HBC-43 Operators Manual
Contents
1. Fig 3 Status All Zones screen Page 14 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 3 1 Main Box The main box shows each zone with its associated thermocouples Columns are provided for 1 Zone number Heater output 2 Thermocouple input number 3 Temperature 3A Set point temperature 3B Actual temperature 4 Cycle stage 4A Stage number currently running 4B Time this stage has run 3 3 1 1 Zone number Each zone is listed in numeric order if it is enabled from the System Parameters screen There is one line for each thermocouple associated with the zone 3 3 1 2 Thermocouple input number Each thermocouple is listed under the zone it is associated with in the System Parameters screen The computer will automatically select the hottest thermocouple to use as the control sensor The thermocouple input being used to control each zone is displayed in red If acceptance thermocouples are selected from the System Parameters screen one thermocouple number will be displayed in blue This will be the coldest sensor 3 3 1 3 Set Point Temperature This column shows the current set point for each zone and thermocouple The set point is determined by the cycle that was selected to run and the stage of that cycle currently being run 3 3 1 4 Actual Temperature This column shows the actual temperature for each zone and thermocouple Color coded information warnings are displayed in this column Color Meaning Soluti2. C PID Each T C can be nominated by zone Control will be from the highest temp in each zone Any T C can be nominated as an acceptance T C The coldest T C will be plotted The soak time can be automatically set 1 C 1 to 9 99 C per minute in 0 01 degree increments O to 12 hours in one minute increments Up to six ramp soak stages each cycle Up to 100 pre programmed cycles Selectable on the keyboard Available automatically during cycle including Time of day zone number zone status control T C number acceptance T C number stage number set point run time vacuum level and job name Available on request from the keyboard Graph of temperature and vacuum pressure for current cycle Completed run is saved on the hard disk and on floppy disk for backup Selected by part number operator adhesive job description or date time Auto manual over ride on each heater output On screen display and hard copy print Alarm in case of computer or software failure Temperature deviation Keyboard settable T C burnout vacuum over pressure condition Selectable from the keyboard re start from beginning resume control from the last point Re start at last point Cycle data is stored on disk every minute 15 October 2001 2 2 System Specification Number of thermocouple inputs Sixteen K type thermocouples No of ramp soak control stages Six Number of controlled outlets Six Type of controlled output Ph
3. Solutions The ambient temperature is extremely important because an error in the ambient temperature will cause the same error in all the thermocouple readings The ambient temperature and the heatsink temperature are checked regularly in the control case The thermocouple temperatures will all read 460 C if one of the following conditions exists 1 The ambient temperature is not between 0 C and 65 C 2 The heatsink temperature is not between 0 C and 85 C 3 The ambient temperature is more that 10 C from the heatsink temperature Check that which of the above conditions exist Check the 100 Q RTD temperature sensors that are connected to both the thermocouple input connector block and the heatsink 7 8 The temperatures are all reading 470 C or 480 C Solutions The calibration memory has been check and found to have lost the calibration factors or the memory check sum is incorrect The controller has gone into to a safe operating mode Send the control box for a calibration check 7 9 The temperatures are all reading 490 C Solutions The calibration memory has been check automatically and found to have been not operating The bridge rectifier BR4 on the HBC 1 PCB may have failed Send the control box for repair and calibration 7 10 A temperature is reading 500 C Solutions The thermocouple may be open circuit or have a broken connector in the thermocouple plug Also check that the input is enabled in the S
4. of the heaters will reduce the temperature 3 3 2 3 Vacuum 1 amp 2 The vacuum as measured by the two remote transducers is displayed here A value of between 100 to 0 kPa is acceptable About 60 kPa is normal A value of 100 means the transducer is either not connected or is not functioning 3 3 3 Start time amp Run time 3 3 3 1 The start time is simply the time of day that the cycle was started This is important when automatic start was used 3 3 3 2 The run time is the total elapsed time since the cycle was commenced It will include time incurred because of the guaranteed soak feature See Glossary of Terms for further explanation 3 3 4 From the main Status All Zones F1 screen you have two option keys 1 Pressing the A key will show only the thermocouples that have been nominated as ACCEPTANCE thermocouple from the System Parameters screen A second press will toggle the other thermocouple s back on 2 The ESC key from any screen will return you to the main menu screen Page 17 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 4 Individual Zone Performance 3 4 1 Normal View This is the most useful screen to monitor the continuing performance of a heat cycle When selected from the main menu this screen will show an edit box for selection of zone of control Types a zone number between 1 amp 6 and press 4 Hot Bonding Controller 21 1 2001 14 20 48 Individual Zone Performance H
5. 6 minutes after a ramp Reduce the Derivative value by 10 to 20 The tuning of the PID values should only be done by an operator that has a knowledge of process control and the HBC 43 An informed and experienced judgement must be made to determine the settings based on the contribution of The size of the structure being heated The size and power of the heating blanket The set point temperature The ambient temperature The insulation around the structure After any change is made to the PID values monitor the Individual Zone Performance graph for the result of the change Do not make another change for at least 15 minutes After the values are changed the new value will be saved on the hard disk and used for all the following jobs Page 37 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 13 Review Jobs Alternate Main Menu NOTE Review Jobs functions are only available if a job is NOT running To enable complete records to be kept and recalled for later examination without the use of hard copy print outs each cycle is saved at the end of the cycle The Review Jobs function allows the operator to recall any job that has been run The job can be found easily by searching for within a time period for Jobs run by the same operator Jobs run with the same adhesive Jobs with the same part number Jobs with the same job description or any job within a time period The data is saved during the tempera
6. Actual Prog SP Temp C Accept Run SP Zone 6 Cycle No 97 Sgt T Conolly Adhesive FM 73 Heater Enabled Yes Job Running Start Date 21 01 97 Start Time 14 07 80 Actual Temp 120 4 Set Point 120 0 Accept TC4 112 3 60 Vacuum 1 60 2 Vacuum 2 100 0 Stage Time 51 20 40 Run Time 00 51 Stage 2 Power 45 2 20 00 00 01 02 Z zoom P Print V vacuum 1 6 Zone ESC Exit Fig 4 Individual Zone Performance Screen The screen provided shows a graphical profile for that zone of control and a window on the left hand side of the screen with data which describes the current performance of the zone of control In this window the information provided is 1 The selected heater 2 Program number running for that zone of control 3 Whether or not the heater for that zone of control has been enabled by the operator 4 Current operating status which can be Job Running No jobs Running Waiting to Start 5 The date and time when this cycle was started These fields are particularly important if the job has been started automatically on date and time 6 The actual temperature for the control thermocouple for this zone 7 The current set point for this zone Page 18 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 8 The time that the current stage either ramp or soak has been running The stage time will not commence until the actual temperature gets within 2 5 C of the
7. HBC 43 15 October 2001 6 Glossary of Terms Guaranteed Soak If the actual temperature is not within 2 5 C of set point on the change of the minute when a soak stage begins the soak time will not be started This can cause the total cycle time to be extended beyond the calculated time by a few minutes Cycle The recipe for the temperature profile is called the cycle It includes six stages which each have a ramp and a soak Stage The temperature cycle is broken up into 6 stages Each stage has a ramp and a soak Zone Each of the six heater power outputs provides a zone of control Each zone is controlled individually based on the thermocouples within the area of that heater blanket There are six zones available with the HBC 43 Page 47 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 7 Trouble Shooting Guide 7 1 A zone does not heat up Solutions 1 The zone has not been enabled on the System Parameters screen 2 The auto manual switch on the control box is in the manual position 3 If the power output lamp is on the blanket is faulty 4 The heater is plugged into the wrong power outlet socket 5 One of the thermocouples configured for that zone in the System Parameters screen is in actually in another zone 6 Zones 4 5 or 6 require the second 3 phase power lead into the control box 7 2 A zone heats above the set point temperature Solutions 1 The auto manual switch on the contro
