 degrees F 11 Product may now be processed through laminator 12 OPTEK DPL 24 OPERATION EXAMPLE
11. h quality high volume 45 CFM 3 horsepower rotary vane vacuum pump an end point below two Torr is typically achieved OPTEK DPL 24 OVERVIEW The vacuum 15 displayed on a thermocouple sensing computer calibrated digital gauge located on the front panel e The substrate is exposed to this Vacuum Dwell for a time determined by a precision digital timer which is adjustable from 1 seconds to 9990 hours e At the end of the Vacuum Dwell a preheated silicone rubber diaphragm descends onto the work piece and drives springe mounted drawer mechanism into intimate contact with the lower heater platen The temperatures of both the upper and lower heat platens are controlled independently by digital proportional Temperature Controllers positive pressure of up to 10 PSI is applied to the top of the diaphragm to bring the combined differential to nearly 25 PSI e The Pressure Dwell is adjusted by a precision digital timer identical to that employed by the Vacuum Dwell e Upon completion of a cycle the drawer mechanism is retracted and the product s removed for further processing e The entire process is governed by a microprocessor driven programmable controller Programming modifications are available from the factory OPTEK DPL 24 PRINCIPLES OF OPERATION The following is an explanation and diagram of the operation of the DPL 24 differential pressure laminator When the DPL 24 is turned on two proportio
12. lling to be optimized The system combines real time X Ray Video Imaging with the positioning and metrology features of Operations Technology s OPTEK V Series Video Measurement and Inspection System The result is the most sophisticated X Ray Inspection and Measurement System available today 17 OPTEK DPL 24 WARRANTY 1 PERIOD OF WARRANTY Operations Technology Incorporated warrants this product to be free of defects in material or workmanship for a period of 180 days commencing on the shipping date from Blairstown New Jersey 2 LIABILITY OF WARRANTY Operations Technology Incorporated warrants to the original purchaser that equipment sold under this agreement shall be free from defects in material and workmanship Defective materials will be replaced or repaired at the discretion of Operations Technology Incorporated Liability will be determined by Operations Technology Incorporated All liability is expressly limited to said repair or replacement of defective parts all other damages and warranties statutory or otherwise being expressly waived by the purchaser This warranty is null and void if the equipment failure is due to negligence accident abuse improper operation It is also nullified by tampering alteration or unauthorized repair of subject equipment or components This warranty does not include filters oil Platen and Diaphragm as they are generally considered to be
13. nal controllers independently drive the top and bottom heaters to the heat the diaphragm and platen to the temperatures set on the front panel After a brief warmup time the laminator is ready for use Cycle Diagram Vacuum Pressure Vacuum Above the Diaphram In the DPI 24 Vacuum Applied Pressure Applied Top Heater pL RE E E a EE Diaphram dB e Material to be laminated Drawer Platen Heated Platen Figure 1 Drawer Open The drawer is pulled open to allow access to load the vulcanized rubber platen with materials ready for lamination Products of differing thicknesses and geometries can be intermixed during a cycle if adequate hold down techniques are employed The layered material is placed on the platen mounted in the sliding drawer When the drawer is closed the platen is positioned in the vacuum chamber and an O ring seal on the drawer face contacts the opening in the vacuum pressure vessel Before the beginning of the cycle there is a vacuum drawn above the diaphragm Air at atmospheric pressure is in bottom of the vessel pushing the diaphragm upwards As shown in figure 1 the diaphragm is up above the material on the drawer platen The drawer platen 15 spring loaded upwards to allow the drawer to be opened and closed MEM PRINCIPLES OF OPERATION CONTINUED When the cycle starts vacuum is drawn on both ports above and below the diaphragm Utilizing a high volume
14. vacuum pump an end point approaching two Torr is achieved This vacuum 15 displayed on a digital gauge located on the front panel A programmable timer adjustable from 1 seconds to 9990 hours determines the vacuum dwell time before continuing to the next step Figure 2 It is important to note that this dwell time will allow air between the layers of material to be evacuated before the lamination pressure cycle begins eliminating trapped bubbles Because the vacuum 1s equal above and below the diaphragm it does not move and does not contact the material in the drawer Top Heater ELM Diaphram dB Drawer Platen Heated Platen Figure 2 Vacuum Dwell Cycle At the end of the Vacuum Dwell positive air pressure at up to 10 PSI is applied to the port above the diaphragm bringing the pressure differential to nearly 25 PSI see figure 3 The preheated silicone rubber diaphragm descends onto the workpiece This action drives the spring mounted drawer platen into contact with the lower heater platen Isostatic pressure is transferred to the material by the diaphragm The stretching effect that occurs with roll type laminators is minimized The flexible diaphragm conforms to the surface shape assuring positive contact between the layers thereby eliminating voids The pressure dwell time is controlled by another timer identical to the vacuum dwell timer Top Heater Material Being Laminated Diaphram dB gs Drawer Pl
Download Pdf Manuals
Related Search