8. Remake Index Files Rebuild Entire Database Backup Database Restore Database Help Page 41 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 14 1 Remake Index Files If the database file does not contain the same list of temperature files that are available on the hard disk or if a job does not appear on the list of available retrieve jobs it may be possible to recover the job by remaking the index file from the backup floppy disks Advise Backing Up Database Before Remake Any Key To Continue ESC to Exit The prompt box shown above will copy all the currently saved files to a backup directory when any key is pressed Rebuild Database The program will rebuild the dBaselll database for completed jobs from the backup floppy disks created at the end of each job cycle The files on the backup floppy disks will also be copied back onto the hard disk You will be prompted to install each floppy disk one after another The order is not important but you must insert all floppy disks with jobs that you want in the database Fig 22 Help box for Remake Index screen Press ESC to exit the Rebuild Database function if a rebuild is not required Press J Enter to continue NOTE The floppy disks containing all the files of the past jobs will have to be inserted into the computer to rebuild the database If these disks are not available DO NOT PROCEDE All the jobs that were backed up onto the hard d
9. Systems Hot Bonding Controller HBC 43 15 October 2001 3 4 3 Zoom screen with the temperature scale expanded Enter the Zoom mode by pressing the Y or key while in the Individual Zone Screen Hot Bonding Controller 21 1 2001 14 20 48 E Run Time 00 46 17 Temp C Zonel SetPoint 120 0 Actual 119 6 Accept TC1 116 2 P Print V Vacuum CR Prev Graph Review Vr Range ESC Exit Wa O Y UR s dr du Fig 6 Individual Zone Performance Zoom screen temperature scale adjusted When either the up or down cursor keys is pressed in the Zoom screen the temperature scale can be adjusted to view a 50 window of the temperature profile The option keys available when the temperature scale has been adjusted are the same as from the main Zoom screen Pressing either up or down cursors keys PAN will move the temperature scale in 50 steps to allow closer examination of the temperature Page 22 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 4 4 Zoom Review screen Enter the ZOOM PREVIEW mode by pressing the key while in the Individual Zone Screen and while in the Zoom Mode Hot Bonding Controller Zoom Review E Zone 1 Set Point 115 4 Actual 113 8 Accept TC1 110 6 TYF FERRY ERFYN fererererereesererereererereneeeererereneerenereneerereneferrerenerenrereneneneererenenenrereneneeserereneneetenpeeneererereneererereren
10. absorb adhesives When pre preg materials or wet lay up materials are specified excess resin has to be removed to provide the correct fibre resin ratio The amount of resin that is absorbed is regulated by the number of thicknesses or plies of the bleeder cloth that are used If there is too much absorption the repair will be resin dry and if not enough the repair will be resin rich It is most important that both of these situations is avoided by using the correct amount of bleeder cloth Vacuum Bag Sealant Vacuum bag sealant is used to provide an air lock between inside of the vacuum bag and the atmosphere The sealant tape is laid down along the outer edges of the repair area and encloses the entire lay up and bagging up materials The sealant tape should be capable of withstanding the high temperatures of the cure cycle and is easily removed from the panel when the repair is finished Sealant tape should never be re used Page 45 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Vacuum Bag Film The final part of the bagging up procedure is the application of the bagging film The film is very thin and conforms easily to the shapes that may exist in some repairs Once the air has been removed from the bag and the vacuum is created a leak test must be performed as follows 1 _ Connect a vacuum pipe to one of the vacuum outlets on the control panel 2 Make sure the vacuum transducer is connected to the o
11. and then one line for each alarm condition reported A sample of the alarm report is shown below Alarm Report 15 05 2001 21 45 32 Cpl John Thompson Part AS0904 5 Started at 15 01 2001 11 11 Run Time 03 11 32 No Description Temperature too LOW on heater Temperature too LOW on heater Temperature too LOW on heater 1 Low Vacuum 2 we ABN ki Page 31 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 9 Exit To DOS NOTE Always follow these instructions back to DOS before turning off the computer To leave the HBC 43 program select Exit To DOS from the main menu You will be prompted for a confirmation If you press Y the computer will go back to the Disk Operating System Do you really want to Exit Y N Fig 18 Exit to DOS screen To re start the HBC 43 program from DOS type Run from any directory The computer will start the program by checking for communications with the control box HBC 1 interface electronics When it establishes communications it will report the version number of the software running in the HBC 1 interface Page 32 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 10 Heat Cycle Set Up Alternate Main Menu The 99 heat cycles stored on the hard disc can be edited before starting a cycle Select Heat Cycle Set Up from the main menu and press 4 You will be prompted for a cycle number Page up page down and the cursor up and down can be used
12. between 1 amp 6 that you wish to modify and press 4 The graph on the left of the screen will show you the shape of the temperature profile being used The table of temperatures and times on the right define the shape of the profile The table may be edited and the result can be seen immediately on the graph The prompt line at the bottom of the screen shows the two options E to edit the table ESC to accept exit the screen Note Editing one heater zone will not affect the other zones The box above the graph shows Stage il The R or it could be S in the Time Left is to signify whether the Time Left R 00 42 current stage is a Ramp or a Soak Fig 8 Change Zone In Progress Information Box The edit table to the right of the screen defines the graph shape Heat Stage Temp Mins Rate Dev LA LA LA LA Fig 9 Change Zone In Progress Temperature Data Table The gt symbol to the left of the table points to the stage currently being run The YES or NO in the right hand column is an enable or disable flag for the vacuum pressure alarms Using the space bar can toggle the flag If NO is set here the vacuum pressure alarm will not occur for this stage of the cycle Pressing E for edit will allow any of the values within a stage to be changed Highlight the value to be changed using the cursor keys Typing over the current value will replace it in th
13. is waiting for the turn of the minute to start an Immediate job you will be prompted to either abort the job Y or cancel the HALT command N It is not necessary to press J 3 Job In Progress Do you wish to HALT this Cycle Y N The prompt is to get confirmation of the HAT Ting of the current job Press Y to halt the current job or N to let the job continue It is not necessary to press J Page 30 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 8 Alarm Reports The computer keeps a record of the last 128 alarms They can be viewed by entering this screen from the main menu screen Use the cursor up down and the page up down to view all the alarms Using the ESC key to exit will accept any new alarms and stop the alarm sound Hot Bonding Controller 27 05 2001 08 54 16 IM f Alarm Reports Alarm Description 25 05 2001 S reem Cireuie Tahezmoceousle a 5 23 0 5 Z0O01 S 2 Temperature too HIGH on heater 21 08 2001 S Temperature too HIGH on heater 27 05 2004 E S Temperature too LOW on heater 27 05 2001 S Temperature too LOW on heater 8 7 6 5 4 3 2 1 Scroll with MY PgUp PgDn P Printout ESC accept exit Fig 16 Alarm reports screen The P key can be used to print an alarm report of all the alarms for the current job The alarm printout starts with the date and time the operator s name and job description the start date and start time the total run time
14. the following box will appear Job Profiles Loaded OK Press Any Key To Continue After the job has been loaded the computer will return to the main menu The F2 function key Individual Zone Performance can be pressed to view an zone the graph of the job that was loaded While in the Individual Zone Performance screen all the zoom features can be used to examine the graph more closely Zoom Zoom screen with the temperature scale expanded e Zoom review screen e Zoom review screen with the temperature scale expanded The graphs from all these screens can be printed Page 40 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 14 Database Utilities Alternate Main Menu NOTE Database Utilities functions are only available if a job is NOT running Function Not Available While Job In Progress Press Any Key If this prompt box appears the job that is currently running must be HALTED before the Database Utilities will be available Pressing the F5 function key Database Utilities will only be necessary if some of the file in the database are corrupted If this happens a prompt box will appear No Job Profiles Database Found Press Any Key Fig 21 Database error prompt box If this prompt box occurs contact Novatech Systems Some of the file in the database have been corrupted and it may not be possible to recover the recorded jobs The options available in the database utilities are
15. the option to have the computer automatically monitor the cycle that has been selected If an adhesive type is chosen the highest temperature soak stage will be set to the characteristics of the selected adhesive Confirmation of the new time temperature will appear for each zone that is selected 8 To monitor the cycle in progress go to the Status All Zones screen or the Individual Zone Performance screen Page 25 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 6 2 The Start Cycle Screen details The Start Cycle screen shown below provides a summary in tabular form of the cycles last used for each of the heater zones Hot Bonding Controller OOOO 27 05 2001 08 53 51 N Current Progrdfi aaa Zone Number d 2 3 4 5 6 Zone Enabled YES YES NO NO NO NO Acceptance TC 0 0 0 0 0 0 Stage Set Point 80 5 S S 507 5 100 5 100 5 100 zk S 1 Soak Time 5 5 5 30 30 30 Heat Rate 9 90 9 90 2 00 2 00 2 00 2 00 Stage Set Point 120 5 120445 715 5 120 5 1 20 5 120 E5 2 Soak Time 5 5 10 40 40 40 Heat Rate 9 90 9 90 2 00 2 00 2 00 2 00 Stage Set Point 160 5 L LH 5 160 5 L S S 160 5 3 Soak Time 5 5 15 50 50 50 Heat Rate 9 90 9 90 2 00 2 00 2 00 2 00 Stage Set Point 110 5 MOE 120 5 200 5 200 5 200 5 4 Soak Time 5 5 20 60 60 60 Heat Rate 9 90 99 2 00 2 00
16. 09000040000000090900000090009000000909000000909009009099 47 7 TROUBLE SHOOTING GUIDE essusnsesessnensesensnsnsnsensnenensensnenennenenensnsensnsnsnssnsnenssnensnenenssnsnsnsnssnsnensnssnenensnssssnsnsnssssnsnenee 48 7 1 A ZONE DOES NOT HEAT UP 7 2 A ZONE HEATS ABOVE THE SET POINT TEMPERATURE geis deu 7 3 THE COMPUTER KEEPS BEEPING iu WT GY ee YTT GR NAU 7 4 THERE ARE TOO MANY TEMPERATURE TOO HIGH LOW ALARMS nnr nn n nL LL LL LY YL LLY HYLL n Ynn Ln nn Ynn FnHo 48 7 5 THE SCREEN OF THE PC GOES BLANK sgt 7 6 THE TEMPERATURE DOES NOT CONTROL TO THE SET POINT scssscsssscsesesessescsesecscescsssesensesesenecessesesasseseaeecsesesaaeeseeeeeases 48 7 7 THE TEMPERATURES ARE ALL READING A0 49 7 8 THE TEMPERATURES ARE ALL READING 470 C OR 480 C cecsssssescssseseccsesesencsesesescaeseseseneaeseecaeaeseecasaeseecaeacseecaeacsecenearseeeas 49 7 9 THE TEMPERATURES ARE ALL READING 490 C 7 10 A TEMPERATURE IS READING 500 9C bs go 7 11 REGULAR MAINTENANCR nennen 8 TUNING THE CONTROLLER USING THE PID VALUES SL BACKGROUND isis 22 2 2000 anna cates lon gen ann RR Eege EES Eege EENEG 50 22 CHANGING TAE PID VALUES see doses dd y dyn teat eh Ree tush ie hs WYF ear at else 50 9 MANUFACTURE OF THE THERMOCOUDPLE ususnssssnsnsnsessnsnsnssnensnsnsensnsnsnsenenenensnssnsnensnssnsnenssnensnenenssnsnsnsnssnsnenee 52 10 USE OF THE DATABASE OF PAST JOBS ususessnsnsnsesenenenssnenenensenessnensunsnsnenenssnenene
17. 2 00 2 00 Stage Set Point 90 5 AE 79 69 140 2 5 140 2 5 140 2 5 5 Soak Time 5 5 10 70 70 70 Heat Rate 9 90 II 2 00 2 00 2 00 2 00 Stage Set Point 40 5 40 5 60 5 60 5 GO 15 60 5 6 Soak Time 5 5 5 80 80 80 Heat Rate 9 90 9 90 2 00 2 00 2 00 2 00 Edit S Select Cycle C Copy CR I Accept ESC Exit Fig 11 Start Cycle Table Screen This screen provides a table of data for all of the heater zones The top line shows the zone number The second line shows whether or not the heater is enabled for that heater zone The third line shows the control thermocouple for that heater zone and the remaining lines on the screen show the set points soak times and the heat rates for each of the six heater zones The functional keys available Start Heat Cycle are E Heater Zone Cycle Edit After the cycle has been selected fine tuning of the cycle for one or more of the heater profiles may need to be altered Pressing the E and selecting the heater zone number key will take you to the edit screen for that heater This edit facility is now the same as when selected from Change Heater In Progress S Select Cycle Press the S key to continue the cycle start process You will be prompted with a window to either start just one zone or all enabled heater zones Use the up down cursor keys to select the zone s reguired Enabled Zones will start all the zones that are enabled from the System C
18. During the running of the cycle the coldest of the acceptance thermocouples is plotted on the Individual Zones screen Fifteen minutes into the hottest soak stage the acceptance temperature is used to calculate the soak time reguired to cure the adhesive The change to the soak time is confirmed by a box that displays the new soak time The computer beeper gives will give short warning bursts while the box is displayed on the F1 Status All Zones screen F2 Individual Zone screen normal view F2 Individual Zone screen zoom view Pressing F3 will stop the beeper and remove the confirmation box F1 Status All Zones screen Ifthe Status All Zones screen is being displayed when the change of soak time is to be confirmed a box will appear reguesting the operator to either accept or reject the soak time extension A box will appear for each of the zones that reguire a soak time extension as they reach the 15 minute time into the soak stage showing the current soak time and the new soak time Page 28 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 F2 Individual Zone screen normal view and zoom view If the extension has been applied to the zone currently being displayed then the confirmation box will be displayed the graphics profiling will stop and the program will wait for the operator to Accept or Reject the soak time extension If there are other zones which also need their soak times extended the box will
19. HBC 43 15 October 2001 Appendix 3 Control Case Component Identification Page 56 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001
20. LUE TOO SMALL If the P value is too small the controller will provide too greater power variation for a small temperature variation This will lead to instability in the patch temperature and there will be a slow oscillation of the temperature over a few minutes Double the P value and test the stability again Page 50 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 P VALUE TOO LARGE If the P value is too large the temperature will not follow the ramps closely and will not reach the soak temperatures Halve the P value and test the control again Integral Value This value is used to stop the temperature from settling just off the set point The larger the number the smaller the integral effect A 0 will turn all integral action off 1 is the largest action I VALUE TOO SMALL The actual temperature will oscillate above and below the set point Increase the I value by 50 of the current value If this does not reduce the oscillation of the temperature set the PID values to the default values P 25 I 220 D 15 I VALUE TOO LARGE The actual temperature will settle usually below the set point on a soak stage Halve the I value and let the controller settle down again for 15 minutes Differential Value This value is used to fine tune control It modifies the power out in response to the rate at which the actual temperature is approaching the set point ie When the set point gets to the top of a ramp but the powe
21. Novatech Systems HBC 43 Hot Bonding Controller Operators Manual Page 2 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Table of Contents 1 GETTING GOING FAST 99292222299992929202099090909020000909090090909000090909090000309000000900090000009090000009000900909000000909090900009090090909 5 2 SPECIFICATIONS niinn n E i R RRE 7 2 1 OPERATIONAL DESCRIPTION 2 2 SYSTEM SPECIFICATION 2 3 HARDWARE DESCRIPTION 3 SOFTWARE DESCRIPTION 3 7 HALT HEAT CYCLE 3 3 ALARM REPORTS ES Ae eege Ed GYW deeg e 3 9 EXIT TODOS fs i BER 3 10 HEAT CYCLE SET UP ALTERNATE MAIN MENU ENNEN 33 3 11 SYSTEM PARAMETERS ALTERNATE MAIN MENU 34 3 12 PID PARAMETERS ALTERNATE MAIN MENU 3 13 REVIEW JOBS ALTERNATE MAIN MENU 3 14 DATABASE UTILITIES ALTERNATE MAIN MENU 4 HARDWARE DESCRIPTION usssessnensessssnsnsenenensnonsensnenensensnensnnenenensnnensnsnsnssnsnsnennenenenenssnsnsnsnssnsnenenssnenensnssssnsnsnssnsnsnsnee 43 4 1 CONTROL CASE SER aha AA 43 A2 AGCCESSORY BOX mun id Y YF Y YI Y I YDD NON 43 4 3 COMPUTER PRINTER CASE nii Zora aan aa dee EE dee 43 5 ASSEMBLY AND BAGGING uusssessnenssssssnensenensnennsensnenensensnenennenenenenssnsnsnsnssnsnsnennenenensnssnsnsnsnssnsnsnenssnsnensnssssnsnsnsussnsnenee 44 6 GLOSSARY OF TERMS 9 949299222992902902929290290909000080909090090909000000908000000803090900300
22. The Quicktip is then crushed to hold the two wires securely A tool is available to crush it or a gentle pressure can be applied with smooth jawed pliers The Quicktips are available from Temperature Controls 412 Moreland Road Brunswick West Victoria 3055 Phone 03 9384 0444 Fax 03 9384 0204 Nominate the thermocouple type as type K and the gauge as 24 to 30 Part number QT 128540 Page 52 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 10 Use of The Database of past jobs The Hot Bonding Controller program has the ability to save and recall jobs to and from a database storage system 10 1 The concept of a backup system The database feature allows the record of the jobs to be kept on either a series of floppy disks or transferred to a larger computer for backup on hard disk tape backup system The backup system will consist of the following steps e Allow the computer to save each job as it finishes on both the hard disk and the backup floppy disks e Label the backup floppy disks clearly with Date the disk was first used Date the disk was filled Which Hot Bonding Controller it was used on e Save the floppy disks as they are filled about 10 jobs per disk in a secure place Keep the disks in date order e Set up a maintenance procedure that will guarantee that the hard disk copy of the files will be copied into the BACKUP directory at least every week This will keep a dual copy of a
23. ase angle fired SCRs to operate infra red heater lamps or mats Power to controlled outlets 240V 10A 2 4KW per outlet 17 4 kW total or 110V 10A 1 1 kW per outlet 7 8 kW total Vacuum source Air operated ejector down to 80 kPa Power supply safety protection Earth leakage circuit protection on each output Case Three transportable cases Computer Printer Control system Accessories Heater mats cables etc Power requirements Two 3 phase outlets 415 or 220V 50 60 Hz Case Sizes Computer Printer 220 mm high by 520 mm deep by 620 mm wide Control 220 mm high by 520 mm deep by 620 mm wide Accessory Case Size 320 mm high by 520 mm deep by 835 mm wide Weight Computer Printer 15 kg Control 22 kg Accessory Case Size 30 kg Page 8 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 2 3 Hardware Description One notebook computer with VGA active matrix colour screen Pentium processor 2 GB hard disk 64MB RAM CD ROM 3 5 floppy disk drive One control case providing for 16 thermocouple inputs 2 vacuum transducers 6 outputs for power control and one alarm sounder Six phase angle fired Triac circuits to operate heater mats or infra red lamps 10 Amp with earth leakage safety breakers One Cannon color bubble jet printer with single sheet auto paper feeder One set of pressure amp two vacuum gauges pressure regulator vacuum transducer and ejector type vacuum pump requiring a 60 psi air supply Tw
24. ation 7 1 Select the zone in which each thermocouple is mounted 1 to 6 7 1 Enable all the thermocouples inputs that are connected to thermocouples yes no 7 2 Select from these thermocouples or others the thermocouples to be used for monitoring the lowest temperature areas For automatic adhesive curing Zone Control 7 3 Enable all the output heater zones that are connected to heaters yes no 7 4 Select the PID settings for each enabled heater zone usually PID No 1 7 5 Tie the stages of all of the enabled zones together to synchronise the cycle stage start times Vacuum 7 6 Select the alarm vacuum levels and the maximum vacuum temperature change over point Enable the external vacuum transducers being used 7 7 Use the default settings for Data Log period 15 and Communications port 1 e8 Select Start Heat Cycle F4 from the main menu 8 1 Check that all required heater zones are enabled YES If not ESC back to the System Parameters window 8 2 Select required zones by typing S Normally use Enabled Zones 8 3 Select the cycle number that was set up in the Heat Cycle Set Up earlier press 8 4 Change the cycle description if necessary press J 8 5 ESC out of the Cycle Set Up screen back to the Current Program window 8 6 Press J to accept the cycle 8 7 Enter Operator name J and Item being repaired 1 and Part No 8 8 Press I to go to the Immediate Auto window Immedia
25. ation on the bond process please refer to the adhesive manufacturer or the Training Notes supplied by the Air Force Before the heater blankets thermocouples and release films can be assembled the physical damage must be repaired and the surface preparation must be carefully done Surface Preparation comprises Cleaning the Surface Exposing Fresh Material Chemically Modifying the Metal Surface For details of these processes please refer to Training Notes supplied by the Air Force Before starting the assembly stage the HBC 43 controller and accessary equipment supplied with the controller should be checked to make sure it is complete Heater blankets in particular should be checked for sharp creases in the pad or bared wires in the lead Also check the blanket power extension leads and the thermocouples for frayed or damaged leads The actual bagging sequence involves the positioning of the heater blanket and thermocouple wires in the correct positions the proper placement of bleeder cloths breather cloths and release films as well as the vacuum sealant tape bagging film and vacuum sniffer ports Thermocouples The thermocouple placement is extremely important to a successful bond The HBC 43 has provision for 16 thermocouples The HBC 43 also allows for up to 6 heaters If the area to be bonded spans areas with different thermal loading more than one heater must be used ie The patch may go from honeycomb core to a structural membe
26. display the relevant information for each of them in turn giving the operator the chance to accept or reject each soak time change If an extension is to be applied to a zone other than the one currently being displayed then the new zone will be displayed before displaying the confirmation box 3 6 3 Automatic Cure Cycle additional notes In addition to the confirmation box on the screen a record of the soak time extension will be printed showing zone original programmed soak time recalculated extended soak time acceptance thermocouple temperature If the operator rejects the extension then the previously programmed time will be restored If the operator does not respond before the soak goes into the extension time then the program will print out a report which includes original programmed soak time recalculated extended soak time actual soak time as at time of rejection Page 29 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 7 Halt Heat Cycle When you select this option the screen will display a message indicating the current operating status The messages which may be displayed are 1 No Job In Progress Press any key to Continue If there are no temperature profiles are currently being run there is no job to Halt 2 Job Waiting To Start Do you wish to HALT this Cycle Y N If the current job has been programmed for an Auto start at a later time or if it
27. e table The cursor keys or the I key will move the highlight to the next table position produce an update on the graph Use the ESC key to save the change s and exit back to the main menu screen Page 24 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 6 Start Heat Cycle 3 6 1 The easiest way to get a selected cycle running Normally all the heater zones that were configured in the System Control Parameters screen will need to be started The procedure is 1 Press the S key to select the cycle 2 Press 1 to choose the default Enabled Zones 3 Scroll through the alphabetic ordered list of cycle recipes until you find the one you want to run Type the cycle number followed by a J Change the Description if required as prompted or Jl to continue to continue 4 You now have the option to edit the time temperatures of the selected cycle The changes entered this way will not be saved to disk for any future runs They will only be used for this running of this cycle Press ESC to continue 5 Press I to enter the operator name and particulars of the work being done Use the tab key to toggle between the fields 6 Press the I key to go on The immediate auto window gives the user the option of starting immediately on the turn of the next minute or by selecting Auto and by setting the start time to do a delayed start Press J on the start mode required 7 The operator is now given
28. enty heater mats of various sizes One set of accessories comprising eight heater leads 100 metres of thermocouple wire quick connect hoses two sniffer valves and two sniffer vacuum gauges Page 9 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 Software Description The software running on the computer provides a complete control system interface to the user There are screens that show all the temperatures in table form or a graph of the way the heater has followed the set point Temperature profiles can be user designed or automatically set using the published adhesive specifications The heaters and thermocouples are configured in the System Parameters screen The hottest thermocouples for each heater are automatically selected for the PID control and the coldest thermocouple is graphed and logged to assure reliable temperature control User settable alarm conditions for the temperatures and vacuum pressure levels are monitored Alarm conditions are displayed on the screen and printed for a hard copy The graph can be printed at any time on a color bubble jet printer As the run is finished the temperature vacuum time graph can be saved to hard disk and floppy disk and can be retrieved for later examination for quality control records 3 1 Turn The Computer On When the computer is turned on the HBC 43 software will automatically load and start running The batteries will always start the computer if they are char
29. essing the Z key will get a Zoom and Zoom Review screens of the graphical profile The I key will return you to the main Individual Zone Performance screen See the next page for further detail 2 Pressing the P key will print the screen This will provide an immediate hard copy of the temperature vacuum profile and numerical data 3 Pressing the V key will toggle on and off a vertical scale and two traces for the vacuum pressure transducers on the graph The scale is from zero to one atmosphere of either vacuum or pressure See Fig 5 4 Any of the other heater zones can be displayed immediately from the main Individual Zone Performance screen by simply pressing the zone number 1 to 6 5 The ESC key from any screen will return you to the main menu screen Page 19 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Hot Bonding Controller 21 1 2001 14 20 48 Individual Zone Performance Actual Vacuuml Temp C Accept Vacuum2 140 Zone 6 Cycle No 97 120 Sgt T Conolly Adhesive FM 73 Heater Enabled Yes 100 Job Running Start Date 21 01 01 Start Time 14 07 80 Actual Temp 120 4 Set Point 120 0 Accept TC4 112 3 60 Vacuum 1 60 2 Vacuum 2 100 0 Stage Time 51 20 40 Run Time 00 51 Stage 2 Power 45 2 20 ool 00 Z zoom P Print V vacuum 1 6 Zone ESC Exit Fig 5 Individual Zone Performance Screen with Vacuum Pressure scale From the main Individual Zone Perfo
30. evious selected Press J The data in the table for both zones that were selected will now be the same Note It is also possible to make several heater zones follow the same temperature profile by 1 Enabling the required zones in the System Parameters screen 2 Starting all Enabled Zones from the Start Heat Cycle screen Press the key to proceed with the starting of the heat cycle ESC Press the ESC key if you want to abort the start cycle process and return to the main menu ver 2 13 Cycle Run 27 05 2001 08 55 45 Hot Bonding Controller Operator John Thompson Job Component Description Here Start Mode Immediate Auto Adhesive Change Fields Enter accept exit ESC abort exit Fig 12 Start cycle screen Page 27 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 6 2 Automatic Cure Cycle based on Adhesive Selection Fig 13 Start cycle screen Adhesive selection Adjustment to Heat Cycle gt gt gt gt gt gt gt gt gt gt gt gt gt Rome Adhesive Highest Temperature Stage Temperature was Soak Time was New Temperature is New Time is Press Any Key Fig 14 Start cycle screen Automatic Adhesive Selection Parameters The cure cycle can be automatically set based on the time temperature data on particular common adhesives types The highest temperature soak stage will be set to the correct time and temperature for the selected adhesive
31. ged however to use the computer for any extended period gt 30 minutes always use the power adaptor Use the IEC lead supplied to connect the mains outlet on the HBC 43 control box Computer Power to the computer power adaptor Plug the power adaptor into the computer Use the RS232 lead to connect the computers serial port on the rear of the computer 9 pin D connector to the HBC 43 control box If there was a cycle running and not halted when the computer was turned off the previous time you will be prompted Job In Progress Do you want to RE Start Y N The program will default to halting the current cycle if neither key is pressed within 15 seconds Initialisation Initialisation under way Reading Profile for Heater No Reading Profile for Heater No Reading Profile for Heater No Reading Profile for Heater No Reading Profile for Heater No Reading Profile for Heater No 6 Reading Profile for Acceptance TC Reading Profile for Vacuum 1 Reading Profile for Vacuum 2 Fig 1 Start up screen Page 10 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 If the HBC 1 interface circuit board inside the HBC 43 does not respond to the serial communications within 10 seconds the computer will flash the message COMMs Failure To Start Press any key to continue Continuous attempts to restart communications will be made Beeps will be heard from the computer until communications is established The po
32. he product described in this manual and products for use with it are subject to continuous developments and improvement All information of a technical nature and particulars of the product and its use including the information in this manual are given by Novatech Systems in good faith However it is acknowledged that there may be errors or omissions in this manual A list of details of any amendments or revisions to this manual can be obtained upon request from Novatech Systems Technical Enquires Novatech Systems welcome comments and suggestions relating to the product and this manual All correspondence should be addressed to Technical Enquires Novatech Systems Pty Ltd 309 Reserve Road Cheltenham Victoria 3192 Phone 03 9585 2833 Australia Fax 03 9585 2844 Website www novatech com au All maintenance and service on the product should be carried out by Novatech Systems authorised dealers Novatech Systems can accept no liability whatsoever for any loss or damage caused by service or maintenance by unauthorised personnel This manual is intended only to assist the reader in the use of the product and therefore Novatech Systems shall not be liable for any loss or damage whatsoever arising from the use of any information or particulars in or any error or omission in this manual or any incorrect use of the product Page 4 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 1 Getting Going Fast Once you are famil
33. iar with the HBC 43 it will only be necessary to be prompted with a brief description of each of the operations to get the heat cycle going For further details on follow the chapter references written in bold type el Heaters and thermocouples 1 1 Place as many thermocouples and heaters on the patch area as required Note which heaters and thermocouples are associated 1 2 Connect the heater power leads to the power outlet sockets 1 3 Connect all thermocouples to the input connectors e2 Cable connections 2 1 Connect the 3 phase power lead to the master input socket 2 2 Turn on the circuit breakers for all the heater zones that are connected 2 3 Connect the power leads to the computer power pack amp the printer 2 4 Plug the power pack into the computer 2 5 Connect the RS232 lead to the computer 9 pin COM1 port 2 6 Connect the printer lead from the computer to the printer e3 Turn the 6 manual auto power switches to auto e4 Turn on the main supply power switch on the wall e5 Turn on the computer 6 Select a heat cycle from the main menu Edit a pre designed cycle if necessary from the Heat Cycle Set Up ALT F1 screen or go straight to the next step configure the system using an existing cycle Page 5 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 7 Configure the system to match your current thermocouple heater set up in Systems Parameters ALT F2 from the main menu Current Thermocouple Configur
34. isk will be erased if a rebuild if started If a rebuild is found to be necessary select A in the above prompt box and press the Enter key Insert the backup floppy disks as required Check the available jobs in the Preview Jobs function ALT F4 Page 42 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 4 Hardware Description 4 1 Control Case The control box contains The HBC 1 interface circuit board The two HBC 3 input module circuit boards 6 single phase I0Amp power output controllers 6 auto manual power switches and controls An ejector vacuum pump Air supply on switch pressure regulator Air supply pressure gauge vacuum gauge 4 2 Accessory Box The accessory box contains 20 heater mats of various sizes 2 three phase power leads 8 single phase heater extension leads 100 meters of type K thermocouple lead 2 vacuum transducers and leads 2 sniffer gauges and fittings 2 vacuum pipes 1 five meter exhaust hose 4 3 Computer Printer case The Computer Printer box contains The computer Notebook PC Cut paper color ink jet printer The computer and printer connecting cables A hand held temperature gauge Page 43 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 5 Assembly and Bagging NOTE This manual does not claim to have sufficient information to prepare and bond a patch It must only be used as reference manual for the HBC 43 Hot Bonding Controller For complete inform
35. l box is in the manual position 2 One of the thermocouples configured for that zone in the System Parameters screen is in actually in another zone 3 The PID control values are not set correctly See Chapter 8 Tuning the Controller Using the PID Values 7 3 The computer keeps Beeping Solutions 1 The RS232 communications cable is not connected to the computer 2 The power is not on at the control box 7 4 There are too many temperature too high low alarms Solutions 1 The temperature deviation tolerance is set too small in the Change Heater in Progress screen 2 Thermocouples and zones are configured incorrectly in the System Parameters screen 3 The incorrect PID number has been selected in the PID field of the System Parameters screen 4 The PID values being used are incorrect 7 5 The screen of the PC goes blank Solutions 1 The PC battery has gone flat and the computer has gone into stand by mode Check the power and power pack leads 7 6 The temperature does not control to the set point Solutions 1 Check that the correct PID group is being used in the Zone Control section of the System Parameters screen 2 Change the PID values back to the default values of P 25 I 220 D 15 3 Re tune the controller PID values See chapter 8 Tuning the Controller Using the PID Values Page 48 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 7 7 The temperatures are all reading 460 C
36. ll the jobs e Ifa file in the database is corrupted the BACKUP copy can be recalled using the Restore Database function e Ifa backup is required feed the backup floppy disks into the HBC 43 computer as requested in the program Rebuild Entire Database 10 2 Saving the current job when finished As each job is finished the computer will save a copy of the temperature profile of the job to the hard disk if required by the operator Press the Y key to save the job on the hard disk and insert the latest backup floppy disk when requested by the program or leave the disk in the computer Make sure the Write Protect Window on the disk is closed Each floppy disk will hold between 10 and 14 jobs 10 3 Retrieving a previous job Any of the jobs previously run can be recalled by searching the database The search can be based on Operator Adhesive Job part number Job description And a time period can be nominated For full details of the Retrieve Jobs function see chapter 3 13 Page 53 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Appendix 1 Vacuum System Block Diagram Vacuum In 1 Pump On off Pressure Valve Regulator Pump Pressure Vacuum 0 to 1000 kpa 0 to 100 kpa Page 54 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Appendix 2 Electrical Block Diagram amp Printed Circuit Board Schematics Page 55 Novatech Systems Hot Bonding Controller
37. not connected It will need to be re enabled in the System Parameters screen NOTE Refer to the Novatech Systems HBC 43 Routine Calibration and Operational Check manual RAAF reference AAP 7656 032 2M The table above shows the possible abnormal temperatures that may be displayed for one or all the Actual Temperatures and the suggested solutions For further information check with either Novatech Systems or the calibration authority 3 3 1 5 Stage number This column shows the stage of the cycle that is currently being run There are six stages in every temperature cycle Each stage has been programmed with a ramp and a hold section See Heat Cycle Set Up for more details 3 3 1 6 Time this stage has run As soon as the stage of a cycle is started this time will be displayed in minutes and seconds It will appear once in the table for each zone on the control thermocouple row Page 16 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 3 2 Ambient Heat sink Vacuum Box 3 3 2 1 The ambient temperature is measured on the thermocouple terminal strip The same sensor is also used for cold junction compensation for the thermocouples 3 3 2 2 The heat sink temperature is a measure on the finned aluminium SCR heat sink block on the top panel of the control box It should never be allowed to rise above 80 C Under normal operating conditions it will be very close to the ambient temperature Reducing the power load
38. nssssnsnensunsnsnsnssnensnensensssnsnsnsenene 53 10 1 THE CONCEPT OFA BACKUP SYSTEM uii a En names GR YY sites 53 10 2 SAVING THE CURRENT JOB WHEN PINISHED Ynn YY a LLY E e ea E e DUEDD DYL i RE DE Yn FndY0n 53 10 3 RETRIEVING A PREVIOUS JOB 880020088 un I RL EEE BESSER SER ONE el 53 APPENDIX 1 VACUUM SYSTEM BLOCK DIAGRAM sussssnsssnsensnsnsnssssnenssnensnenenssnsnsnsnssnsnensnnenenenenssnsnsnsnsunsnenensnnen 54 APPENDIX 2 ELECTRICAL BLOCK DIAGRAM amp PRINTED CIRCUIT BOARD SCHEMATICS 55 APPENDIX 3 CONTROL CASE COMPONENT IDENTIFICATION usssesesensnssnensnensesensnsnsenenenensnsenenensnsenenenennen 56 Page 3 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Note Throughout this manual several important keys have been referred to by an abbreviation ie A Refers to the Enter key ESC Refers to the Escape key ALT Refers to the Alt key ie ALT F1 means to hold down the Alt key when the function key F1 is pressed l lt amp Refers to the Cursor keys Copyright NOVATECH SYSTEMS PTY LTD 2001 Edition 5 0 September 26 2001 It describes the notepad PC software version 2 13 and the control case software version 1 79a5 1 79j5 and 1 80a Neither the whole nor any part of the information contained in or the product described in this manual may be adapted or reproduced in any material form except with the prior written approval of Novatech Systems Pty Ltd Novatech Systems T
39. on Normal Actual temperature is below the set The temperature control will adjust point by between 2 5 C and 5 0 C the power level automatically Actual temperature is below the set The temperature control will adjust point by more than 5 0 C the power level automatically White on red Actual temperature is above the set The temperature control will adjust point by between 2 5 C and 5 0 C the power level automatically point by more than 5 0 C the power level automatically Flashing red on white o c The thermocouple is open circuit Repair the thermocouple or Disable the thermocouple in the System Parameters screen Page 15 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 The Actual Temperature display is also used to indicate an abnormal condition of the of the temperature reading electronics in the control case Abnormal Probable cause Solution Temp en heatsink temperature are too far apart temperature sensors 470 0 The calibration memory module has Perform a full calibration Not been initialised or It has lost all calibration data 480 0 The check sum in the calibration Put the HBC 43 into calibration mode i memory is incorrect Type FINISHED Check the calibration accurac Ke O The active memory check has failed Replace the bridge rectifier soe on H the HBC 1 3 PCB a O The temperature has been read as The thermocouple is probably open circuit gt 400 C or
40. ontrol Parameters Zone Control panel See section 3 9 Selected zones are shown with a YES in green at the top of the Start Heat Cycle screen Alternatively moving the high light bar with the cursor keys will enable any one of the enabled heater zones Use cursor page up down keys to scan the 99 pre recorded cycles in list Type the cycle number and press CR to go on Page 26 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Change the description if required as prompted or Jl to continue to start the cycle Enter the operator name and particulars of the work being done Use the CR key to toggle between the fields This identification will be printed on the hard copy reports during or at the end of the cycle Press the ESC key to go on The immediate auto window will give you the option of starting immediately on the turn of the next minute or by selecting Auto and setting the start date and time as prompted do a delayed start C Copy zone The copy command is used to copy the profile from one heater to another Use this if you want two heater zones to follow the same heater profile You will be prompted with a window From Which Heater Use CURSOR KEYS To Select Use the left right cursor keys to move the high light on the heater zone number Press J You will then be prompted To Which Heater Use CURSOR KEYS To Select Select the heater zone that you want to be the same as the one pr
41. r Determine how many heaters will be used and where they will be placed Between 3 and 6 thermocouples must be placed under each heater Place the thermocouples in positions that will show the extremes of temperature Put some of the thermocouples in the centre area of the heater and others around the perimeter The hottest thermocouple will automatically be selected to control the temperature to the set point and the coldest thermocouple will be monitored to allow an extended bake to be calculated Release Film During the cure cycle the adhesive will expand and melt As it melts it flows In order to prevent the adhesive from bonding to other elements of the lay up a release film is placed over the repair area and the thermocouples overlapping the repair by about 50 mm The film is usually made of Teflon and is capable of withstanding the temperatures of the heater blanket When the cycle is complete the release film allows the bagging materials to be removed easily without them bonding to the repair area Page 44 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Heater Blankets The HBC 43 has provision for 6 heater blankets Choose a heater blanket close to the size of the patch If the patch has any heat sink areas such as an attachment point choose heater blankets to match the shape of the heat load The HBC 43 will individually control the blankets to maintain the required temperatures The heat blanket is assembled s
42. r out is still set high expecting a continuing ramp up The D value will help stop over shooting of the soak temperature If the D value is increased the P value will probably also have to be increased The larger the number the larger the differential effect A 0 will turn all differential action off D VALUE TOO SMALL The actual temperature will approach the soak temperature too slowly Before changing the D value make sure you have big enough blanket to heat the patch at the required rate Increase the D value by 20 of the current value The P value may have to increased as well D VALUE TOO LARGE The temperature will be unstable Reduce the D value by 50 of the current value If this does not reduce the oscillation of the temperature set the PID values to the default values P 25 I 220 D 15 Page 51 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 9 Manufacture of the thermocouple One of the most critical components in the bonding process is the thermocouple If the two wires that make the thermocouple are not joined precisely significant is not errors in the measurement of the temperature can occur The simplest way to join the wires if a thermocouple welder is not available is to use a joining piece known as a Quicktip The quicktip is a tiny figure eight shaped piece of alloy The two thermocouple wires are fed into the two holes so that they appear 2mm out the opposite side of the Quicktip
43. ram to match your hardware There are three boxes Hot Bonding Controlle 27 05 2001 08 54 16 Sc S stem Control Kee Current Thermocouple Configuration Ee 2 3 4 a4 12 499 SS CS Zone 1 if 2 4 4 4 4 4 Enabled Y E X No No No No No Nee pe ES X 3 No No No No No No Zone Control Vacuum Zone L 2 B Min 5 0 Enabled Yes Yes Yes No Max low Temp W350 PID No ll 1 H il Max high temp 55 a Tie Stages Yes Yes Yes No Temp Limit 120 Pressure EE Miskial 85 Bergem beta MSIE LO Log Every lS mes E Vacuum COMB Jeep R 1 E le 2 Pressure Key in Number Enter for Next AV TAB Select Field ESC to accept exit Fig 15 System parameters screen Current Thermocouple Configuration Each thermocouple input must be nominated by the zone in which it is mounted Use the cursor keys to move the high light to the Zone line and to under the thermocouple number to be changed Type in the new number Enable each thermocouple that is being used Move the high light to the Enable line and toggle the yes no with the space bar for the correct thermocouple number The hottest thermocouple that is enabled from each zone will be used for control of that zone during a cycle run A thermocouple input that is enabled but does not have a thermocouple connected will display o c open circuit in the Status All Zones screen If an individual thermocouple appears faulty or yo
44. re Window Alarm Levels Vacuum If the vacuum rises above the Min Vacuum level there will be an alarm ie If the vacuum rises to 40 and the Min Vacuum is set to 50 there will be a Low Vacuum alarm If the vacuum falls to below either of the Max Vacuum levels low temp or high temp level there will be a High Vacuum alarm The Max low temp level is used when the temperature of any of the control thermocouples are below the Temp Limit set in this box Alarm Levels Pressure If a pressure transducer is connected to one of the transducer inputs it must be Enable d as pressure Only one alarm level is used for a pressure transducer There is no MAX pressure alarm If the pressure falls below the Min Pressure level there will be an alarm ie If the pressure falls to 40 and the Min Pressure is set to 50 there will be an alarm The vacuum pressure transducers option should be set to None if a transducer is not connected to inhibit false alarms Use the space bar when the Enable field is high lighted The options are None Pressure Vacuum Page 35 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 12 PID Parameters Alternate Main Menu The power output level is set by a calculation using three components Proportional Temperature error of actual temperature from the set point temperature Integral The time and distance the actual temperature is from the set point temperature Deri
45. rerenereneerenerenenrerenenenfereneneeeerereneneerereneneeeerereneerenerenennetant P Print V Vacuum CR Prev Graph Move Review Range ESC Exit Fig 7 Individual Zone Performance Zoom Preview Screen From the main Zoom Preview Screen you have several option keys Page 23 1 Pressing the P key will print the screen This will provide an immediate hard copy of the temperature vacuum profile 2 Pressing the V key will toggle on and off a vertical scale and two traces for the vacuum pressure transducers on the graph The scale is from zero to one atmosphere of either vacuum or pressure 3 gt left right cursor keys will move the display backwards and forwards in 30 minute intervals always displaying 60 minutes of the profile 4 YA down up cursor keys will move the display backwards and forwards in 30 minute intervals always displaying 60 minutes of the profile 5 Pressing either up or down cursors keys YA will move the temperature scale in 50 steps to allow closer examination of the temperature 6 ESC will take you back to the Zoom screen Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 5 Change Zone in Progress The actual heat cycle currently being run may be altered while the run is still in progress without stopping the cycle Select Change Zone in Progress from the main menu An edit box will appear for selection of heater zone of control Types the zone number
46. rmance F2 screen one of the option keys is Pressing the V key will toggle on and off a vertical scale and two traces for the vacuum pressure transducers on the graph The scale is from zero to one atmosphere of either vacuum or pressure See Fig 5 Page 20 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 4 2 Zoom screen Enter the Zoom mode by pressing the key while in the Individual Zone Screen Hot Bonding Controller 21 1 2001 14 20 48 E SEN Run Time 01 40 17 Temp C Zonel SetPoint 141 4 Actual 140 8 Accept TC1 136 6 P Print V Vacuum CR Prev Graph Review Vr Range ESC Exit Fig 6 Individual Zone Performance Zoom screen From the main Zoom screen you have several option keys 1 Pressing the P key will print the screen This will provide an immediate hard copy of the temperature vacuum profile 2 Pressing the V key will toggle on and off a vertical scale and two traces for the vacuum pressure transducers on the graph The scale is from zero to one atmosphere of either vacuum or pressure 3 CR will return to the full profile graph 4 left cursor key will take you to the Zoom Preview screen See the next page for further details 5 Pressing either up or down cursors keys YA will move the temperature scale in 50 steps to allow closer examination of the temperature 6 ESC will take you back to the main menu Page 21 Novatech
47. soak temperature For further explanation of Guaranteed Soak see Glossary of words 8 The run time The length of time for which the cycle has been running 9 The stage number that the cycle currently timing This number can be from 1 to 6 10 The percentage of full power being sent to the heater for this zone On the right hand side of the screen is a temperature time graph The Green profile shows the set point temperatures that have been calculated and sent to the temperature controller The actual set points will vary from the selected cycle profile when the Guaranteed Soak control operates The Red profile is the predicted set points as calculated from the cycle selected Superimposed on this will be the actual temperature profile white verses time for the current process as it has been running The blue trace records the acceptance thermocouple temperature ie The lowest temperature of all the thermcouples nominated as acceptance thermocouples on the System Parameter screen As the temperatures are being measured the graph of actual and set point temperatures will up date on the screen every second If a graph is re drawn using a zone number or going to another menu screen the graph will be re drawn from temperatures acquired on the minute readings For this reason there may be up to a one minute mismatch in the traces of the graph From the main Individual Zone Performance F2 screen you have several option keys 1 Pr
48. tch temperature is from the set point temperature 2 The time the patch has been away from the set point temperature 3 The rate at which the patch temperature is varying compared to the set point temperature 8 2 Changing the PID values NOTE Tuning a temperature controller takes time Only change the values if you have no choice If you do change the PID keep careful notes of the values and the temperature reactions Make sure you have waited long enough to let the system settle before taking the next action NOTE There is provision for 3 sets of PID values to be saved in the HBC 43 program Before you re tune the controller make sure the correct values are being used in the Zone Control section of the System Parameters screen and the PID parameters screen The PID values should not have to be changed The values of P 25 I 220 D 15 have been found to control the temperature of the heaters within 1 C of the set point Proportional Value This is the most important term The other two actions I amp D could be turned off a value of 0 will disable both I amp D and proportional action alone could control the temperature quite well It set a band of temperature above and below the set point When the actual temperature is within this band the controller will select a power level between full off and full on The larger the number the smaller the proportional effect Proportional action cannot be turned off P VA
49. te mode will start the cycle at the start of the next minute 8 9 Select the adhesive type for auto soak extension or None and J 8 10 Press any key to confirm each automatic temperature time if required e9 Select Individual Zone Performance F2 from the main menu 9 1 Select the heater zone you wish to monitor 1 to 6 All other zones can be selected from the individual zone screen by pressing the desired zone number to 6 e 10 If alarms occur because of temperature deviations on warm up check the Alarm Reports F6 screen ESC will accept the alarm and silence the horn Page 6 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 2 Specifications 2 1 Operational Description Display of 16 temperature inputs Display of control temperatures Temperature control Selection of control T C Selection of acceptance T C Accuracy Temperature ramp rates Cycle duration Cycle profile Memory Heater configuration Hard copy of data Storage of finished cycle Retrieval of previous runs Manual power output over ride Alarm identification Watch dog timer Alarm status Alarm shutdown re start Power fail re start Page 7 Novatech Systems Hot Bonding Controller HBC 43 Simultaneous C Colour coded graphic display of six states for up to 12 hours These states include open circuit T C T C OK at set point cold hot and off control T C coldest T C 0 to 400
50. ther end of the vacuum pipe 3 _ Test the ultimate vacuum by turning on the vacuum with the Air Supply on off switch 4 _ Note the vacuum obtained on the Status all Zones screen The vacuum will be about 70kpa with a supply line air pressure of 400kpa 5 Connect a vacuum pump to one of the vacuum ports 6 _ Connect the vacuum gauge to the other vacuum port 7 Turn on the vacuum with the Air Supply on off switch 8 _ Work the vacuum bag sealant and the vacuum port seals until no air leaks can be heard and the vacuum pressure on the computer screen shows the value obtained in step 4 9 Hold the vacuum for several minutes 10 Disconnect the vacuum pipe from the control panel 11 Watch the vacuum on the computer and monitor the leak rate 12 If the vacuum falls by more than 7kpa per minute it is not acceptable 13 Re work the vacuum bag sealant and the vacuum ports until all leaks are eliminated There are two major functions that contribute to the successful repair of a bonded panel 1 The vacuum allows the atmosphere to exert pressure to keep all the components of the patch pressed together until the adhesive has cured 2 _ The removal of chemicals that retard the curing rate from within the adhesive These vapours referred to as volatiles if not drawn out of the adhesive during the cure cycle will cause porosity which greatly reduces the strength of the joint Page 46 Novatech Systems Hot Bonding Controller
51. to view the list of cycle descriptions available Choose the required cycle from the description column Type the cycle number between 1 and 99 that corresponds to this description number and press 1 A new cycle description can be entered or simply press J to continue to the edit screen The Cycle Set Up screen like the Change Zone in Progress screen has a graph on the left and a table on the right The line above the graph shows the cycle number that was selected and description of that cycle Use the cursor keys to move to the data point you wish to change and enter the value or use the space bar to toggle YES and NO The A key will move to the next entry field Use the ESC key to take you back to the main menu screen The table will be saved to the hard disk on exit The 5 columns are 1 Stage number 1 to 6 2 Target temperatures 3 Soak time 0 to lt 720 mins 6 hours per stege with a maximum of 12 hours for a complete cycle 4 Heat cool rate in 9C minute 0 to 9 99 5 Vacuum pressure alarm enable amp Deviation alarm temperature 1 to 99 C Hot Bonding Controller 27 5 01 08 53 51 Cycle Set Up 88 Job Component description here Temperature 0 1 2 Key in new data I to next ESC accept exit Fig 10 Heat Cycle Set Up Screen Page 33 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 11 System Parameters Alternate Main Menu This screen is used to configure the prog
52. traight over the release film to enable good thermal coupling to the repair Breather Cloth Breather cloth is used to maintain an even vacuum over the whole potch area without close off It is capable of withstanding pressures of up to 700 kPa There are different grades of cloth available designed for particular applications such as thin cloths for tight corners and small radii The cloth should extend past the edge of the repair by 100 150 mm if possible so that the vacuum ports can sit over the cloth without any risk of them sitting on the heater blanket Vacuum Ports There are usually two bleeder ports or sniffer ports installed through the vacuum bag film The port comes in several parts The base plate is placed between the on top of the breather cloth under the vacuum bag film The rubber seal and upper section is attached to the base plate after the vacuum bag has been stuck down with the vacuum bag sealant by cutting a slot in the vacuum bag film long enough for the key tags to go through the film The upper section is pushed through into base plate and twisted to lock the parts together The valve section that is screwed to the upper section has a non return valve This allows the vacuum supply or the vacuum gauges to be disconnected from the lay up without the vacuum being lost Bleeder Cloth The bleeder cloth is used for absorbing excess resin from the repair For repairs that use film adhesives there is usually no need to
53. ture cycle every minute NOTE When a previous job is retrieved the current temperature profile will be lost Hot Bonding Controller Job Retrieval Options E Enter Function No Required 1 Report All Jobs Report By Operator Report By Adhesive Report By Job Part Number Report By Job Description Press ESC To Exit Fig 18 Review job Job retrieval screen Page 38 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Press the number key corresponding to the search function required Fig 19 Review job Report all jobs screen Page 39 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 To select a job press the S key and use the MW cursor keys Press the J Enter key view the Job Retrieval Data found OK Operator John Douglas Adhesive FM73 Part No 123456 Start Date 23 05 2001 Time 11 45 Job Description Star fighter wing File Name ZSHSRCK QA This is now used to retrieve the data Is This The Job You Want To Load Y N Fig 20 Review job Job retrieval data screen Press either the Y or the N key in response to the question in the above screen If it is not the correct job pressing the N key will return to the data base select screen While the job is being loaded from the hard disk this box will appear The loading takes about 20 seconds Loading Previous Job Profiles From LOGDATA ZSHSRCK QA When the job has been successfully loaded
54. u want to remove it from control of that zone in can be disabled during a run Page 34 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Zone Control Each zone that is to be controlled must be Enabled Move the high light to the Enable line and toggle the yes no with the space bar for the correct zone number The PID number is a convenience option to allow for different thicknesses of the structure being patched There are three sets of PID values They can be individually set in the PID Parameters screen See section 3 11 PID Parameters and 8 0 Tuning the Controller Using the PID Values The number for each zone is saved on disk Generally the set number one of PID values should be used The Tie Stages will synchronise the start times of each of the soak stages of the temperature cycle Use the space bar to toggle the yes no for the correct zone The soak times will automatically extend to make sure that the heater is within 2 5 C for the required time for each soak period If one zone is slower to respond than another they may get out of step Tying the stages will hold the faster zones until the slower zones catch up Miscellaneous Window The temperatures can be displayed in either Centigrade or Fahrenheit The computer will print a report at the interval nominated in the Data Log Every field The serial port used to communications to the control box can be set as either COM 1 or COM 2 Vacuum Pressu
55. unctions that are used to set up a heat cycle or to save and recall completed cycles 1 To select a function either 1 Press the corresponding function key ie Function key F3 will select Change Zone In Progress 2 Use the up down cursor keys to highlight the required function Press the J key 2 To access the Alternate Menu hold down the Alt key and then press a function key 3 To return from a function to the Main Menu press Esc Page 13 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 3 Status all Zones On this screen is display The current operating status of all of the heaters or zones of control The ambient temperature The temperature of the power controller heat sink The vacuum level of both remote transducers The start time and cycle run time Hot Bonding Controller Status ALL Zones _ 17 05 2001 08 53 24 Temperature Stage nia Zone TC Cycle eler Set Actual No Time 1 i 97 150 0 1497 2 tee 97 150 0 1496 2 1 3 97 150 0 149 9 2 00 09 53 Ambient 27 4 1 4 97 150 0 1497 2 Heat Sink 32 8 Te nb hO OD O E EI a 97 o 15500 2 CEFIN Be iR 97 150 0 1504 2 3 9 97 150 0 150 2 2 3 10 97 150 0 150 8 2 00 09 53 a MM 97 150 0 150 0 2 AD 97 150 0 1503 2 4 13 97 150 0 150 4 2 4 14 97 150 0 150 6 2 00 09 53 09 15 A i5 97 150 0 1501 2 Run Time 4 16 97 150 0 1502 2 01 12 24 A Acceptance TCs ESC to Exit
56. vative The rate at which the actual temperature is approaching the set point temperature In most case the values can be left at Proportional Band 25 Integral 220 Derivative 15 The Proportional value should always be between 10 and 100 The Integral value should always be between 150 and 400 The Derivative value should always be between 10 and 80 A value of zero for either Integral or Derivative will disable them Proportional control can never be disabled For convenience three sets of PID values are saved Select the set to be used from the System Parameters screen Zone Control box Hot Bonding Controller 27 05 2001 08 54 16 SS Heat Cycle PID Parameters Ke i Ta m Place Proporcional Bance 15 tege Derivatives 60 2 Normal Proportional Band 25 mt Derivati ves 10 3 Thick Plate Small Proportional Band 35 Intecjzele Derivative 15 Key in Number Enter for Next MVY gt ETAB Select Field ESC to accept exit Fig 17 PID parameters screen Page 36 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 These values will only need to be adjusted if 1 The temperature oscillates continuously over at least 3 C Increase the Proportional value by 5 to 10 2 The temperature is consistently more than 2 C from the set point when the set point has been constant for at least 10 minutes Reduce the Integral value by 10 to 40 3 The temperature does not approach up to the soak temperature within
57. wer output will be inhibited from the HBC 1 interface circuit board If this message is displayed check the cable from the HBC 43 control box RS232 4 pin socket to the serial port on the rear of the computer 9 pin D connector For further information see the trouble shooting guide at the end of this manual Note If the power adaptor is not plugged into the external power socket in the top of the computer or the mains power is not plugged into the computer power adaptor the batteries in the computer will only last an hour The computer will go into stand by mode until the power is connected to the computer See the Operators Guide for further information Page 11 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 3 2 Main Menu Hot Bonding Control System vers 2 13 20 05 2001 16 28 58 Available Functions CO e gt Fig 2A Main menu screen Hot Bonding Control System vers 2 13 20 05 2001 16 28 58 Available Functions Fig 2B Main menu screen ALTERNATE functions Page 12 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 Notes on Using the Main Menu The program functions accessible via the menu system have been split into two groups When the program first starts the menu displayed provides access to the most common of the functions that are required to run a heat treatment cycle The ALTERNATE menu which is displayed when the ALT key is held down provides access to f
58. ystem Parameters screen 7 11 Regular maintenance The accuracy of the Hot Bonding Controller is dependant on the electronics built into the control case Electronics was design to need very little maintenance by the use of extremely stable voltage references which are used in a continuous self calibrating process which is all supervised by a micro computer However for safety the control box should be checked every year When the calibration check adjustment is required Contact Novatech Systems Phone 03 9585 2833 Fax 03 9585 2844 www novatech com au Page 49 Novatech Systems Hot Bonding Controller HBC 43 15 October 2001 8 Tuning the Controller Using the PID Values 8 1 Background P is short for PROPORTIONAL measured in of full scale range 400 C full scale I is short for INTEGRAL measured in seconds D is short for DIFFERENTIAL measured in seconds The term PID refers to the three values used to calculate The power required to get a process variable in this case the temperature of the patch equal to the desired value in this case the set point temperature The power can be varied from zero volts on the heater to full mains voltage on the heater mat in 256 steps The amount of heat has to be continuously assessed to get the temperature to the set point or to maintain the temperature at the set point There are 3 considerations when the controller calculates the P I and D values 1 The distance the pa
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